Enhancing Robotic-Based Propeller Blade Sharpening Efficiency with a Laser-Vision Sensor and a Force Compliance...

Area of Science:

• Manufacturing Engineering
• Robotics
• Aerospace Engineering

Background:

• Propeller blade edge sharpness is critical for energy transmission efficiency and reduced propulsion power.
• Casting methods face challenges with edge breakage and wax model deformation, hindering precise edge thickness.
• Existing robotic grinding methods have limitations in achieving fine edge sharpness.

Purpose of the Study:

• To develop an automated intelligent system for precise propeller blade edge sharpening.
• To overcome limitations in traditional manufacturing and previous robotic approaches.
• To improve the accuracy and efficiency of propeller blade edge machining.

Main Methods:

• An intelligent system integrating a six-DoF industrial robot and a laser-vision sensor was developed.
• An iterative grinding compensation strategy utilizing vision sensor profile data was implemented.
• A custom-designed compliance mechanism with active force control was employed for robotic grinding.

Main Results:

• The system achieved accurate and efficient machining of propeller blade edges within specified thickness tolerances.
• Validation was performed on three different four-blade propeller models.
• The iterative grinding compensation and compliance mechanism enhanced machining accuracy and performance.

Conclusions:

• The proposed intelligent robotic system offers a reliable solution for achieving finely sharpened propeller blade edges.
• This automation addresses key challenges in manufacturing critical propeller components.
• The system demonstrates significant improvements over previous robotic grinding studies for propeller blades.