Project Management and In-Process Quality Control for Modular Robotics Production

About the Project

Our client focuses on developing modular robots adaptable to various industries, including aerospace, space exploration, and marine applications. These robots are built from interchangeable robotic blocks, allowing users to customize functions for tasks such as automated inspection and maintenance in various settings. Key components include the robotic body, which provides mobility through wheels, and modular attachments, such as actuators and robotic arms, that expand functionality.

Since 2019, WayKen has proudly partnered with our client, meeting their needs for highly customized robot parts from prototypes and batch production. Recently, the client launched a new project requiring custom components for modular robots. In this case study, let’s check how WayKen delivered professional machining solutions to support the custom robotics project.

WayKen’s Production Solutions for Custom Modular Robotic Parts

The core of this project focused on manufacturing robotic parts with complex, multi-surface features. These parts required through-holes and threaded sections for assembly, along with slots that needed precise sealing. After carefully analyzing the design of the parts, WayKen’s engineering team decided to machine the parts using a 5-axis CNC center.

Compared to 3-axis CNC machining, which required multiple re-positionings to reach different sides, 5-axis CNC allowed us to machine all surfaces in a single setup. This not only preserved strict geometric tolerances but also prevented potential assembly issues. Additionally, our high-speed 5-axis machines achieve exceptional surface smoothness on aluminum workpieces, which enhances sealing quality – a key factor for machining modular robotic parts.

Challenges Relating to Surface Finishes and Management

This project presented complex requirements for surface finishes on each part, as various sections were designated for visual appeal, mating, or sealing, depending on the function. Achieving the specified finishes involved precise planning and execution across multiple steps to ensure quality and alignment with customer expectations.

The project presented a series of requirements about surface finishes for each part. That’s because various sections were designated for visual appeal, mating, or sealing, depending on the function. Achieving the specified finishes involved effective planning across multiple steps to ensure surface requirements.

Surface Finishes and Requirements

Here is one example regarding the part named Main Housing Body. Generally, the part was supposed to be entirely anodized and sandblasted. However, because certain areas (marked in green) would be sealed and assembled with the robot body, it is required to protect the colored areas from being sandblasted in order to maintain the roughness of machining. In contrast, non-visible areas (marked in red) were permitted to show minor rack marks from anodizing hangers.

At the beginning of the project, WayKen’s engineering team collaborated closely with the customer to clarify which surfaces should remain visible and un-sandblasted across all parts. More examples of the other two robotic components can be seen in the below images.

As we can see, there are many surface needs in this project, ranging from flat to internal surfaces. At WayKen, we have experienced craftsmen who can carefully mask small areas and features to achieve the best expectations.

How to Accurately Communicate Surface Treatment Requirements?

When the surface treatment process and operations are highly complex, it can also present challenges in production management. The parts of the modular robot involved plenty of surface finishes including deburring, sanding, anodizing, and bead blasting. Each work was accomplished in different departments at WayKen. Therefore, How could it be ensured to pass on the requirements without any misunderstanding to every department step by step? That was an issue for us to deal with.

For each robotic part, there were a few documentations that elaborated all details of treatments for each part. First of all, the project manager put briefs in the “Parts List” in order to ensure all parties involved in the production are informed.

For all drawings, all important notes relating to treatment were highlighted by coloring. This helps operators and the QC team check and confirm all workpieces are correctly processed at each step.

Thinking of that the details in parts’ drawings were scattered, so there was also a PowerPoint including all information in the internal project profile for everyone to review. With that documentation, we could make sure the entire process is under control, and all people understand the project requirements.

In-Process Quality Control

There was another concern during the machining of modular robotic parts. How to identify defective parts early in production to avoid discovering them only at the final QC, which could delay the project. To address this, WayKen applied In-Process Quality Control (IPQC) methods, commonly used in batch production, to detect unqualified parts before advancing them to the next stage.

For instance, manufacturing the Main Housing Body involved several stages:

• machining
• hand finishing
• pre-cleaning
• anodizing
• sandblasting

Our QC team has carried out inspection tasks several times. The first was after machining, the main focus was to measure the key features to find out unqualified due to failing tolerances. Any parts failing this inspection were separated.

The second was to check surfaces visually after the parts were anodized and sandblasted. The visual check was based on WayKen appearance standard, which is to observe the appearance of parts from a distance of 30-45cm under daylight lamps with eyes.

When all parts were passed aesthetic check, our team did the final measurement for all tolerances according to the drawing. By this way, all parts were delivered with excellent quality within a reasonable timeline.

Get Start With Your Project at WayKen

This robotic project was a typical custom small-batch production. It was not only about the production quantities but also each part was highly customized. This requires the manufacturer to have excellent project management and control of the quality.

At WayKen, with comprehensive CNC machining capabilities, an extensive network of flexible suppliers, and a professional QC team, we can ensure each part meets strict standards and achieves your expectations. With decades of machining and management expertise, WayKen efficiently delivered high-quality, offering machining solutions aligned with different industry needs. Just contact us to start your projects！