Applications of Aluminum Alloy Die Casting And Zinc Alloy Die Casting in Robotics

Due to their different material properties, aluminum alloy die castings and zinc alloy die castings have very clear applications in robotics.

I. Applications of Aluminum Alloy Die Castings in Robots

Aluminum alloy die casting perfectly balances lightweight, strength, and cost, making it the preferred choice for large structural components in robots. It is mainly used for any moving parts requiring weight reduction, large load-bearing structures (such as arms, chassis, and main frames), and structural components requiring good heat dissipation.

Application Structures:

1. Robot Main Skeleton and Large Shell

Base, upper arm, and forearm of articulated robots (robotic arms): These are the core load-bearing and moving parts of the robot. Through integrated die casting, they can replace the assembly of multiple sheet metal or machined parts, achieving higher structural rigidity and lighter weight.

Chassis and Body of Mobile Robots (AGV/AMR): Die-cast chassis can integrate motor mounting bases, bearing housings, cable channels, etc., resulting in a compact structure with good rigidity, capable of withstanding collisions and vibrations.

Humanoid Robot/Exoskeleton Torso Frame: Extremely lightweight requirements necessitate large die-cast aluminum alloy components, making them ideal for the robot's "skeleton" system.

2. Robot Joint Module Housing

Robot joints (servo motors) typically integrate motors, reducers, and controllers.

Die-cast aluminum alloy housings provide high-precision mounting interfaces, ensuring coaxiality of the motors and reducers. Excellent heat dissipation allows for rapid heat dissipation from the motors and actuators.

3. End Effector (EOAT) Body: The body structure of pneumatic and electric grippers. Lightweight grippers reduce end effector inertia, allowing for faster and more precise robot movement.

4. Controller and Actuator Housing: Protects sensitive internal electronic components while utilizing the excellent thermal conductivity of aluminum alloy through the design of heat sinks and other methods for efficient heat dissipation.

Commonly used die-cast aluminum alloy grades: ADC12 (A383), A360, ALSi9Mg, etc.

II. Application of Zinc Alloy Die Castings in Robotics

The core advantage of zinc alloy die casting lies in its superior casting performance, enabling the production of dimensionally stable, thin-walled, complex-shaped parts with extremely high surface finish, as well as very high rigidity and strength. It achieves extremely high dimensional accuracy, rigidity, and surface quality. Zinc alloys are suitable for producing small functional parts with extremely complex shapes and thin walls, parts requiring wear resistance, and parts with aesthetic requirements.

Application Structures:

1. High-precision, small structural parts and brackets

Sensor brackets: Used to fix lidar, vision cameras, IMUs (Inertial Measurement Units), etc. These sensors are very sensitive to minute deformations. The extremely high rigidity of zinc alloy brackets can effectively prevent deformation caused by vibration or stress, ensuring the accuracy of measurement data.

Internal precision gears and transmission components: Although high-strength plastic gears are common, zinc alloy die-cast gears are used in miniature transmissions requiring extremely high rigidity, wear resistance, and dimensional stability. 1. Connector Housings and Interface Components: Zinc alloy die-castings are perfectly suited for complex snap-fit structures and precision interfaces.

2. Reducer Core Components: Especially in planetary reducers, zinc alloys are widely used to manufacture planetary carriers, end caps, and housings. These components require extremely high precision and rigidity to ensure proper gear meshing and transmission accuracy.

3. Wear-Resistant Parts and Bushings: For wear-resistant components such as bearing bushings and sliders in robot joints, zinc alloys are an economical and durable choice.

4. Decorative Parts and User Interfaces: Brand nameplates, buttons, switches, joysticks, etc. Zinc alloy die-castings can achieve very fine textures and details, and through exquisite electroplating (such as chrome plating, gold plating, and antique bronze), a high-end metallic feel can be obtained, enhancing the overall appearance of the robot product.

5. Counterweights: In a few designs that require adjustment of the robot's center of gravity, the high density of zinc alloys is utilized as compact counterweights.

Commonly used die-cast zinc alloy grades: Zamak 3, Zamak 5, ZA-8, etc.