π Case Study
Vision-Guided Deburring Robot for Cast Aluminum Engine Blocks
Variable burr height (0.1β2.4 mm) and location due to inconsistent casting; complex freeform surfaces limiting fixed-tool paths
ποΈ Project Overview
Fordβs Romeo Engine Plant modernization initiative
π― Challenge
Variable burr height (0.1β2.4 mm) and location due to inconsistent casting; complex freeform surfaces limiting fixed-tool paths
π§ Design Approach
Confocal chromatic displacement sensor + 2D vision fusion; adaptive force control with vision-triggered toolpath modulation; CAD-based surface normal alignment with real-time offset correction
π Design Diagram
AI-generated project design illustration
π Key Calculations
Maximum Allowable Burr Height Error
|h_measured β h_actual| β€ 0.08 mm
Result: 0.06 mm RMS
Prevents over-deburring critical sealing surfaces
Surface Normal Deviation Threshold
cosβ»ΒΉ(nβΒ·nβ) β€ 4.2Β°
Result: 3.8Β°
Ensures consistent tool engagement angle across curved faces
π Results
100% burr removal compliance (per ASTM B117); 41% reduction in tool wear; zero rework due to surface damageπ‘ Lessons Learned
- β’Confocal sensor compensated for paint and oxide layer variance better than laser triangulation
- β’CAD-based normal alignment reduced programming time by 70% vs. teach-point method
- β’Force-vision fusion prevented chatter on thin-wall sections
β Key Takeaways
- 1Confocal sensor compensated for paint and oxide layer variance better than laser triangulation
- 2CAD-based normal alignment reduced programming time by 70% vs. teach-point method
- 3Force-vision fusion prevented chatter on thin-wall sections
π Prerequisites
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β‘οΈ Next Step
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π Engineering Applications
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