Heavy-duty positioner + KUKA robot seventh-axis ground rail for laser cladding are customized for the laser cladding, surface repair, and alloy strengthening processes of ultra-long, heavy-duty shaft/cylinder workpieces,

It is widely used in heavy industries such as mining, metallurgy, construction machinery, marine, hydraulics, and electric power, addressing the challenges of automated laser processing for large heavy-duty components.

1. Specialized positioner for heavy-duty laser cladding

The complete machine is composed of a modular assembly including an annealed and welded base, a 500-type three-jaw self-centering chuck headstock, a manually sliding locking tailstock, two sets of three-point opening and closing center frames, and a closed dust protection assembly, which provides both stable support for ultra-long workpieces and convenient loading and unloading.

The spindle rotation unit is equipped with a 500 three-jaw self-centering chuck, featuring a wide range of stepless speed adjustment from 0.3 to 50 r/min;

The manually sliding tailstock mechanism allows the tailstock to slide freely along the base guide rail and lock mechanically for positioning; it is suitable for clamping both long and short workpieces, enabling quick clamping and unclamping.

The three-point opening and closing center frame allows the support to slide and lock on the base, which suppresses the rotational deflection of long workpieces and ensures uniform thickness of the laser cladding coating.

Fully enclosed dust-proof chuck, spindle, and workpiece support areas are equipped with dust shields to isolate laser cladding metal powder and high-temperature splashes, protect precision transmission structures, and reduce the frequency of routine equipment maintenance.

3. High-precision performance indicators (compatible with precision cladding process)

Three-jaw chuck positioning accuracy: ±5 arcmin

The radial runout of the main shaft is less than 0.05mm, and the axial runout is also less than 0.05mm

The positioning accuracy of the tailstock center over its full length is ≤0.15mm

The coaxiality of the entire length between the spindle chuck and the tailstock center is ≤0.15mm, ensuring no offset or vibration during heavy-load long-duration rotation. This meets the stringent requirements for form and position tolerances in high-precision laser cladding, repair, and quenching processes.

Applicable industries & scenarios of positioner

Mining machinery: hydraulic prop, long shaft of large mining machine, laser repair and cladding of wear-resistant roller

Metallurgical steel rolling: wear-resistant strengthening of hot/cold rolling rolls, conveyor rolls, and straightening rolls

Construction machinery: cladding strengthening of excavator piston rods, pump truck telescopic booms, and large heavy-duty pin shafts

Shipbuilding: Processing of anti-corrosion and wear-resistant coatings for ship transmission shafts, stern shafts, and large hydraulic cylinders

Power equipment: repair and strengthening of wind turbine main shafts, generator shafts, and high-pressure valve stems

Hydraulic industry: automated cladding production line for ultra-long heavy-duty hydraulic cylinders, plungers, and piston rods

II. Dedicated seventh-axis ground rail for robots

The main body of the ground rail includes an annealed welding base, a high-precision linear guide rail slider, a precision gear and rack transmission, a robot-specific mounting slide plate, a fully enclosed drag chain with a wire divider, a guide rail protective sheet metal, and an automatic timing lubrication system.

The precision transmission system incorporates imported precision gears and racks, coupled with heavy-duty linear guide rails, resulting in minimal transmission clearance. It ensures smooth high-speed start-stop operations without impact or vibration, significantly reducing the time taken for workstation switching and enhancing the overall processing efficiency of the entire production line.

The fully enclosed wire sorting and towing chain comes standard with a sealed pipeline towing chain, featuring an internal independent wire sorting partition. The cables, air tubes, and oil tubes are arranged in separate zones, ensuring wear resistance and bending resistance, and withstanding harsh working conditions such as dust and oil contamination in the cladding workshop.

The fully automatic lubrication system automatically and quantitatively supplies oil to the guide rails and racks, eliminating the need for frequent manual maintenance. This extends the service life of precision transmission components and is suitable for 7x24-hour continuous automated production.

The fully enclosed protective cover with sheet metal integrates all-round protection, preventing cladding metal dust and high-temperature debris from infiltrating the track transmission mechanism, ensuring minimal accuracy degradation even after long-term use.

III. Five core advantages of the product

✅ Ultra-large load capacity: The positioner stably supports 2-ton ultra-long workpieces, and the ground rail supports a 1-ton heavy-duty KUKA robot. It ensures no deformation or shaking during heavy-load processing

✅ Micron-level ultra-high precision: Strict form and position tolerance control in all dimensions of rotation and movement, ensuring uniformity and precise dimensions of the laser cladding coating

✅ High-speed and efficient production: With a maximum reciprocating speed of 1000mm/s on the ground rail and wide-range speed adjustment for the positioner, the production line's processing cycle time is significantly improved