The assembly of a customized three-axis robot is a precision engineering process, from initial requirements
to final product. The entire process strictly adheres to the core principles of "from base to top, main body be
fore accessories, mechanical before electrical." Each step involves targeted adjustments based on the custo
mer's specified load, stroke, and accuracy requirements, ultimately delivering a customized device perfectly
suited to their production scenario.
The pre-assembly preparation stage is fundamental to ensuring accuracy. First, it's crucial to confirm that all
customized components are complete: three single-axis linear modules with different strokes selected accor
ding to customer needs, a customized connecting plate, an end effector (suction cup or gripper) adapted to
the working conditions, servo motors, cable chain kits, high-strength locking screws, a high-precision marble
mounting platform, and specialized tools such as torque wrenches, dial indicators, and feeler gauges. The
assembly environment must be kept clean to prevent dust and chips from entering the guide rails. Simultane
ously, the flatness of the mounting platform must be verified beforehand to ensure an error of less than 0.05
mm/500mm, preventing positioning deviations during subsequent operation.
The first step is the baseline installation of the X-axis, which is the foundation of the entire robot's accuracy.
The customized X-axis single-axis module is placed stably on the marble countertop. Initial positioning is
achieved using the locating pin holes. Then, the fixing screws are tightened sequentially from the center
outwards to prevent slight deformation of the module's bottom surface due to uneven stress. During tighten
ing, a dial indicator is used to monitor the straightness of the module's guide rails in real time, making repe
ated fine adjustments until the parallelism error throughout the entire stroke is controlled within the custo
mer's required accuracy range. After completion, the reference position is marked to provide a reference for
subsequent Y-axis installation.
The second step is to complete the XY-axis bridging assembly. The custom-machined high-strength XY-axis
connecting plate is precisely aligned with the locating pin holes on the X-axis slide for pre-installation. After
confirming there are no gaps on the mating surfaces, the screws are tightened to the specified torque. The
Y-axis single-axis module is then hoisted onto the connecting plate, again using locating pins for initial posit
ioning. A dial indicator is used to check the perpendicularity of the Y-axis and X-axis, and angular deviations
are eliminated by fine-tuning shims to ensure that the orthogonal error of the two axes is controlled within
the allowable range. The cable tray on the Y-axis side is installed simultaneously, with the cable routing plan
ned in advance to avoid pulling interference during subsequent wiring.
The third step is to assemble the Z-axis and YZ-axis connecting plates. First, fix the YZ-axis connecting plate
onto the Y-axis slide, ensuring the connecting plate is perpendicular to the Y-axis's direction of movement.
Then, vertically install the customized stroke Z-axis module onto the connecting plate, focusing on verifying
the Z-axis's perpendicularity to prevent cantilever vibration during subsequent end-load operation. Based
on the customer's actual working conditions, rivet and fix the pre-selected module suction cups or grippers
to the end of the Z-axis slide. After adjusting the actuator's posture, tighten all connecting screws to ensure
the end-load installation accuracy fully meets the customer's loading and unloading requirements.
The fourth step is the cable chain layout and electrical wiring. Gently pry open the cable chain's movable co
ver with a flathead screwdriver and neatly place the power cable, encoder cable, air hose, and other cables
into the cable chain's inner cavity in sequence. The total cable area should not exceed two-thirds of the cab
le chain's internal space; twisting or crossing cables is strictly prohibited. After closing the cover, fix both en
ds of the cable chain to the machine base and the motion axis respectively, leaving sufficient movement ma
rgin to ensure the cables will not be pulled or tangled during full-stroke operation of the three axes. During
wiring, each cable should be clearly labeled, and the power cable and encoder connectors at the motor end
should be tightened one by one to prevent signal loosening during subsequent operation.
In the final assembly stage, a full machine inspection and no-load test should be completed. Use a torque
wrench to tighten all screws one by one to prevent any missed locks or loosening. Manually push each axis
to its full stroke to confirm there are no jamming, abnormal noises, or other abnormalities. Finally, connect
to the control system and conduct a low-speed no-load test run, gradually increasing the operating speed
and acceleration to verify the repeatability and smoothness of the three axes. Only after confirming that all
parameters fully match the customer's customization requirements is the assembly of the entire customized
three-axis robot considered complete.
