Estun Robotics: “Invisible Craftsmen” for Cell Phone Glass Cover Manufacturing
When you slide the screen of your cell phone to catch up with dramas, brush short videos or interact with AI virtual idols, have you ever thought about the precision manufacturing behind this piece of glass? A piece of curved glass less than 1 millimeter thick, need to go through more than 20 stringent process, any small defects may affect the touch sensitivity or visual effect.
In the high-end production line of a head enterprise in Zhejiang, Estun robots are taking the identity of “invisible craftsmen” to provide full escort in the back-end of the intelligent production of cell phone glass cover plate - from opening, coating, to engraving, heat bending, the whole process automation solutions to make the The whole process automation solution makes the glass cover plate both thin and tough, brings efficiency leap for the enterprise, and brings the ultimate experience for you who use the cell phone.
The Intelligent Manufacturing Code from Raw Material to Finished Product
The manufacturing of cell phone glass covers is a masterpiece of precision craftsmanship. The differentiated solutions provided by Estun cover the core processes of material opening, material dividing, CNC engraving, hot bending, grinding, silk screen printing, coating, inspection, etc., and through the synergy of robot clusters and high-precision operation and control systems, the efficient manufacturing of cell phone glass covers is realized.
Cutting
Uncutting is the “first cut” in cell phone glass manufacturing, which cuts the whole glass plate into blanks that fit the size of the cell phone and need to be cut to size. The main pain points faced by our customers in the unloading process include: the difficulty of loading and unloading the glass manually, the difficulty of turning and cutting the glass, the challenge of designing fixtures with high load and inertia requirements for robots, the low utilization and waste of glass due to traditional processes, and the need to meet the customer's high production efficiency requirements.
Advantages：
1. high speed: a robot loading and unloading with two openers, the speed of the piece can reach 66 pieces / line / min.
2. Saving: One-stop solution saves communication cost, debugging cost, and reduces personnel skills to save salary cost.
3. High efficiency: double cutter head coordinated cutting, each time can be more than 3 pieces of material, improve the utilization rate of glass.
4. High reusability: Adjustable fixtures adapt to various glass sizes to improve the reusability of the production line.
5. Stable operation: Estun provides a stable supply chain, products through the perfect quality management process, to ensure the stable operation of the cooperative equipment.
Carving
As a “double-sword combination” of CNC and robot, precision grinding refers to the use of diamond drills to chamfer and drill the edge of the glass, shaping the curved surface prototype. In this segment, the main pain points faced by customers include: low efficiency of manual loading and unloading, unable to meet the simultaneous work of multiple CNC, and unable to realize the traceability of defective materials; the complexity of the prismatic section of the process, which includes cleaning, stacking, grinding, slitting, etc., customers need a one-stop solution.
Estun Solution：
Advantages：
1. Stable production: AGV automatic handling system with high degree of automation, robot + AGV to achieve 24 hours a day unmanned work, reducing human operation, to avoid the loss caused by human negligence
2. High protection: The prismatic section needs to be cleaned several times, and there is often a lot of water vapor at the site. For this harsh environment, Estun Robotics is specially equipped with IP67 protection grade motors to ensure that the robot can still work stably in a high humidity, water vapor filled environment, effectively preventing moisture from intruding into the internal motors, thus prolonging the service life of the equipment and improving the durability and reliability of the overall system.
Hot Bending
Hot bending is the “nirvana moment” of cell phone glass, which refers to the flat glass pressed into a graphite mold at a high temperature of 800 ℃, shaped into a curved form. In this section, the main pain points faced by customers include: high temperature in the hot bending section, harsh environment, heat radiation will cause damage to the skin of employees; the overall cleanliness requirements of the hot bending section are high; the traditional single-channel loading efficiency is low, and can not meet the production capacity requirements.
Estun Solution：
Advantages：
1. low cost: with the composite robot to the hot bending machine up and down the glass insertion frame, save labor transfer insertion process
2. High cleanliness: Estun robots comply with the hot bending section of the cleanliness of ISO Class 5, in a dust-free environment, the robot can continue to carry out stable production operations to improve productivity.
3. High efficiency: dual-channel loading and unloading, greatly improving the efficiency of hot bending.
Silkscreen
Silk screen printing is like the “personalized makeup” of glass, which is printed on the back of the glass with brand logo and decorative texture, and the color should be even and non-staining. In this segment, the main pain points faced by customers include: serious product homogenization, cost pressure; high printing accuracy requirements; fast printing speed requirements.
Estun Solution：
Advantages：
1. High precision: Estun ER3-400 with screen printing machine loading, screen printing accuracy relative to industry requirements increased by about 33%.
2. High efficiency: production efficiency has been significantly improved, successfully shortening the original production cycle from a long period to match the industry's high standards.
3. Ease of use: can be adapted to a variety of specifications of the glass material
Film peeling
Tear-off is a delicate operation to unprotect the glass of the cell phone, removing the protective film on the cell phone's glass cover through a precise process to reveal the original luster and texture of the glass. In this process, the main pain point faced by customers is that the operation process is cumbersome, manual tearing of the film is easy to lead to edge damage, affecting the aesthetics of the product, and the manual operation is time-consuming, affecting the overall production efficiency.
Estun Solution：
Advantages：
1. High cleanliness: Estun SCARA robots can reach ten levels of cleanliness, effectively avoiding the dust, fibers and other contaminants that may be introduced in traditional manual operation, ensuring that the final product reaches the optimal state in terms of appearance quality, optical performance and long-term reliability.
2. High Stability: Through precise programming and control system, it greatly improves the stability and consistency of the production process. It helps to minimize operational errors caused by human factors, ensure consistent and reliable product quality, and thus improve the overall production line's operational efficiency and capacity.
As an indispensable smart device in our daily life, the performance and quality of cell phone cannot be improved without the precise manufacturing process and efficient automated production process behind it. Estun's automation solutions in this field are not only the “digital engine” for B-end customers to improve quality and efficiency, but also quietly shape the daily experience of C-end users - more sensitive touch, more transparent display, more durable screen, all from the manufacturing process of the millimeter of the struggle. In the future, with the emergence of new forms such as folding screen and ultra-thin glass, Estun will continue to promote 3C manufacturing to a higher dimension of precision and reliability with the innovative ecology of “Robot+Motion control” in the cell phone industry.
