Force Controlled Knife-Grinding with Industrial Robot

This paper investigates the application of sharpening knives using a force controlled industrial robot, for an arbitrary knife shape and orientation. The problem is divided into different parts: calibration of the knife by identifying its unknown orientation, identification of the knife blade contour and estimation of its position in the robot frame through force control, and grinding of the knife, following the path defined by the earlier identified shape, while applying the desired contact force to the revolving grinding wheels. The experimental results show that the knives can be sharpened satisfactorily. An industrial application has also been developed and tested, and it has produced a sharpening quality equal or greater to that achieved manually

A macro-micro robot for precise force applications

This paper describes an 8 degree-of-freedom macro-micro robot capable of performing tasks which require accurate force control. Applications such as polishing, finishing, grinding, deburring, and cleaning are a few examples of tasks which need this capability. Currently these tasks are either performed manually or with dedicated machinery because of the lack of a flexible and cost effective tool, such as a programmable force-controlled robot. The basic design and control of the macro-micro robot is described in this paper. A modular high-performance multiprocessor control system was designed to provide sufficient compute power for executing advanced control methods. An 8 degree of freedom macro-micro mechanism was constructed to enable accurate tip forces. Control algorithms based on the impedance control method were derived, coded, and load balanced for maximum execution speed on the multiprocessor system

Robotic Grinding Process of Turboprop Engine Compressor Blades with Active Selection of Contact Force

The work presents a robotic system for grinding the blades of a turboprop engine compressor. The proprietary conceptual solution includes a data acquisition system based on a robotic 3D scanner, a neural decision system and a robot performing a grinding process with force control. The contact force of the tool to the blade was assumed as a variable and controlled process parameter. A neural network was used to generate the contact force on the basis of measured machining allowances on the blade. A virtual grid of several dozen regularly spaced points was placed on the surface of the blade. The neural network was learned the allowance-force dependence for the selected points, making it possible to select the proper contact force on the surface to be machined. The developed algorithm for the process of robotic grinding of the blades takes into account the necessity of ongoing quality control of the processing and the introduction of corrections in the process

Extending an industrial root controller : implementation and applications of a fast open sensor interface

An overview is given of the design and implementation of a platform for fast external sensor integration in an industrial robot system called ABB S4CPlus. As an application and motivating example, the implementation of force-controlled grinding and deburring within the AUTOFETT-project is discussed. Experiences from industrial usage of the fully developed prototype confirms the appropriateness of the design choices, thus also confirming the fact that control and software need to be tightly integrated. The new sensor can be used for the prototyping and development of a wide variety of new application

Experimental investigations of the effects of cutting angle on chattering of a flexible manipulator

When a machine tool is mounted at the tip of a robotic manipulator, the manipulator becomes more flexible (the natural frequencies are lowered). Moreover, for a given flexible manipulator, its compliance will be different depending on feedback gains, configurations, and direction of interest. Here, the compliance of a manipulator is derived analytically, and its magnitude is represented as a compliance ellipsoid. Then, using a two-link flexible manipulator with an abrasive cut off saw, the experimental investigation shows that the chattering varies with the saw cutting angle due to different compliance. The main work is devoted to finding a desirable cutting angle which reduces the chattering

A chewing robot based on parallel mechanism-- analysis and design : a thesis presented in partial fulfilment of the requirements for the degree of Master of Engineering in Mechatronics at Massey University

Masticatory efficiency, dependent on number and condition of the teeth, length of time spent in chewing a bolus and the force exerted when chewing, influences an individual with the selection of food and therefore nutritionally diet. A characterisation of the masticatory efficiency could be possible with a chewing robot that simulates human chewing behaviours in a mechanically controllable way (Pap et al. 2005; Xu et al. 2005). This thesis describes such a chewing robot, developed from a biological basis in terms of jaw structure and muscles of mastication according to published articles. A six degrees of freedom parallel mechanism is proposed with the mandible as a moving platform, the skull as a fixed platform, and six actuators representing the main masticatory muscle groups, temporalis, masseter, and lateral pterygoid on the left and right side. Extensive simulations of inverse kinematics (i.e., generating muscular actuations with implementing recorded human trajectories) were conducted in SolidWorks and COSMOS/Motion to validate two mathematical models of the robot and to analyse kinematic properties. The research showed that selection of appropriate actuation systems, to achieve mandible movement space, velocity, acceleration, and chewing force, was the key challenge in successfully developing a chewing robot. Two custom designed actuation systems, for the six actuators, were developed and built. In the first approach, the muscle groups were presented as linear actuators, positioned so as to reproduce the resultant lines of action of the human muscles. However, with this design concept the spatial requirements specified from the human masticatory system made the physical building of the model impossible. The second approach used a crank mechanism based actuator. This concept did not allow a perfectly linear actuator movement that copied the muscle line of action. However, it was possible to fulfil the spatial requirements set by the human system and to allow reproduction of human chewing behaviours in relation to kinematic requirements and chewing force. The design, manufacture and testing of the entire chewing robot with crank actuators was then carried out. This included the implementation of realistic denture morphology, a mechanical jaw and the framework design for the whole system. In conclusion, this thesis research has developed successfully a mathematical and a physical robotic model. Future work on the control and sensing of the robot and design of a food retention system are required in order to fully functionalise the device

Material removal simulation for steel mould polishing

The surface finish of an injection mould influences the quality of the moulded polymer optic parts. In order to improve and control the surface finish of the mould it is important to be able to predict the material removal during the polishing process of this mould. The aim of this work is to predict the material removal during the polishing process, comparing the results obtained from polishing attempts on steel samples and the results obtained from a simulation model. A simulation model is developed with the abrasive wear Holm-Archard equation in ANSYS. This simulation model will help to eliminate the iterative trial and error polishing, therefore facilitating the steel mould production