Breaking Through Cast Iron Grinding Challenges: Neview Automatic Empowers Automotive Parts Manufacturer to Achieve Efficiency Leap Amidst the transformation wave in the foundry industry, automating the post-processing of cast iron components has become a critical breakthrough for enhancing competitiveness. Neview Automatic, leveraging its deep technical expertise in intelligent equipment for the back-end of foundry processes, provides customized grinding solutions to numerous industry leaders. The following case study details how Neview Automatic’s cast iron product line solved common industry challenges using a project for grinding cast iron brake discs for a renowned automotive parts manufacturer (hereafter referred to as "the Customer"). I. Customer Background & Pain Points: The Efficiency Bottleneck of Traditional Grinding As a leading domestic supplier of automotive braking systems, the Customer produces over 5 million cast iron brake discs annually. Their original production line utilized a "manual + simple machinery" grinding model, exposing three core pain points: Low Efficiency: Single-station daily output was only 800 pieces. Manual grinding involved high labor intensity, requiring 120 workers during peak seasons while still struggling to meet delivery demands. Unstable Precision: Burr retention rate reached 15%, and dimensional tolerance fluctuations exceeded ±0.3mm, leading to persistently high assembly defect rates downstream. Significant Safety Hazards: Open grinding environments resulted in dust concentrations exceeding limits by 3 times, with an annual workplace injury rate of 8%, alongside significant environmental compliance pressure. After evaluating multiple equipment suppliers, the Customer ultimately selected Neview Automatic's cast iron series DR-750B grinding equipment. Its 200kg payload capacity and ±0.02mm repeat positioning accuracy were the key advantages that won the Customer over. II. Technological Breakthrough: 8-Axis Coordination Redefines Cast Iron Grinding Standards Neview Automatic's customized solution for the Customer centered on the DR-750B single-arm, dual-station equipment, integrating three innovative technologies: (1) Ultra-High Rigidity Structural DesignThe equipment employs a robust, short-arm mechanical structure and an integrated base. Testing confirmed it withstands grinding forces exceeding 165kg, offering rigidity equivalent to traditional 400kg-class robots, completely solving the challenge of cutting large sprue/riser remnants. Dual-spindle configuration enables "rough grinding + fine grinding" in a single pass, increasing single-station daily output to 2,400 pieces – a 300% efficiency gain over the original process. (2) AI Intelligent Compensation SystemDisplacement sensors detect workpiece variations in real-time. The backend system automatically corrects the grinding path, achieving ±1.5mm adaptability to casting dimensional variations. Taking the brake disc flange surface grinding as an example, the proportion requiring manual secondary rework dropped from 15% to below 3%. (3) Flexible Contour-Adaptive TechnologyAddressing the brake disc edge's susceptibility to deformation, the equipment utilizes triple closed-loop control (current loop, position loop, torque loop) to achieve adjustable contour-following pressure ranging from 0.1-5N. This prevents dimensional deviations caused by over-grinding, boosting product qualification rates from 82% to 99.2%. III. Implementation Results: From Single-Machine Upgrade to Full-Line Intelligence The project was implemented in two phases. Phase 1 deployed 8 DR-750B units alongside an automated feeding line. Phase 2 introduced an AI sorting and handling system, achieving complete unmanned production flow: Capacity & Cost: Single-line daily output increased to 12,000 pieces. Labor costs reduced by 75%, achieving annual energy savings of 1.2 million RMB. Precision & Quality: Dimensional tolerances are controlled within ±0.05mm. Burr retention rate is <0.5%. The line successfully passed the Customer's OEM IATF 16949 certification audit. Safety & Environment: A fully sealed protective structure combined with a centralized dust collection system reduced workshop dust concentration to 8mg/m³, meeting national standards. The Customer's Technical Director commented: "The rigidity and intelligent compensation technology of Neview Automatic's *equipment have completely resolved challenges we struggled with for years. Crucially, changeover time was reduced from 4 hours to just 30 minutes, significantly enhancing our flexibility to handle high-mix, low-volume orders."*

Lightweight Revolution Breakthrough in Aluminum Grinding: Neview Automatic’s Aluminum Series Empowers New Energy Vehicle Parts Manufacturer to Achieve Efficiency Leap Amid the explosive growth of the new energy vehicle industry, the large-scale application of aluminum alloy components is driving innovation in post-casting processing. Neview Automatic, leveraging deep technical expertise in aluminum grinding, has delivered customized intelligent solutions to leading enterprises. The following case study examines how Neview Automatic’s aluminum series products overcame grinding challenges tied to aluminum material properties through a project for a new energy vehicle battery casing manufacturer (hereafter "the Customer"). I. Customer Challenges: Three Industry Pain Points in Aluminum Grinding As a TOP 3 domestic supplier of new energy battery casings, the Customer produces over 800,000 aluminum alloy battery trays and casings annually. Their original production line used traditional robotic grinding, exposing three bottlenecks directly linked to material properties: Material Property Challenges: Aluminum alloy’s low hardness and high plasticity caused edge deformation under rigid grinding, resulting in 12% dimensional deviation and 18% burr retention. Efficiency Ceiling: Daily output per station was limited to 1,200 pieces. Frequent model changes (requiring 4-hour shutdowns) severely disrupted capacity amid rapid vehicle iterations. Environmental Compliance Pressure: Open grinding generated aluminum dust at 2.5× regulatory limits, while dry grinding caused internal chip accumulation, leading to 15% annual equipment failure rate. After 6 months of technical evaluation, the Customer selected Neview Automatic’s MR-600D dual-arm, triple-station equipment. Its 14-axis coordinated structure and ±0.02mm repeat positioning accuracy became the key to flexible aluminum grinding. II. Technological Innovation: Three-Dimensional Breakthrough in Flexible Grinding Neview Automatic’s solution centered on the MR-600D, establishing a 3D technical framework of "Material Adaptation – Process Optimization – Intelligent Control": (1) Six-Axis Coordination + Flexible Force ControlThe 14-axis system employs triple closed-loop control (current/position/torque) to achieve adjustable grinding force (0.1–3N). For deformation-prone battery casing flanges, "constant-force contour grinding" limits edge distortion to <0.03mm, reducing scrap rate from 8% to 0.8%. (2) AI Vision + Unordered Sorting for Smart LogisticsIntegrated 3D vision detects incoming part orientation, while adaptive grippers enable unordered pickup—boosting loading efficiency by 40%. AI sorting cut model changeover from 4 hours to 25 minutes, ideal for high-mix, low-volume production. (3) Fully Sealed + Pulse Dust ExtractionDouble-layer sealed steel housing with integrated dust collection achieves 95% chip capture, reducing workshop dust to 5mg/m³ (complying with GBZ2.1-2019). Internal chip accumulation dropped 90%, slashing annual failure rates to <3%.   III. Results: Integrated Intelligent Production Capacity & Quality: Daily output per line surged to 3,600 pieces (+200%). Dimensional tolerance held within ±0.04mm, burr retention <0.3%, passing CATL’s IATF 16949 audit. Cost Optimization: Labor costs fell 65%, with annual energy savings of ¥850,000. Changeover costs reduced 70%, enabling simultaneous production of 10+ vehicle models. The Customer’s Technical Director stated:"*Neview Automatic’s flexible grinding technology completely resolved aluminum deformation issues. The triple-station turntable and dual-robot coordination slashed cycle time from 25s/piece to 12s/piece—perfectly matching mass production demands for battery casings.*"

Cast Steel Grinding Breakthrough: Neview Automatic’s GR Series Empowers Heavy Industry to Overcome High-Hardness Material Processing Barriers In heavy machinery manufacturing, cast steel components are widely used in critical parts due to their high strength and wear resistance. Yet their high hardness (HB200–300) and complex structures pose significant post-processing challenges. Neview Automatic developed the GR Series intelligent grinding equipment to address these material properties, successfully resolving efficiency and precision challenges for heavy industry enterprises. This case study examines Neview Automatic’s technical breakthroughs through a cast steel flange grinding project for a major valve manufacturer (hereafter "the Customer"). I. Customer Pain Points: Industry Challenges in High-Hardness Cast Steel Grinding As a core supplier of nuclear valves in China, the Customer produces over 20,000 cast steel flanges (DN1000+) annually, primarily using WCB carbon steel (HB240–260). Their original "manual + 5-axis dedicated machine" workflow faced three critical issues: Low Efficiency: Daily output per station was only 15 pieces. Large-diameter flanges required 3 fixturing cycles and >8 hours of grinding, extending peak-season delivery by 40%. Insufficient Precision: Sealing surface roughness (Ra) reached only 6.3μm, failing nuclear-grade valve requirements (Ra1.6μm). Rework rates hit 20%. High Costs: Manual grinding consumed 12 grinding wheels/worker/day. Annual consumable costs exceeded ¥1.5M, with significant occupational hazards. After technical benchmarking, the Customer selected Neview Automatic’s GR-950B single-arm, dual-station system. Its 420kg payload and ±0.02mm repeat positioning accuracy became the foundation for high-hardness material grinding. II. Technological Breakthrough: Synergistic Rigid-Flexible Grinding Solution Neview Automatic’s solution centered on the GR-950B, integrating three innovations: (1) Ultra-Rigid Structural DesignFeaturing a high-strength ductile iron body and reinforced robotic arm, the system withstands >200kg axial grinding force. Paired with a 16.5kW high-power spindle, it achieves 2.5× higher material removal rates on HB260 steel versus conventional equipment. Dual-spindle "rough-to-finish grinding" in one setup boosts daily output to 45 pieces per station while reducing fixturing from 3 cycles to 1. (2) AI Error Compensation SystemLaser displacement sensors scan workpiece surfaces in real-time, enabling adaptive grinding paths for ≤1.5mm casting deviations. Flange sealing surfaces now consistently achieve Ra1.2μm (33% above requirements), reducing rework to <3%. (3) Flexible Force Control TechnologyTorque-loop control enables adjustable grinding force (5–20N). "Constant-force flexible grinding" at vulnerable areas (e.g., bolt holes) slashed edge chipping rates from 12% to <1%. Tool life extended 3×, saving ¥900,000 annually in consumables. III. Implementation Results: From Single Machines to Digital Workshop** The project deployed in two phases: Phase 1 installed 3 GR-950B units; Phase 2 integrated AI sorting lines for full-process automation: Capacity & Quality: Annual output per line surged to 32,000 pieces (+200%). First-pass qualification rate for sealing surfaces rose from 75% to 99.1%, securing ASME B16.5 certification. Cost Optimization: Labor costs reduced 60%; consumable expenses dropped from ¥1.5M to ¥600K. Changeover time shortened from 2 hours to 40 minutes, enabling flexible multi-spec production. Safety & Environment: Fully sealed housing with pulse dust collection cut workshop particulates to 10mg/m³ (meets GBZ2.1). Workplace injury rate fell to 0. The Customer’s Production Director stated:*"The GR-950B’s rigidity and AI compensation solved our DN1200 flange grinding challenges. Its 420kg payload increased large sprue remnant removal efficiency by nearly 4×—unthinkable with traditional equipment."*

Intelligent Line Solutions Break Heavy Industry Grinding Bottlenecks— Neview Automatic’s Line Series Empowers Construction Machinery Group to Achieve Unmanned Production Upgrade In construction machinery manufacturing, high-volume casting grinding and sorting face dual challenges of efficiency and intelligence. Neview Automatic developed a full-line solution addressing heavy industry needs—from bin picking and tray pre-sorting to line feeding, AI sorting, and smart warehousing. This case study examines a digging machine structural component grinding project for a leading construction machinery group (hereafter "the Customer"), showcasing how Neview Automatic’s line solutions achieve breakthroughs in capacity and precision through unmanned production lines. I. Customer Challenges: Three Efficiency Barriers in Traditional Lines As an industry leader producing 100,000+ excavators annually, the Customer’s structural workshop processes 5,000+ daily castings (e.g., iron brackets, counterweights). Their original "manual loading + isolated grinding" model revealed critical pain points: Inefficient Logistics: Manual bin picking took 40s/piece, requiring 20 workers. Peak seasons still faced feeding bottlenecks. High Changeover Costs: Switching product types required 3-hour manual fixture adjustments, causing ~80,000-piece annual capacity loss. Safety Hazards: Open lines generated 2× excess dust, with 5% annual injury rates—failing smart factory standards. After evaluation, the Customer selected Neview Automatic’s integrated solution ("bin picking + AI sorting + smart warehousing"), leveraging its 210kg payload and ±0.02mm positioning accuracy. II. Technical Solution: Three Innovations in Fully Unmanned Lines Neview Automatic’s custom solution centered on KUKA robots, creating an integrated "Smart Identification – Flexible Handling – 3D Warehousing" line: (1) High-Efficiency Unmanned Bin PickingEight DR-750B units with 3D vision achieved 99.8% success rate in disordered grasping of complex brackets. With 2,700mm reach and 210kg payload, per-unit handling stabilized at 20s/piece—100% faster than manual. (2) Flexible Changeover via AI SortingIntegrated 3D vision + control system auto-generated handling paths for different parts. Switching from brackets to counterweights reduced changeover from 3 hours to 20 minutes through model-based programming (zero manual teaching), saving ¥3M+ in downtime annually. (3) Intelligent 3D Logistics ManagementA smart warehousing system (2,000kg max load, 300m X-axis / 30m Y-axis travel) enabled automatic buffering and transfer. MES integration boosted logistics efficiency by 40% and space utilization by 3×. Bin Picking Al Smart Sorting and Handling System for Casting Smart Logistics and Warehousing System for Casting III. Results: Leap from Discrete Production to Smart Lines** Phase 1 deployed 12 line systems; Phase 2 networked 56 workshop devices: Capacity & Efficiency: Daily output per line rose from 500 to 1,200 pieces (+140%). Labor costs dropped 75%, saving ¥8M annually. Precision & Quality: Line positioning and compensation achieved ±0.02mm repeat grinding accuracy. Dimensional pass rates rose from 88% to 99.5%. Intelligence & Sustainability: Fully unmanned lines reduced dust to 8mg/m³ (meets national standards). Smart warehousing enabled material traceability, raising OEE from 65% to 90%. The Customer’s Smart Manufacturing Director stated: "Neview Automatic’s flexible changeover capability liberated us from multi-product constraints. The synergy between AI sorting and smart warehousing elevated our logistics to automotive-grade efficiency."