Application Scheme of 6-Axis Robots in Complex Curved Surface removing burrs Projects

I. Project Background

We recently delivered a batch of automated deburring solutions in Indonesia. This helps with tough burr removal on curved plastic parts. It also improves manual efficiency and reduces safety hazards. Additionally, it lowers dust-related health risks. This project is a typical example of robotics in manufacturing applied to plastic part finishing.

II. Overview of the Solution

An integrated solution of "6-axis robot + precision fixture + fixing device" was adopted.

III. Working Principle of the Robot removing burrs Equipment

The robot follows set paths to move the removing burrs tool to the right spot. It finishes the removing burrs task by rotating, scraping, grinding, and using other methods.

IV. Features of the Robot Deburring Equipment

High Precision and Efficiency

The robot boasts a repeat positioning accuracy of up to ±0.06 mm. With a 1710 mm arm span and a 467 mm deep reach, it can control tool deviation within 0.1 mm for 3D curved surfaces. This enhances deburring precision and consistency. Meanwhile, the robot enables continuous operation, rapidly completing large-volume deburring tasks and boosting production efficiency significantly.

Strong Flexibility

The robot deburring equipment is a program-centric flexible unit. On the same platform, you can quickly switch between workpieces of different shapes, sizes, or materials. Just call the right process package, change the tools, and adjust the force or speed settings.

You can run different parts without making mechanical changes.. A single machine can handle 12 or more types of parts. This makes it cost-effective and adaptable for small-batch, multi-variety production.

High Safety

High-speed splashing particles and respirable dust (<5 μm) generated during deburring pose major workplace health risks. The robot deburring equipment works in a closed space. This helps reduce burr and dust splatter. It also enhances worker safety and health protection

Stable Quality

Through precise motion control and force output, the robot deburring equipment ensures consistent deburring results. It maintains the same deburring quality regardless of the number of workpieces   processed, improving overall product quality stability.

 V. Deburring Demand Assessment

 Workpiece Type and Material

Manual deburring of complex curved surfaces is often slow and hard to standardize. In contrast, a robotic system can easily manage burrs of different shapes and sizes with precise control.

 Deburring Precision Requirements

Siemens high-resolution sensors and KND’s precise motion control system work together. The robot deburring equipment uses them. This combination allows for accurate regulation.

To solve the problem of lightweight workpieces that can easily move, we created special fixing devices. These devices keep the workpieces stable during robotic operations. This helps prevent mistakes in precision and reduces safety risks. Additionally, the solution enables one operator to manage multiple machines, significantly cutting labor costs.

VI. Equipment Performance Evaluation

Robot Performance

1. Load Capacity: The robot can carry a load of 20 kg. This is enough for the deburring tool and the workpiece. It can hold the weight of the deburring tool and workpiece, with a 20% safety margin.

Motion Range and Flexibility: It has a 1243 mm front-rear travel and a 6-axis joint design. This allows it to cover all deburring areas of the workpiece in 360°.

3. Repeat Positioning Accuracy: The ±0.06 mm repeat positioning accuracy ensures that deburring positions are consistent. The tool path deviation is ≤ 0.1 mm. This meets the edge consistency needs for high-precision plastic parts.

4. Speed and speed adjustment: The end-effector can move at a maximum speed of 900°/s. This supports a two-step process of "fast rough deburring and slow finishing." You can adjust the speed adjustment curve online to balance efficiency and vibration suppression.

Deburring Tools

Targeting the burr characteristics of PC+ABS plastics, diamond-plated grinding heads are selected. A single tool holder combines two grit levels: rough grinding and fine polishing. It can do both deburring and mirror polishing in one pass. The surface roughness is Ra ≤ 0.4 µm.

Service Life and Efficiency

Under working conditions of 6,000 r/min and 0.2 mm cutting depth, a single grinding head has a service life of ≥ 8,000 workpieces. Tool change intervals are pre-set in the process recipe, with automatic system reminders for replacement.

Maintenance and Spare Parts

The manufacturer furnishes each robot with 10 spare grinding heads as standard configuration. Local operators clean tools every day for about 5 minutes. They also do a weekly calibration for 10 µm runout to ensure stable performance. With this maintenance routine, annual downtime remains below 2 hours.

Control System

Graphical wizard-based programming allows operators without coding experience to create standard processes within 30 minutes. Built-in plastic part deburring process packages enable one-click activation of "edge following + force-controlled floating" strategies.

The force control sensor provides real-time feedback with ±1 N precision, automatically detecting tool wear. It supports offline simulation with 1:1 reproduction of actual trajectories, reducing first-piece debugging time by 50%.

The "robot deburring + flexible plastic part grinding + fixing device" solution solves three main problems. These are dead spots on curved surfaces, movement of lightweight parts, and keeping batch consistency.

It has helped the Indonesian client boost production by 55%. The system now delivers a consistent product yield of 99.2%, increasing productivity significantly。 
This case shows how robotics in manufacturing helps factories achieve higher quality and output.