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Xiaoya Customised Easy Control Grinding Robot1
Industrial Robot, Grinding, Polishing
Shandong Xiaoya Precise Machinery Co., Ltd.
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Product Description Product DescriptionI. Process Technology1. 3D Vision Real-time Modeling TechnologyUtilizing high-precision 3D cameras, the system dynamically scans workpiece surfaces at 2 million points/sec, generating point cloud models with ±0.05mm resolution. Automatic spatial alignment between point clouds and the robot base frame eliminates manual fiducial marking and removes dependency on original CAD models. Integrated vision algorithms feature noise-reduction filtering and surface reconstruction, ensuring stable imaging even for reflective metals or complex geometries.2. Intelligent Path Planning EngineOperators define arbitrary polishing zones (polygon/free-draw) via a PC-based GUI. Deep learning algorithms segment point cloud regions and generate collision-free optimized paths in <0.5 seconds, incorporating robot reach limits and joint constraints. Path planning includes adjustable overlap control (default: 30%) and edge-transition smoothing to prevent over-polishing or omissions.II. Core Hardware ConfigurationComponentTechnical SpecificationsKUKA KR120-3100-2 Robot6-axis articulated arm, ±0.06mm repeatability, 2m/s max speed. 3100mm reach covers 6.2m spherical workspace. IP65 rating withstands polishing dust. 120kg payload (50% above tool weight) ensures stability during high-speed operation.Custom Floating Force Grinder SFC1020-Q55Integrated servo motor enables stepless speed control (0-12,000 rpm). Dual-mode pneumatic-spring compensation maintains constant grinding force (1-100N ±3%) within 20mm float range. Quick-change interface supports belts/wheels/nylon brushes.Square Force Control Module SFC30206-axis F/T sensor monitors XYZ forces/torques at 1kHz sampling. Closed-loop algorithms dynamically adjust robot pose to compensate ±2mm part dimensional errors or robot positioning drift, ensuring normal-direction constant force on complex surfaces. III. Process Workflow1. Point Cloud Acquisition PhaseOperators use a pendant with precision handwheel (0.01mm resolution) to position the robot-mounted 3D camera. Automated multi-view capture (5-8 angles) stitches point clouds via ICP algorithms, achieving ≤0.5mm point spacing. Software auto-compares with CAD models (if available) to identify material buildup zones; model-free workpieces require manual area selection.2. Trajectory Generation PhaseGaussian filtering reduces point cloud noise. NURBS-based surface fitting calculates per-point normals. Path planning generates iso-parametric parallel paths (adjustable stepover) with automatic contour-tracking mode at edges. Critical zones allow manual waypoint insertion for fine-tuning.3. Execution Monitoring PhaseDuring robot operation (0.5m/s path speed), force feedback triggers Z-axis retraction within 10ms upon detecting geometric discontinuities (e.g., hole edges) to prevent tool damage. Process database auto-selects material parameters (e.g., stainless steel: 80N force, 8,000 rpm).IV. Safety Protection System1. Hardware Safeguards2m-height dual-layer steel mesh fencing (50mm outer/10mm inner aperture)Safety doors with SICK interlocks: Cut robot power and engage pneumatic brakes upon access8 emergency stop buttons (response ≤0.3s) distributed per ISO 138502. Software ProtectionRole-based access: Operator (preset recipes), Engineer (path tuning), Technician (diagnostics)Tricolor beacon + audible alarms: Green (operational), Yellow (standby), Red (low air pressure/vision fault/collision)3. Process MonitoringAir pressure sensors halt operation below 0.4MPa (threshold: 0.6MPa)Safety scanners detect human intrusion for immediate decelerationElectrical cabinets feature positive-pressure dust-proofing and 55°C-triggered cooling V. Service Terms1. Critical Failure (Level 1)For robot runaway/safety failures: Remote diagnosis in 1hr, on-site support with spares in 2hrs. Module replacement (e.g., force control unit) restores operation within 24hrs. Full RCA report provided.2. Performance Degradation (Level 3)For path deviations >0.2mm or Ra outliers: Remote calibration in 8hrs. Hardware replacements (e.g., camera lens) shipped in 2 business days, installed via engineer-guided video call with laser tracker validation.3. Preventive MaintenanceQuarterly remote log analysis for early warnings (motor overload/gearbox wear)Annual on-site service: Robot regreasing, force sensor calibration, safety circuit testsComplimentary consumables kit (3x grinder bearings, 5x camera lenses) VI. Core Technical Advantages1. Precision & Adaptability20mm float compensation handles casting dimensional variations (±1.5mm). Closed-loop force control maintains Ra consistency (σ≤0.05μm). Reduces part changeover time from 4hrs to 15min vs. hard tooling.2. Human-Robot Collaboration EfficiencyNo-code programming lowers skill barriers (8hr operator training). Handwheel fine-positioning (0.01mm) is 3x faster than teach pendant. 100+ material recipes enable instant product switching.3. Lifecycle ManagementIoT modules stream real-time current/temperature/vibration data to cloud platforms. Mobile app displays equipment health scores and consumable life (e.g., "Grinder bearings: 600k cycles remaining"), auto-generating maintenance work orders. *Deployed in aerospace (aero-engine blades, Ra0.2μm) and automotive (alloy wheels, Ra0.8μm) sectors. Single-cell throughput: 120 pcs/day, 400% higher than manual polishing.*
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