Grinding and polishing are crucial processes in manufacturing. Robots are increasingly used to address issues like low efficiency and high costs associated with traditional manual methods. In China, the market for these robots reached 9.61 billion RMB in 2022, with 8,752 units installed. Over the next five years, installations are expected to surpass 30,000 units, showcasing substantial growth potential.

However, challenges in precision and stability limit broader adoption compared to processes like welding, handling, and palletizing.

Challenges

1. Material Inconsistency: 

Variations in raw material batches and prior processing steps result in inconsistent external dimensions, challenging precise positioning and identification of products.

2. Low Polishing Yield: 

Precision requirements and workpiece deviations make it difficult to maintain a consistent finishing effect, leading to uneven grinding and a hindered mass production yield.

3. Complex Programming: 

Diverse materials and complex shapes require numerous programming points, posing a challenge for the robot to adapt its grinding trajectory and demanding high operator skill.

4. Flexible Production Changeovers: 

Small batch, diverse production patterns necessitate universal fixtures and compatibility with different processing methods, requiring a polishing program with closed-loop control.

5. Stringent Robot Performance: 

The grinding process puts significant torque on robot joints, and environmental factors like water mist and dust challenge core capabilities such as rigidity and stability.

6. Diverse Tool Requirements: 

Complex polishing processes and varied material types require the robot to frequently change tools and consumables without compromising production efficiency.

Key Technologies

ROKAE Robotics has developed an intelligent polishing solution with a deep understanding of the polishing process and extensive practical experience. This solution tackles the challenges of automating polishing and meets diverse polishing needs, accumulating essential technological advantages in the process.

1. Force Control:

ROKAE's compliant force control system ensures constant contact force during polishing, with precision at ±0.5N. It allows parameter quantification for process adjustments, enhancing product consistency and polishing quality.

2. Vision:

The AutoGen vision system collects real-time workpiece information, enabling automatic trajectory planning and error compensation. It facilitates rapid adjustment of process parameters for diverse production scenarios, lowering operational barriers.

3. Offline Programming:

RokaeStudio, the offline programming software, meets simulation needs for complex surface modeling and interference scenarios. It shortens programming time and improves efficiency.

4. Robot Main Body Performance:

① High Precision and Speed:

Equipped with the xCore control system, ROKAE robots lead in motion accuracy and speed, ensuring precision in small curve trajectories and effective vibration reduction.

② Flexibility:

New path generation supports smaller transition radii, ensuring smoother polishing actions and accurate trajectories for product consistency.

③ Reliability:

Upgraded collision detection protects equipment and ensures zero-point retention. The robots maintain high performance in misty and dusty environments.

Comprehensive certification ensures stability, reliability, and lifecycle cost reduction.

5. Peripheral Equipment and End Tools:

ROKAE designs professional fixtures, recommends suitable tools, and provides cost-effective self-made mechanisms to meet various polishing requirements.

With extensive experience in polishing, ROKAE excels in processes for diverse materials, including cast aluminum, cast steel, forging, plastic, and sand cores. The company delivers intelligent force-controlled polishing solutions, driving the transformation and upgrading of industries like automotive components, hardware, and the power sector.