Complex tasks that used to be done manually, such as assembly, deburring and polishing, can now be replaced by robots.

Sensors play a key role in many workplaces, and these are now being replaced by robots. For example, torque sensors can accurately identify process parameters and deliver them to the control unit. If the robot path is adjusted in real time based on these data, it is possible to have a continuous workforce and reproducible results. Modern, standardized sensor solutions are simple, fully actuator compatible and easy to use.

The hidden potential of the sensor

Currently, the most versatile torque sensors for industrial automation measure force and time in all six degrees of freedom. The sixth axis is equipped with a robot control interface, so the connection is greatly simplified. The high-precision sensor outputs data at a high frequency of 7,000Hz and follows five communication protocols (Ethernet, Ethernet / IP, DeviceNet, Profinet and a CAN-Bus interface), remote control via LAN, and unique interface compatibility Through the web interface configuration. It can be applied to product testing, robotic assembly, processing tasks such as grinding and polishing, robotic surgery, and other areas like rehabilitation and neurology. The sensor also supports the concept of highly dynamic control and can therefore be used to automate complex assembly, machining and completion of tasks that were previously performed manually or with complex special machines.

Tactile sensors are first-class modern sensors. Such sensors can be on the scene to solve the clamping force and surface monitoring. Therefore, it can hold the object with high sensitivity while recognizing the object. Tactile sensors can help reliably and safely handle fragile components of different geometries, and can place and connect changing objects. In the future, tactile sensors will play an increasingly important role in the field of service robots. They turn gripping hands into sensitive assistants for efficient use in complex and unorganized environments.

Polishing, polishing and deburring accessories

Currently, robot parts are also available for undefined machining methods such as grinding, polishing, brushing and deburring. These accessories are very reliable, there is no need to use the sensor. They complement tool wear and inaccuracies in workpiece positioning, as well as deviations of the robot from the specified path. As a result, processing time has been cut by as much as 75% while improving the quality of the work. Burr spindles can be realistic and accurate simulation of the process of deburring. With a working speed of up to 65.000 rpm, the spindle and monitoring system is flexibly located on a self-aligning bearing. Several small pneumatic pistons ensure radial or axial compensation of 9 mm for the spindle. Therefore, the pneumatic motor can move into the housing and compensate for the error between the tool path and the actual workpiece contour. Even if the components are irregular shapes, you can achieve consistent results. The hardness of deburring spindles can be controlled via a separate pneumatic interface and the tidiness of the chamfered edges can be guaranteed for each mounting position.

The compensation unit ensures the flexibility required when the manipulator and the robot work together, such as using robotic seams, fitting and embedding. They avoid system interference and damage and process reliability is increasing. Two-way flexibility can be achieved with spring adjustment screws, while three-direction flexibility is achieved with elastomer elements. Because these units have nothing to do with pneumatic components, they are flat and well suited for use in confined spaces. Smooth running roller guidance can even compensate for forces without stick-slip effects. The spring-driven reset piston ensures high repeatability.

Automation tools change

Even retrofit holders, tools, and other effectors can replace or reduce manual labor with suitable robotic accessories. A well-trained operator will need 10 to 30 minutes to retrofit a pneumatic effector, while a quick retrofit system will do the same in 10 to 30 seconds, with pure locking and unlocking in just a few milliseconds. High-speed conversion systems can be periodically applied to new product and product variants, especially those that require significant effector processing or downtime due to component or tool repairs.

When choosing a quick retrofit system, users and system integrators should pay attention to the possible low weight-to-power ratio, short retrofit time, and standard size energy transfer modules. Modular systems are particularly economical if the various electronics and fluid modules can be connected to each other. If locking and unlocking do not require labor, a so-called contactless system would be the perfect choice, and it would also ensure a safety lock. Heavy-duty retrofit systems are designed to handle heavy duty workpieces and work with heavy-duty grippers, vacuum spiders, hydraulic / pneumatic / electric machining spindles, rivets, welding tongues, and bolting for automatic feed. Moreover, they are also applicable to the automation industry where assembly and pressure bonding are common. Due to its high performance, rapid retrofit systems are more suitable for flexible production lines to build and process light or heavy workpieces.

Rapid retrofit systems are perfect if all four exterior surfaces are equipped with a uniform mounting flange. This provides more space for the components and supplies, and can be pneumatically, hydraulically or electrically fed to the coupling effectors. However, the single module coupled and decoupled by rapid retrofit systems is an exception. The remaining three surfaces can be optional.

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