Robotic grinding, sanding, polishing and deburring a wide variety of materials are key operations in numerous industries and branches. The applications are extremely diverse and are usually still done manually due to the lack of solutions and machines. Here in particular, the high-tech end effectors from FerRobotics offer ideal solutions and generate enormous added value, because they “feel” what they are doing and deliver optimal results. Even in 24/7 operation, consistent quality is generated and in addition, shorter cycle times, lower costs and higher productivity are achieved. Robotic surface finishing also solves the dirty, dull and dangerous problems (3D Jobs). Process-optimized complete solutions enable quick and immediate integration into existing systems, both for industrial robots and collaborative robots.
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Fully automated spot repair on clear coat
The elimination of defects on the clear coat is crucial for the final paintwork. In combination with an automated detection system and the Active Orbital Kit it is possible to fully automate this delicate manual process. The AOK/XS provides the essential active force control and sensitivity and therefore not only delivers a perfect paintwork quality, but also achieves substantial cost savings.
Automated polishing with UR cobots and the FerRobotics sanding kit
Using the AOK905 for the automation of sanding or polishing processes with a collaborative robot is not much effort. Fast and easy to programm, this combination achieves perfect polishing results in constant high quality. The AOK905 autonomously compensates surfaces tolerances with consistent contact force.
Automated polishing of carbon parts
The automated polishing of parts with complex surfaces, such as a carbon hood in this case, becomes efficient only through the use of the Active Compliant Technology. Active compensation of tolerances, immediate adaptation to complex shapes and an always constant contact pressure result in a high quality and faster cycle times.
Forklift truck robotic sanding – FerRobotics fullfills Jungheinrich quality level
How does a forklift truck counterweight body meet the Jungheinrich quality level? With a perfect surface treatment (sanding) supported by the FerRobotics ACF (Active Contact Flange) or solution package AOK (Active Orbital Kit). The benefit: An exactly repeatable process can be performed much faster and more uniformly than manually and requires no rework.
Fully automated power-controlled brushing of welding spatters
The ASK Brush as a process-optimized end-of-arm comfort solution contains important peripherals such as servo technology, electronics and extraction. It controls all process parameters individually but coordinated with each other. The ASK Brush brushes guns and welding spatters without damaging the galvanized surface and removes residues.
Fully automated surface preparation for paint finish
The AOK delivers a perfect surface preparation for the finishing in just a few steps. In 24/7 use it removes sharp edges and burrs from the workpiece quickly and efficiently, without changing its geometrical form. No need of rework. Providing active compliant force control, the extraordinary durable orbital grinder generates a uniform, reproducible surface appearance.
Force-dosed automated weld leveling
Due to the exactly constant contact pressure and the resulting constant removal of a protruding weld seam, a perfect and exactly reproducible result is achieved. With this industrial angle grinder with integrated force control, all process parameters such as rotation speed, contact force and feed rate can be adjusted individually. The excellent abrasion performance in 24/7 operation requires no rework.
Grinding the exhaust pipe of car with the ABG
The ABG is the perfect tool for grinding stainless steel surfaces. Ideal for small and medium sized workpieces, the ABG achieves identical reproducible surface quality and a high production output through fully automated grinding. The results are reliable cycle times and there is no rework necessary.
Automatic grinding of overhangs
The Active Compliant Technology from FerRobotics removes material overhangs fully automatically. The technology is characterized by automatic tolerance compensation and exact force control. As a result, undesirable material overhangs are inspected and removed with precision.
Automated deburring of injection molding parts
The ACF from FerRobotics is the velvet glove whose precise force control guarantees perfect results. With the automated processing , precise cycle times, productivity gains, as well as higher quality are achieved at lower costs. This innovative technology from FerRobotics brings this manual task to an automated top standard.
Industrial sanding process of car attachment parts
Due to its sensitivity, the ACF is the ideal equipment for the automated processing of plastic parts. Thanks to autonomous contact sensitivity, ACF processing attains absolutely top quality. The results are so outstanding that manual reworking is no longer necessary.
Automatic removal of weld spatter
The proper brushing process can only be guaranteed by the Active Compliant Technology. The AOK automates this application easily and is therefore already successfully installed in many car factories all over the world. High-grade steel alloys are galvanic coated and shouldn't be damaged due to corrosion risk in no case .
Perfect paintwork quality
Perfect paintwork quality can only be achieved with a perfect grinding process prior to the top coat. Through automation of this grinding procedure, the luster of the paintwork is significantly improved. As FerRobotics is for both, body filler grinding and spot repair, the leading solution provider, car manufacturers all over the world use this high-quality grinding technology.
Automated grinding of thin-walled workpieces
With the ACF it is possible to reproduce lower forces (3 - 8 N) constantly 24/7. This force control prevents grinding through of thin-walled or soft workpieces, like they are used in high-quality car seats. This very thin layer of breathable coconut fibers which is integrated in car seats needs to be processed very carefully.
Grinding of door welding seam
Due to the interactive compensation and guaranteed consistent contact force of the ACF, tolerances in surfaces can be balanced automatically and thus reproducible high quality can be achieved. The automation of the grinding process not only results in 100% savings in problematic manual work but also in significant reductions in abrasive consumption.
Fully automated polishing of challenging outlines
Despite many recesses the AOK polishes the complex surface of a motorcycle part with high speed. The contact-sensitive Active Orbital Kit is worldwide the only end-of-arm comfort solution for fully automated polishing. The AOK is suitable for highest quality requirements regarding shapes, materials or for delicate workpieces.
Automated car wing polishing
With the AOK905 polishing and sanding processes can be automated easily. The package solution consisting of an orbital sander and the Active Compliant Technology is a Plug’n’Play solution that delivers high-quality results even for complex shaped parts. The outstanding benefits of the system are the automatic tolerance compensation and precise consistent contact force.
Automated sandpaper changing station for finesse sanding
For a fully automated sanding process not only the robot suitable orbital sander is essential but also the equipment it comes with on order. The delivered abrasive changing station includes a paper removing tool and a paper magazine with internal process control. The changing station can be used for our AOK XS with adhesive papers daisy shape.
Automated deburring with ACF-Kit - Die Grinder
The ACF-Kit with its large selection of tools covers an extremely wide range of applications. The versatile and user-friendly plug & play tools are suitable for surface processing of almost all shapes and materials. Needless to say that tool change is ingeniously simple and flexible.
Automated deburring with the cobot surface treatment solution ACF-Kit - Small Angle Grinder
Using the, especially for cobots developed, ACF-Kit deburring is as easy as it gets. The patented Active Compliant Technology ensures adjustable contact force and automatic tolerance compensation and therefore guarantees optimal quality. Thanks to the modular structure, the user-friendly Plug & Play tools can be changed within seconds.
Automated sand paper changing station
For a fully automated sanding process not only the robot suitable orbital sander is essential but also the equipment it comes with on order. The delivered abrasive changing station includes a paper removing tool and a paper magazine with internal process control. The package is designed for industrial use, 24 hours a day, 7 days a week.
Scan and polish with CraftMate software and ACF-Kit - Orbital Sander
The combination of CraftMate and ACF-Kit achieves best effects possible: easy path creation, exact force control, autonomous tolerance compensation and high precision. The ACF-Kit with its large selection of tools was especially developed for cobots to automate surface treatments of small to middle lot sizes.
Rapid contacting of surfaces subjects
This polishing process demonstrates that with the ACF surfaces can be contacted rapidly and reliably. Special functions prevent the formation of grinding marks. This significantly shortens cycle times and the process becomes precisely reproducible and seamlessly controllable. Uniform 24/7 processing ensures a constant level of quality.
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Automated fireplace sanding and finishing
Due to labor shortage, companies like the stove manufacturer HASE Kaminofenbau have to automate their production. Together with our partner SHL AG we designed a grinding cell for a a flawless structure-free surface finish. With the integrated AOK not only high-quality was achieved but also huge abrasive savings and an unbeatable fast ROI in less than 2 years.
Automated propeller grinding with the ACF-Kit - Die Grinder Angular
The ACF-Kit is presumably the simplest and most flexible Cobot tool on the market and optimizes a wide range of previously manual surface treatments. Equipped with the Active Compliant Technology, the ACF-K offers a high degree of sensitivity and guarantees ideal process quality. The versatile and user-friendly plug & play tool is suitable for surface processing of almost all shapes and materials.
Fan blade sanding + Hip Stem implant polishing with FerRobotics Active Belt Grinder
A beltgrinder solution with real force control to sand the surfaces of a fan blade. The blade gets prepared for perfect flow characteristics and efficient turbine operation. This set-up is also approved for the medical device sector. Improve your production with a robotic polishing system for joint replacement implants such as hip and knee.
Automated deburring of complex shaped workpieces
The process optimized end-of-arm package solution Active Angular Kit compensates tolerances on workpieces and applies a consistent contact force. That way the AAK delivers exactly reproducible deburring quality even on complex shaped objects. Industrial grinding and deburring processes can be automated and optimized for 24/7 production.
Perfectly sanded bathtubs
Modern high-end bathtubs need to be sanded and polished carefully to achieve a perfect surface quality with a perfect surface feel. Instead of costly and time consuming manual work the ACF helps to increase productivity enormously. Less manpower, less abrasive consumption, heavily reduced cycle times and constant quality are just some important advantages.
Fully automated sanding or polishing of wooden parts
The Active Orbital Kit 905 sands or polishes complex shapes, edges and curves of shaped wooden parts with an exact constant contact force under interactive consideration of material-related tolerances. Automated sanding of the sensitive material wood enables a reproducible, high quality standard as well as a significant expansion of production capacities.
Automated sanding of acrylic glass
With its simple set up and easy programming, the AOK905 is beneficial to any production. Due to the automated tolerance compensation, the precise and consistent contact force and low motor currents the quality of the grinding results is on a high level. A long operating life and low maintenance efforts are huge economic benefits.
Automated sandpaper changing station for finesse sanding
For a fully automated sanding process not only the suitable orbital sander is essential but also the equipment it comes with on order. The delivered abrasive changing station includes a paper removing tool and a paper magazine with internal process control. The changing station can be used for our AOK XS with adhesive papers daisy shape.
Automated brushing with the ACF-Kit - Die Grinder
The ACF-Kit with its large selection of tools covers an extremely wide range of applications. Due to the real time force control and the automatic tolerance compensation brushing with the ACF-Kit guarantees the highest quality possible. Flexible as it is, it can be either used as end of arm tool or as a static tool as shown in the video.
Automated weld leveling with the ACF-Kit - Angle Grinder
Modular built, the ACF-Kit has been designed for surface processing of all kinds of different shapes and materials. With minimal programming effort and almost no set-up time the ACF-K automates almost all manual grinding works. Equipped with our patented Active Compliant Technology, the process force remains constant even with changing orientations.
Automated deburring with the ACF-Kit - Belt File
The ACF-K is specially optimized for the needs of the flexible production of small lot sizes. Thanks to the modular structure, the user-friendly plug & play tools can be changed within seconds with no additional programming required in the application. With its large selection of tools the ACF-Kit covers an extremely wide range of applications.
Automated furniture sanding
With the unique ACF-Kit sanding and finishing of surfaces is easier than ever before. Due to the integrated tolerance compensation and force control, generated by the Active Compliant Technology, highest quality standards regarding surfaces condition can be achieved. Besides saving time based on a simple and quick job modulation, saving abrasives is a huge economic benefit.
Automated grinding of a wooden seat shell
With the Active Compliant Technology, which is integrated in all FerRobotics products, grinding of complex shaped surfaces is easier than ever before. Due to the precise force control and the automated tolerance compensation high quality results are guaranteed.
Automated glass engraving
Because of its sensitivity the ACF is the ideal tool for the automated engraving of glasses. The contact intelligence of the ACF allows tolerances automatically to be balanced and thus achieves high and reproducible quality. Due to the reliably dosed force and perfect adaption to the surface an even engraving is guaranteed.
Demo of automatic tolerance compensation
The ACF is an active compensation element that compensates tolerances autonomously and doses and also maintains the required force. As active-sensitive automation solution, the ACF ensures constant and high quality even in case of material-related deviations. It combines reliability with optimal functionality.
Testing automated steel grinding with a cobot
The versatile ACF-Kit enables automated surface processing of various shapes and materials with almost no implementation effort. Due to its active force control and constant contact force all along the entire surface course, the ACF-Kit guarantees optimum grinding quality like on this steel surface.
Automated sand paper changing station
For a fully automated sanding process not only the robot suitable orbital sander is essential but also the equipment it comes with on order. The delivered abrasive changing station includes a paper removing tool and a paper magazine with internal process control. The package is designed for industrial use, 24 hours a day, 7 days a week.
Tolerance compensation with the ACF-Kit - Die Grinder
Thanks to the interactive compensation of surface tolerances and guaranteed constant contact force, the ACF-Kit achieves exactly reproducible quality. Even with changing inclination the process force stays the same and does not require any additional programming effort.
Automated sanding and polishing of large surfaces
Automated grinding, sanding and polishing instead of costly manual work processes - the Active Orbital Kit 601 is the perfect tool for surface treatment of large surfaces like railway cars, busses, planes or ship bodies. The integrated complete solution automates the industrial sanding process with individual control of all process parameters.
Higher productivity through an automated sanding process
In order to prepare air tanks of compressors for painting, an exact sanding process is necessary. Previously, this had to be carried out in a labor intensive, stressful and time-consuming manual work step. The AOK flexibly adapts to the surface and delivers a precisely even and reproducible surface appereance.
Perfect surface for sanitary facilities
Complex shaped sanitary facilities require best results in surface treatment as the quality is essential for the the further manufacturing process. Cycle times get significantly reduced. The ACF comes with the essential combination of interactive surface tracking and active force control which is crucial to the quality.
Active force control for unattended system cooperation
The innovative Active Belt Grinder flexibly automates the reliable surface processing of small and medium-sized work pieces. The ABG adapts to the contour of the workpiece while maintaining a persistent contact force. This is ideal for an effective and reliable automated grinding or polishing process. It is suitable for a high diversity of parts and heavily contoured surfaces.
Fully automated grinding of wooden parts
The Active Contact Flange grinds complex shapes, rough edges or curves of molded wood parts precisely with consistently equal contact force while compensating for inherent material properties. This technological improvement replaces the manual grinding of the delicate material wood, thus delivering a reproducible high quality standard as well as a considerable enhancement of production capacities.
Precise material removal through constant contact force
The constant contact force of the Active Compliant Technology ensures the precise material removal of defects on the outside of iron bars. Since the thin iron bars get blown to tubes, it is crucial to not remove too much material. This fully automated repair solution drastically simplifies the so far manual process and provides a reliable quality record of the relevant process data.
Homogeneous surface roughness in the food industry
The contact-sensitive processing, conducted by the AOK and grinding roller effortlessly achieves the grinding pattern on stainless-steel workpieces required in the food industry. This special solution automates manual stainless-steel grinding, raises quality, lowers processing time, reduces consumption of abrasive materials and is suitable for even small batch sizes.
Rapid contacting of surfaces subject to tolerances
This polishing process demonstrates that with the ACF surfaces can be contacted rapidly and reliably. Special functions prevent the formation of grinding marks. This significantly shortens cycle times and the process becomes precisely reproducible and seamlessly controllable. Uniform 24/7 processing ensures a constant level of quality.
Grinding of visible welds
Welded seams that are visible and have to be painted need to be leveled. The ACF automates this activity with consistently high quality and thereby significantly lowers abrasive consumption. Due to the defined contact force and interactive compensation of surface tolerances the result is always reproducible.
Grinding of visible welds
As a result of the contact intelligence that the ACF provides, tolerances can be compensated automatically and thus a reproducible high quality can be achieved which could never be obtained manually. Therefore welded seams that are visible and painted over in the follow-up inspection can be leveled easily with the ACF.
Manufacturing of complex contours
The ACT-robotized finishing increases productivity visibly with an optimal yield of good parts. It not only reduces processing steps but also increases process reliability. The ACF now conducts fully-automatic handling of precision work, which up to now could only be performed by a few experienced specialists.
The intelligent belt grinding machine
Pressing force and belt speed can be controlled independently on the ABG. The combination of variable force control and belt speed optimizes the surface finishing of all materials and saves work steps. Even when changing the grinding belt, there is no need for readjustment. As a sensitive-active built grinder, the ABG is a customized solution for grinding, polishing and deburring on a highest level.
Contact-sensitive processing of carbon parts
The sensitive Active Compliant Technology follows the surface contour and independently levels the process-dependent tolerances. It produces the surface finish required for further processing and achieves the highest level of quality Products made of carbon can thus be processed easily, reliably and automatically.
Manual assisted sanding
In collaboration with humans, the ACF provides a top quality standard for the world market with significantly lower abrasive consumption. Due to its reliable metered force and perfect adaption to surfaces, the ACF guarantees reproducible quality with significantly lower abrasive consumption.
Belt grinding solution for heavy-duty applications
With this complete solution, productivity is increased by up to 80%, and at the same time, abrasive consumption is reduced by up to 75%. The specially developed heavy grinding solution achieves removal performance of up to 14 kg of material per hour. The optimized design ensures that the weld will not be ground through.
Fully-automated machining of cast parts
This fully-automatic processing ensures the required constant quality for a smooth installation. In the case of bearing housings for chain-driven vehicles, the sprues and burrs must be removed. In the initial step of this process, the position of the sprues is selected by a laser. In the second step, the sprues are fully removed automatically and thus replace burdensome manual labor.
Fully-automated compensation of tolerances
The ACF is an active balancing element that automatically compensates tolerances and thereby doses and precisely maintains the desired levels of force. As an active sensitive automation solution, the ACF also ensures constant quality even in case of material-based variances. Even veneers of 0.2 mm are not undergrinded.
Automated surface finishing in food processing industry
FerRobotics achieves maximum surface roughness of 4µm in a fully-automated robotic process. Only automation by means of ACF and the matching grinding tool guarantees precise force control and stability of this decisive work step. This surface finish is crucial to the quality of the product.
Automated deburring with ACF-Kit - Angle Grinder
The user-friendly Plug&Play tool ACF-Kit has been developed especially for the needs of a flexible production. Thanks to the modular design, the tools can be changed in seconds and thus be used for a wide variety of applications within a very short time. The Kit contains a large selection of attachable devices for all sorts of surface processing and is ideal for almost all shapes and materials.
Testing automated chrome-nickel grinding
The versatile ACF-Kit enables automated surface processing of various shapes and materials with almost no implementation effort. Due to its active force control and constant contact force all along the entire surface course, the ACF-Kit guarantees best possible grinding quality like on this chrome-nickel surface.
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Belt sander with active force control for sensitive surface operations – FerRobotics
Together with AV&R, a specialist for automated surface finishing processes in the field of turbine engine manufacturing, we helped to optimize the sanding process of high-tech blades. This Video shows our advanced compliant belt sander, powered by FerRobotics Active Compliant Technology®, with a response time perfectly matched to this application.
Perfect surface finish in the aircraft industry
The grinding of filler with the proven Active Compliant Technology attains a perfect surface finish. This automation step not only reduces costs but also maintains quality at a high constant level. In this industry, a smooth surface finish is critical in reducing air turbulences to a minimum.
Manufacturing of complex contours
The ACF increases the productivity immense with an optimal yield of good parts. The ACT-robotized finishing reduces processing steps and increases process reliability. The Active Compliant Technology guarantees a fully-automatic handling of this precision work, which up to now could only be performed by a few experienced specialists.
Fully-automatic precision grinding of complex contours
With the ACF the productivity is increased immensely with an optimal yield of good parts. The ACT-robotized finishing not only reduces processing steps but also increases process reliability. The Active Compliant Technology guarantees a fully-automatic handling of this precision work, which up to now could only be performed by a few experienced specialists.
Rapid contacting of surfaces
This polishing process demonstrates that surfaces can be contacted rapidly and reliably with the ACF. Special functions prevent the formation of grinding marks. This significantly shortens cycle times and the process becomes precisely reproducible and seamlessly controllable. Uniform 24/7 processing ensures a constant level of quality.
