Robotic Sanding System Using 3D Surface Models
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Solution Overview
Problem
Current surface sanding methods lack precision and efficiency in achieving uniform surface finishes, especially for complex or one-of-a-kind parts, as they rely on manual operation and do not effectively utilize 3D surface models for automated sanding processes.
Innovation Solution
A sanding system comprising a scanner to create a 3D surface model, a sander with a robotic arm and sanding effector, and a control system that uses this model to guide the sanding process, ensuring consistent contact force and precise movement across the surface, allowing for automated sanding of parts with arbitrary shapes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual sanding methods are used, then operation flexibility is maintained, but manufacturing precision and surface finish consistency deteriorate
Solution Approach 1:
The patent replaces manual mechanical sanding operations with an automated robotic system that uses 3D surface models to guide the sanding effector. The robot controller automatically generates toolpaths based on scanned surface data, eliminating manual operation while achieving consistent surface finishes through precise automated control of sanding parameters.
Solution Approach 2:
The patent creates a digital 3D copy of the surface geometry through scanning, which is then used to generate automated sanding toolpaths. This digital model serves as a template that guides the robotic sanding effector, enabling precise reproduction of desired surface characteristics without manual intervention.
2Productivity
If automated sanding systems are implemented, then productivity increases, but device complexity increases
Solution Approach 1:
The patent employs a universal robotic system that can perform multiple functions: scanning the surface, generating 3D models, calculating toolpaths, and executing sanding operations. This multi-functional approach consolidates what could be separate complex systems into a single integrated platform, improving productivity while managing overall system complexity.
Solution Approach 2:
The system performs self-service by automatically generating 3D surface models from scanning data and using these models to create optimized sanding toolpaths without requiring external programming or manual setup. The robot controller autonomously processes the surface geometry and determines the sanding parameters, reducing the need for complex external control systems.
3Manufacturing precision
If 3D surface modeling is used to guide sanding, then manufacturing precision improves, but measurement and detection difficulty increases
Solution Approach 1:
The patent replaces complex manual measurement and detection processes with automated 3D scanning technology. The scanner automatically captures surface geometry and generates digital models, eliminating the need for manual measurement techniques while achieving high manufacturing precision through accurate digital representation of the surface.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables precise and efficient automated sanding of complex parts with arbitrary shapes, achieving consistent surface finishes with minimal user interaction and reduced time, capable of handling parts of varying sizes and shapes with high accuracy.
Implementation Method 1
a scanner configured to scan the part to obtain a three-dimensional (3D) surface model of the surface of the part
Implementation Method 2
Sanding generally involves rubbing an abrasive media, such as sandpaper, over the surface to remove a thin layer of material from the surface
Implementation Method 3
Sanding generally involves rubbing an abrasive media, such as sandpaper, over the surface
Data Source
AI summary
A sanding system for sanding a surface of a part includes a scanner and a sander. The scanner scans the part to obtain a three-dimensional (3D) surface model of the surface of the part to be sanded. The sander sands the surface of the part. The sander includes a sanding effector that engages and sands the surface of the part and a robot coupled to the sanding effector. The robot moves the sanding effector into engagement with and across the surface of the part based on the 3D surface model to sand the surface of the part.