Autonomous sanding and polishing robot

EKB moves in the area of more complex industrial automation, where different systems are linked and integrated to create a total solution for a customer-specific issue. For example, an automatic sanding and polishing robot was recently commissioned. An autonomous system that moves along a 7-meter linear axis and independently performs surface processing based on CAD data or a vision system.

EKB's strength lies in the complete integration of production automation systems, ranging from a single sensor to overarching control layers in production (MES) or administration (ERP). Because a customer-specific solution is almost always involved, EKB engineers like to be at the table as early as possible. This offers the opportunity to choose the right solution right from the start. This leads to a system that can be seamlessly integrated into business processes, taking into account maximum efficiency and security.

Sanding and polishing robot

A compelling example of a project where everything comes together is the development of an autonomous sanding and polishing robot. This combination of robotics, motion and vision is used to treat steel or plastic surfaces. The total solution consists of the robot itself, the linear axes, the sensors, the vision system, the pressure and position control systems and the sanding or polishing head. For this particular customer, an additional challenge was that the solution had to be suitable for large workpieces with the robot moving along a 7-meter long linear axis.

The movements of the robot, and in particular the robot arm with sanding or polishing tool, take place in the 2D or 3D plane. They are determined by CAD data (a drawing of the product) or a vision system. In the first case, the geometric data of the drawing is read in and the robot is controlled on this basis. When using a vision system, the surface is first "scanned" with a smart camera after which this measurement data is converted to the correct movements of the robot. The vision system also functions as a monitoring system to continuously control the quality of the sanding or polishing process. This quality is also guaranteed by applying force sensors or an adjustable end-of-arm actuator. In order for the robot to perform the correct movements, EKB used extensive simulation. 

Advantages

The vision system makes it possible to also treat the surface of "unknown" products - for which no CAD file exists. This also makes the robot setup suitable for single piece machining. If desired, it can also be flexibly expanded with one or more linear axes when the workpiece or the operating conditions (growth) demand it.

This piece of automation allows the end user to outsource the relatively tedious and, for humans, burdensome sanding and polishing processes to a robot. At a time when it is difficult to find personnel, this means a reduction in workload. But also ergonomic operating conditions because employees no longer have to perform the same movements for long periods of time, which can lead to strain and other injuries. In addition, it is safer when high-speed sanding or polishing heads are placed in the hands of a robot, who also cannot inhale grinding dust. There are also advantages for the quality of the final product: Manual sanding can produce variations in the result due to differences in pressure, speed and movement patterns. EKB programs the robot to treat each surface with exactly the right force and speed to achieve an optimal finish. Robots also work faster, which increases productivity and throughput. Finally, the end user also has the option of operating this solution at night. 

If you see opportunities for this application within your company, please contact EKB. The team of vision and robotics experts can undoubtedly help you further.