Quality Control

TallMan Robotics: Quality Research and Development and International Quality Control System Construction

In the field of industrial automation, TallMan Robotics has established a three-dimensional quality management framework covering research and development innovation, full process quality control, and international certification system with the core concept of "quality is dignity". Breaking through extreme environmental performance bottlenecks through patented technology, relying on a full chain quality control system to ensure product reliability, and opening the door to high-end European and American markets with rigorous international certification, becoming a trusted precision manufacturing partner for global industrial customers.

Full Process Quality Control: the Ultimate Pursuit from Micrometer to Nanometer

1.Raw Material Access Control

Establish a three-level supplier management system, strictly implement ASTM B221 standard for aluminum procurement, and conduct spectral analysis (German Spike SPECTRO LAB direct reading spectrometer) for each batch to ensure Fe content ≤ 0.15% and Si content ≤ 0.4%; The steel plate procurement follows the JIS G4053 standard and uses ultrasonic testing (GE 38DL PLUS from the United States) for internal defect detection. The sensitivity of the testing reaches the equivalent of a flat bottom hole of Φ 2mm, and any metallurgical defects exceeding level II are rejected.

2. Process Quality Control

1). First piece three inspection system: Before each batch of production, CNC operators, process engineers, and quality inspectors jointly inspect the first piece. Use the German Zeiss ZEISS PRISMO coordinate measuring machine (accuracy 0.5+L/500 μ m) to conduct a full-size inspection of the installation surface of the linear module guide rail, including 18 parameters such as straightness (≤ 5 μ m/m), parallelism (≤ 8 μ m), hole position coordinates (± 5 μ m), etc. Only after confirmation of qualification can mass production be carried out.

2). Online real-time monitoring: In the RV reducer cycloidal gear machining process, Renishaw NC4 non-contact measuring head from Germany is deployed to automatically perform on machine detection for every 5 workpieces processed. Real time feedback of tooth profile deviation (≤± 8 μ m) and tooth orientation deviation (≤± 10 μ m) data is provided, and the tool path is automatically corrected through the machine tool control system to ensure that the process capability index CPK is ≥ 1.67.

3. Finished Product Full Inspection System

1). Functional testing laboratory: equipped with the Japanese Ono tester ONOSOKKI high-precision speed and torque tester, conducting 100% load testing on planetary gearboxes. Run continuously for 2 hours under rated load, detect transmission efficiency (≥ 95%), temperature rise (≤ 40K), noise (≤ 60dB) and other indicators, and monitor the spectrum through a vibration analyzer (PCB 356A16, USA) to ensure no abnormal resonance peaks.

2). Environmental simulation testing: The linear module needs to undergo high and low temperature cycling testing (-20 ℃~80 ℃, 10 cycles), humidity alternating testing (20%~95% RH), and vibration testing (5~500Hz, amplitude 2mm). The American Thermotron S100 environmental test chamber should be used to ensure that the accuracy retention rate of the product is ≥ 98% in extreme environments, and the torque attenuation of screw loosening is ≤ 5%.

4.Traceability and Improvement Mechanism

Establish a blockchain based product traceability system, where each component is assigned a unique QR code that records the entire lifecycle information from raw material furnace number, processing equipment number, operator number to inspection data. By using SPC statistical process control software (Minitab, USA) to perform Pareto analysis on monthly defective data and initiating an 8D improvement process for TOP3 issues, the first-time product inspection pass rate has increased from 95.2% to 99.6% in the past three years.

Customized Solution: Meet Diverse Quality Requirements

1. Specialized Products for the Semiconductor Industry

In response to the strict requirements for particle pollution in semiconductor equipment (ISO Class 4), ultra clean linear modules have been developed: using electrolytic polished aluminum alloy (surface roughness Ra ≤ 0.2 μ m), combined with vacuum ion coating (TiN coating, thickness 2 μ m), with a surface particle count (≥ 0.5 μ m) ≤ 100/ft ². The processing is completed in a Class 10000 clean room (temperature 23 ± 0.5 ℃, humidity 50 ± 5% RH). After passing the laser particle counter (TSI 9306, USA) inspection, the finished product is packaged in double-layer anti-static packaging to ensure that the cleanliness meets the standard upon delivery.

2. Medical Equipment High Cleanliness Products

The hollow rotating platform customized for medical robots is made of 316L stainless steel (carbon content ≤ 0.03%) and milled as a whole. The surface is subjected to electropolishing treatment (roughness Ra ≤ 0.4 μ m), and metal ion residues are removed through FDA certified passivation process (nitric acid concentration 20% ± 2%, temperature 50 ± 5 ℃). Silicon containing cutting fluid is prohibited during the processing, and the finished product must pass biocompatibility testing (ISO 10993) to ensure no cytotoxicity or allergenicity, meeting the strict requirements for direct contact of medical devices with the human body.

3. Heavy Industry Enhanced Products

For the field of heavy machinery, the development of high load planetary reducers: The sun gear shaft is made of 42CrMo steel plate (tensile strength 1080MPa), which has undergone quenching and tempering treatment (850 ℃ quenching+580 ℃ tempering) to achieve a hardness of HB280-320, and the tooth surface has undergone nitriding treatment (layer depth 0.5mm, hardness HV900+). By increasing the modulus (m=4) and increasing the number of planetary gears (4 planetary gear structures), the rated output torque is increased to 5000N · m. At the same time, a forced lubrication system (oil temperature control ± 2 ℃) is adopted to ensure stable operation for 10000 hours without faults under continuous heavy load conditions.

Laboratory and Inspection equipment: Display of Our Test Equipment

Test During Production and Before Delivery: the Core Procedures before Packing for Customers

Test Report in Each Procedures to Save in Files for Each Order

Meeting in Proceeding Each Order

Conclusion: Defining Industry Standards with Manufacturing Philosophy

The high-end manufacturing system of TallMan Robotics is essentially a three-dimensional product of "equipment accuracy x process innovation x quality control density". Its CNC based machining equipment group, like the "skeleton" of precision manufacturing, supports micrometer level machining capabilities; The technological innovation from material genes to surface treatment is like "flesh and blood", endowing products with unique performance characteristics; The whole process quality control is like a "nerve center", ensuring that every component follows strict quality logic. This philosophy of integrating industrial aesthetics into manufacturing details not only makes TallMan Robotics' products a benchmark for precision machinery, but also a trusted quality partner for users in fields such as semiconductors, healthcare, and high-end equipment - every single product leaving the factory is an industrial artwork with "controllable precision, traceable performance, and solvable demand", continuously driving the evolution of global industrial automation to higher dimensions.