Our Trolley System Empowers Brazilian Power Tool Leader | CamelConvey Conveyor Chain Manufacturer Cases

Introduction

Brazil is one of the largest power tool markets in South America. To enhance the competitiveness of its premium product line, a leading industry player invested in a new intelligent painting production line. This line demanded extremely high precision, stability, and corrosion resistance from its conveying system, aiming to achieve a production rate of over 15 units per minute while eliminating surface scratches and coating defects caused by the conveying system. After a rigorous global bidding process, the company ultimately chose China's CamelConvey brand, adopting its high-performance X458 conveyor chain and specially designed 4x6'' Trolley system.

Challenges

The customer's outdated conveying system had become a bottleneck for both production capacity and quality improvement, with main pain points including:

● Insufficient Positioning Accuracy: Excessive clearance between traditional chains and trolleys caused shaking during start-stop cycles and when entering/exiting spray booths and drying ovens. This led to inaccurate workpiece positioning, resulting in uneven spraying, sagging, or missed spots, which lowered the first-pass yield rate.

● Poor Stability and Wear Resistance: The high-frequency start-stop cycles and high-speed operation demanded exceptional wear and impact resistance from the chains. The old system's chains wore out quickly, causing pitch elongation, which further exacerbated operational instability, generated noise and vibration, and potentially damaged delicate workpieces.

● Corrosion Resistance Challenges: Processes like cleaning and phosphating in the pre-treatment stage created a humid and chemically corrosive environment. The conveyor chain required an outstanding anti-corrosion chain solution; otherwise, chain rust would not only contaminate the clean workshop environment but also directly pollute workpiece surfaces with rust particles.

Solution: CamelConvey High-Precision Anti-Corrosion Conveyor Chain System

To address the triple challenges of precision, speed, and corrosion resistance, CamelConvey provided a tailored integrated solution.

● X458 High-Strength Conveyor Chain:

Core Surface Treatment: The X458 chain underwent a zinc-nickel alloy plating surface treatment. This process offers corrosion resistance several times better than conventional zinc plating, effectively resisting chemical vapors in the pre-treatment area while maintaining high strength and excellent wear resistance, ensuring precision stability during long-term operation.

Precision Manufacturing: Utilizing precision molds and processing equipment, the dimensional tolerances of chain links, pins, and rollers were strictly controlled, minimizing the chain's inherent cumulative error from the source.

● 4x6'' Trolley :

Precise Fit: The connection holes and guide wheels of the 4x6'' Trolley were precisely calculated and designed to form a tight "rigid-yet-flexible" fit with the X458 chain, greatly eliminating radial shaking typical of traditional systems and achieving near-zero drift operation of the trolley on the track.

Dedicated Tooling: Based on the 3D models of power tool housings provided by the customer, custom fixture tooling was designed to ensure workpieces remained secure and stable during high-speed transportation, facilitating easy robot handling and spraying.

Results & Benefits

Since the new conveying system was put into operation, the customer's painting line performance has achieved a leap forward:

● Quality Improvement: Coating defect rates caused by the conveying system decreased by 90%, and the first-pass yield rate increased to over 99.5%, significantly enhancing the brand image of premium products.

● Efficiency Gain: The production line stably achieved the designed cycle time of 16 units per minute, increasing overall production efficiency by 22% and greatly enhancing on-time delivery capability.

● Reduced Maintenance Costs: Thanks to excellent wear and corrosion resistance design, the system experienced no unplanned downtime caused by the chain or trolley within the first year of operation, with projected maintenance costs 40% lower than the old system.

The customer's Production Manager commented: "The precision and reliability of CamelConvey's X458 chain and 4x6'' Trolley combination exceeded our expectations. It is not just a component but a guarantee of our high-quality coating."

In modern manufacturing, where efficiency and high quality are paramount, precision and reliability in every links are crucial. Leveraging its deep expertise in conveyor chain surface treatment technology and profound understanding of precision conveying systems, CamelConvey provided the Brazilian power tool customer with an anti-corrosion chain solution that exceeded expectations, successfully resolving the challenges of precise positioning and stability in high-cycle production.

If you are also seeking solutions for precision, corrosion, or service life issues in your painting line, assembly line, or other conveying systems, please contact us immediately. Let CamelConvey's professional team customize an efficient and reliable conveying system for you!