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Robotic metal and composite sanding
Sanding is one of the most commonly applied processes in all sectors of the industry.
It improves the surface finish of a metallic part by eliminating geometrical defects and change its roughness value. The result is:
This process is still mainly done by hand as the quality of the sanding depends on the operator’s skill and dexterity. It is, though, a particularly arduous task, that exposes operators to dust that frequently generates MSD (Musculoskeletal Disorders).
GEBE2 has developed a robotic metal sanding solution that reproduces the operator’s gestures and sensitivity. The central element, the effector, is equipped with a random orbital electric sander and a compliant device that applies a constant force in all directions, around +/- 2N.
To enhance the autonomy and performance of their cells, GEBE2 has equipped its robots with automatic disc changers that provide for using a range of grain sizes.
Sanding quality is strongly related to the regularity of the sander’s motion on the part. Our offline programming software simulates all possible trajectories with a graphic display of the material’s removal.
GEBE2 provides custom-engineered CAD/CAM software for sanding robot that programs trajectories in hidden time based on the CAD file of the part. The graphic display of material removal guides the programmer and helps him obtain a smooth surface.
The end-effectors range for robotic sanding includes 2 differents versions :
The compact end-effectors are equipped with a 350W sander and a rotative disc of 80 or 150 mm, perfect for small and medium parts or even complexe geometrie parts.
The high performance end-effectors are equipped with a 900W sander and a rotative disc of 150, 200 and 225 mm, perfect for large parts. This sander perfomrs the operation 1.7 times quicker than a classic end-effector.
All our end-effectors can be mounted with a single-head or a multi-head, until 4 heads for the compact effector and 3 head for the high-capacity effector.
The single-head end-effector is an advantage for parts with complex geometries while the the multi-head enf-effector provides an optimum productivity for medium and large parts.
GEBE2 designed a customized robotized cell for sanding and polishing of titanium blade leading edge for composite blade of an aircraft engine. Those parts are submitted to strict aerodynamic constraints. They must present a perfect homogeneous surface finish to optimise the air flow going into the engine and guarantee better performance and a higher energy efficiency.
The pick-up and removal of air inlet blades are managed by the operators. This manual system, combined to the sanding and polishing automatization provide flexibility and high precision.
Titanium-specific sanding and polishing abrasives have been selected to avoid premature abrasive wear.
Robotic sanding cell realized for SABCA. The robot is mounted on a rail allowing to work on large parts (up to 8m length). It is equipped with a laser recognizing the parts and adjust its position. The robot uses 2 end-effectors to work: a sander with an automated disc change system and an electro-spindle working with different deburring or sanding tools.
More information on the cell with the testimony of Yoann BARON, Manufacturing engineer at SABCA, below
This metal sanding application is designed to hide machining traces and obtain a uniform appearance over the whole surface of this out-of-round piece. This is achieved using a sensitive sanding effector that apply a constant force along the tool path. The sanding machine is still normal to the surface, that optimize the effectiveness of the process and the quality of the part.
Stripping removes all machining traces that could reduce part fatigue strength including, in particular, aircraft wing panels. This application uses rotary tools associated with a compliance that guarantees uniform treatment.
In order to improve the surface appearance of shaped parts post-machining, the robot moves along the workpiece applying a rotary tool fitted with an abrasive material with a controlled force. Great care has been taken to create trajectories in order to obtain uniform roughness. This polishing operation can be combined with a random orbital sanding operation for finishing.
This multi-head robot is perfectly designed to work on large parts. The robot-assisted effector maintains a constant force on each disc, along with remote shape tracking, while remaining perpendicular to the surface. Thanks to this patented technology, it is now possible to sand thin, flexible parts using lightweight, cost-effective tools.
Feasibility study of interior and exterior sanding of bodyworks with complex geometry in order to prepare parts for coating. The programming is fully simulated on the cabin’s digital file using CAD/CAM software.
The disc changer is vital to ensuring autonomous operation of the sanding robot. This device removes used abrasives and distributes new ones. Several disc feed storage can be installed depending on the range of grain sizes used.
Automation of metal finishing operations for SABCA
Discover the interview of Yoann BARON, Manufacturing engineer at SABCA. (video in French)
Why SABCA decided to automate the sanding and deburring operations ? And how GEBE2 met SABCA’s needs ?
Our composite and metal finishing solutions: Acoustic drilling– Composite and metal machining – Deburring – Trimming – Grinding – Collaborative sander
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