A Robot Floating Grinding and Rust Removal Approach Based on Composite Force-Position Fuzzy Control

Area of Science:

• Robotics and Automation
• Materials Science
• Control Systems Engineering

Background:

• Rust removal from large structures like trains and ships is challenging.
• Existing methods (chemical, flame, laser, sandblasting, water jet) have significant drawbacks including high energy use, pollution, cost, and complexity.
• Current robotic systems lack the adaptability for robust rust removal on complex surfaces.

Purpose of the Study:

• To develop an adaptable and robust automated system for efficient rust removal from large equipment.
• To overcome the limitations of traditional and existing robotic rust removal techniques.
• To enhance precision, efficiency, and environmental friendliness in automated rust removal.

Main Methods:

• Proposed a floating grinding actuator scheme utilizing compound force-position fuzzy control.
• Implemented simplified path-point planning, eliminating the need for pre-measurement of workpiece geometry.
• Integrated force and laser displacement sensors for real-time deviation compensation and adaptability to complex surfaces.
• Employed a fuzzy derivative-leading PID algorithm for adaptive grinding force control and enhanced precision.

Main Results:

• The system achieved continuous grinding and rust removal without prior geometric data.
• Fuzzy derivative-leading PID control significantly reduced grinding force and average error fluctuations compared to traditional PID control.
• An exceptional rust removal rate of 99.73% was achieved at an advancing speed of 40 mm/s.
• Demonstrated excellent control performance and adaptability on complex surfaces.

Conclusions:

• The proposed floating grinding actuator with fuzzy control offers an efficient, environmentally friendly, and high-precision automated solution for rust removal.
• This approach significantly improves upon existing methods for large-scale equipment maintenance.
• The system's adaptability and robust control ensure effective rust removal even on challenging surfaces.