Search Results (76)

Digital twins are digital representations of physical entities that enable real-time updates through data transmission between the physical and virtual domains. Based on a cloud–edge–device framework, this paper investigates methods for real-time data transmission, processing, and storage during the polishing process of a belt grinding robot. On this basis, a digital twin monitoring framework is constructed for blade-specific belt grinding robots. First, a virtual robot model was constructed using a joint modeling workflow in SolidWorks 2025 and 3ds Max 2025, incorporating a lightweight high-fidelity mesh processing algorithm based on the QEM method. Second, a data acquisition and transmission architecture was proposed for the belt grinding robot, enabling data reading, writing, and real-time monitoring during machining, as well as establishing a cloud–edge–device database. Finally, a cloud–edge–device digital twin monitoring framework for the blade belt grinding robot was developed, based on real-time monitoring of grinding process data. This work establishes a foundational data acquisition and visualization platform for the blade grinding robot, providing the necessary cyber-physical infrastructure, which future predictive models can develop and validate. Full article

Force control is crucial for robotic contact-rich tasks such as assembly, grinding, and polishing, directly affecting task accuracy, interaction stability, and safety. Yet in unstructured environments, environmental uncertainty, contact oscillations, and friction disturbances make high-performance contact control and reinforcement learning policy optimization difficult. To address this issue, this paper proposes a deep reinforcement learning-based variable-damping impedance control method that integrates parameterized Hindsight Experience Replay (TO-HER) and Importance Sampling (IS). Within the impedance control framework, a residual parameterized policy enables online damping adjustment, improving dynamic adaptability across contact phases. To overcome the training instability of conventional HER in contact-intensive tasks, a parameterized goal relabeling mechanism is introduced to improve relabeled sample quality and sample efficiency. In addition, an importance sampling scheme based on density ratio estimation mitigates the distribution mismatch between relabeled and real samples, enhancing training quality and stability. Experimental results show that the proposed method outperforms baseline methods in convergence, final return, and training stability, while achieving higher tracking accuracy and better dynamic response in typical contact scenarios, demonstrating strong effectiveness and robustness for robotic contact control in unstructured environments. Full article

Rust removal on pipe surfaces is hazardous and labor-intensive, yet it is a prerequisite for inspection and recoating in maintenance. Existing solutions rely on industrial robots or specialized robots with limited obstacle-negotiation capability and cable entanglement risks. This work presents a Robotic Pipe Grinding System (RPGS) for straight pipes and focuses on the latest generation, RPGS-III. Driven by a single motor, RPGS-III integrates cutter self-rotation, revolution about the pipe axis, and axial translation through planetary-gear and bevel-gear transmissions. Passive mechanisms enable adaptation to different pipe diameters, obstacle negotiation, and dust containment during grinding. Kinematic and static analyses, motion simulations, and prototype experiments were conducted to validate the system, with feasibility demonstrated through in situ maintenance tests. The validated design demonstrates a practical solution for automated pipe maintenance in field environments, reducing actuation complexity while maintaining operational effectiveness. Full article

Robotic belt grinding is an effective and widely adopted finishing method for superalloys, offering notable advantages such as high material removal capability, low heat input, and reduced workpiece damage. In addition, robots can readily integrate multiple sensors—such as infrared radiation cameras, force sensors, and high-speed cameras—which facilitate real-time monitoring of the grinding process and thereby enhance grinding quality control. With the establishment and continuous advancement of large-scale artificial intelligence (AI) data models, new breakthroughs have emerged in the optimization of robotic grinding processes. Owing to its dexterous workspace and advantages in high flexibility and cost-effectiveness, robotic belt grinding has become a critical process for the precision forming of complex curved components such as aero-engine blades and blisks. However, factors such as the limited absolute accuracy of industrial robots, time-varying grinding contact states, and significant transient boundary effects make it difficult for the current constant-parameter open-loop machining mode to simultaneously meet the demands for high material removal efficiency and high surface integrity on complex profiles. This paper systematically reviews the technologies for precision control and process optimization of robotic belt grinding aimed at pointwise precise material removal. First, the structural composition of the robotic belt grinding system and the material removal mechanism are analyzed. Then, centered on the compensation concept, a hierarchical progressive technical framework is outlined, covering geometric calibration compensation, force/position hybrid online compensation, transient entry boundary compensation, and system-level comprehensive compensation of multi-source errors, with a comparison of the applicable scenarios and the effects on shape and property control at each level. Furthermore, under the support of effective compensation, the collaborative optimization methods of material removal modeling, multi-objective optimization of process parameters, force-constrained trajectory planning, and intelligent adaptive processes are elaborated. Finally, current technical bottlenecks are summarized, and future trends in next-generation adaptive grinding technology driven by digital twins and embodied intelligence are envisioned. This review aims to provide a systematic theoretical reference for the high-precision and intelligent upgrading of robotic precision grinding systems. Full article

Robotics optimization is essential for improving the performance, efficiency, and reliability of robotic systems, especially when dealing with complex engineering problems involving multiple conflicting objectives. Algorithm-specific parameter-free metaheuristic algorithms have gained attention in such applications because they eliminate the need for problem-specific parameter tuning. However, their performance can be further enhanced by improving convergence and maintaining solution diversity in multi-objective optimization. This paper proposes three multi-objective variants—archive, opposition, and self-adaptive multi-population (SAMP)—for the algorithm-specific parameter-free BxR algorithms such as Best–Mean–Random (BMR), Best–Worst–Random (BWR), and Best–Mean–Worst–Random (BMWR). The proposed variants are evaluated on five robotic optimization problems spanning two to six objectives, including Autonomous Underwater Vehicle shape optimization, power line inspection robot design, inverse kinematics of a 4-DOF manipulator, wall-building robot trajectory planning, and optimization of a reconfigurable parallel cutting and grinding mechanism. Their performance is compared with several established multi-objective algorithms using metrics such as GD, IGD, SPC, and HV, supported by rigorous statistical testing involving Friedman tests, Conover post hoc analysis with Holm correction, and Vargha–Delaney A₁₂ effect sizes over 30 independent runs. The results show that archive variants achieve the best IGD rank in four of the five case studies and the best HV rank in three of them, with the five-objective trajectory planning problem being the sole exception where SAMP and base BxR variants show improved IGD performance. The base BxR algorithms prove to be strong competitors, consistently outperforming established parameter-dependent methods on IGD across all five problems. The opposition variants do not provide consistent improvement; however, they also do not cause catastrophic degradation, suggesting that refined opposition strategies warrant further investigation. The study demonstrates the effectiveness of the proposed algorithms as practical optimization tools for complex robotic optimization problems. Full article

Integrated die-cast components reduce machining/assembly steps and improve mechanical dynamic characteristics, eliminating joint loosening/fracture risks after long-term use. However, the highly variable geometries and random spatial distributions of burrs, flash, parting lines, and risers in castings invalidate pre-programmed or teach-in robotic grinding methods. This paper reviews recent progress and future trends in robotic grinding, analyzing four core aspects: force control stability/adaptability (e.g., adaptive impedance control can reduce average force-tracking error to 0.38 N), trajectory planning/path generation (e.g., error-driven compensation can lower contour error by 34.2–55.1%), process parameter optimization, and challenges of sensing latency/quality evaluation (e.g., deep learning models achieve 97.64% accuracy in identifying abrasive belt wear states). The key enabling technologies are summarized, including active/passive compliant force control, model-/data-driven adaptive trajectory planning, intelligent process parameter optimization integrating physical mechanisms and data-driven approaches, and multi-modal state monitoring with online quality assessment. Representative applications (metal castings, aero-engine blades, thin-walled components, weld seams) are presented, and prospective research directions are proposed. This paper provides a comprehensive reference for theoretical research and engineering practice in this field. Full article

The instantaneous contact zone in robotic abrasive belt grinding involves highly coupled thermo-mechanical interactions between abrasive grains and the workpiece material. Acoustic Emission (AE) signals generated during this process are inherently nonlinear and nonstationary, posing challenges for accurate process monitoring and mechanistic understanding. To address this, this study introduces an innovative AE signal processing framework designed to elucidate the robotic grinding mechanism for Ti-6Al-4V (TC4) titanium alloy. An improved Completely Complementary Ensemble Empirical Mode Decomposition (CCEEMD) algorithm, building upon Empirical Mode Decomposition (EMD), is developed to precisely extract intrinsic mode functions (IMFs) from raw AE data. Subsequently, a novel denoising algorithm utilizing noise statistical characteristics effectively removes invalid noise from the robotic machining system. Validation through robotic grinding experiments on TC4 workpieces successfully established quantifiable relationships between extracted AE features and the underlying grinding mechanism. Significantly, implementing this methodology contributed to extending the effective service life of a structured abrasive belt by approximately 20% while increasing machining efficiency by approximately 12%. This work presents a novel methodology combining improved CCEEMD and statistical denoising for AE analysis in robotic grinding, providing a robust link between AE signatures and material removal mechanisms, ultimately enabling quantitative process optimization. Full article

In robotic grinding of complex curved surfaces, the low stiffness of serial robots causes tool tip deflection and degrades surface quality. The axial symmetry of grinding discs introduces a free rotational parameter at each waypoint, converting a standard 6-DOF robot into a functionally redundant system. However, this redundancy has not been systematically exploited for stiffness optimization along the trajectory. This paper proposes a hierarchical dynamic programming framework to optimize the redundancy angle sequence over the entire grinding trajectory. A kinematic transformation parameterizes the flange target by the redundancy angle, enabling enumeration of feasible candidate configurations over a discretized grid. A composite stiffness index that accounts for the normal, feed, and cross-feed grinding force components is formulated at the contact point. Hierarchical constraint filtering removes configurations that violate posture, singularity, velocity, acceleration, and stiffness constraints. The Viterbi algorithm then recovers the minimum-cost path that balances stiffness performance and joint motion smoothness. Finally, a post-processing step based on a cubic smoothing spline generates $C^2$-continuous joint trajectories. Simulations on a UR5 robot grinding a curved surface evaluate the proposed framework against fixed-angle, greedy, and flange-stiffness baselines. The proposed method improves the mean composite stiffness by 31.7% and 17.9% over the fixed-angle and flange-stiffness baselines, respectively, and reduces the maximum joint jump by two orders of magnitude compared with the greedy strategy. Experimental validation on a UR5 robot confirms that the smoothed trajectory is accurately tracked while the stiffness threshold is preserved. A multi-trajectory analysis further shows that the stiffness threshold is maintained across all grinding trajectories. These results demonstrate the effectiveness of the proposed framework for redundancy optimization in robotic grinding with tool spin symmetry. Full article

Thermal accumulation is a critical constraint in robotic grinding of ZGMn13 high-manganese steel, whereas the variables that can be prescribed or monitored reliably online are often limited to the normal load $F_z$, spindle speed $n$, and feed speed ${\nu }_w$. Most existing studies focus on single-pass conditions or scalar thermal indicators, while full-process near-surface transient temperature histories in multi-layer robotic grinding remains insufficiently addressed. This study presents a full-process near-surface transient temperature histories framework for multi-layer robotic grinding under fixed wheel–workpiece conditions and limited online sensing. Multi-channel near-surface thermal measurements were first reorganized into layer-resolved time-series data. A process-driven thermal surrogate was then constructed from the deployable inputs $\left(F_z,n,{\nu }_w\right)$, and a recursive temperature-evolution model was developed by incorporating intra-layer thermal retention and interlayer residual-heat inheritance. The proposed formulation predicts the near-surface transient temperature history over successive grinding layers. Experimental results showed clear layer-wise transience and progressive thermal accumulation during multi-layer grinding. Under representative conditions, the proposed framework reproduced the dominant transient structure of the measured full-process near-surface temperature histories, and grouped validation further showed that the recursive formulation preserved more useful history-level information than the reduced baselines within the tested domain. Within the tested operating domain, the predicted histories were further reduced to derived thermal indicators and planning-oriented peak-temperature maps. Full article

In the fabrication process of pipelines for petrochemical and other industries, weld reinforcement is often excessive and adversely affects subsequent processes such as anticorrosion treatment and surface coating. Weld reinforcement must be removed through a grinding process. Welding deformation and fit-up errors often lead to highly irregular weld geometries, which makes robotic grinding difficult and causes the task to still heavily rely on manual operation. To address this issue, this study proposes an automatic weld recognition and grinding trajectory planning method based on 3D visualization and deep learning. A weld recognition network, termed WSR-Net, has been developed based on an improved PointNet++ architecture with a cross-attention mechanism, achieving a segmentation accuracy of 98.87% and a mean intersection over union of 90.71% on the test set. An intrinsic shape signature (ISS) key point selection algorithm with orthogonal slicing-based pruning optimization is developed to robustly extract key weld ridge points that characterize the weld trend on rugged weld surfaces. According to the height differences between the weld and the adjacent base metal surfaces, the grinding reference surface is fitted using the weld contour through the moving least-squares method. The ridge line points are projected onto the grinding reference surface along the local normal to generate the expected grinding trajectory points. The grinding trajectory that meets the process constraints is generated through reverse layer slicing. Grinding experiments demonstrate that the proposed WSR-Net achieves robust segmentation performance for both planar and curved surface welds. With the reverse layered trajectory planning method, the proposed method enables high-precision automatic grinding of complex spatially curved surface welds. The results show that the final grinding mean error is 0.316 mm, which satisfies the preprocessing requirements for subsequent processes. The proposed method provides a feasible technical method for the intelligent grinding of spatially curved surface welds. Full article

This research presents a machine learning-based vibration signal acquired from aluminum grinding experiment for potential application in smart and intelligent manufacturing. The study addresses the challenges of traditional surface finishing quality inspection by integrating vibration sensing and support vector machine (SVM). A robot manipulator lab grinding experiment consist of a four-axis DOBOT Magician with a handheld cylindrical grinding tool attached on the end-effector of the DOBOT Magician. This customized lab grinding experiment was designed to perform consistent surface finishing experiment for different aluminum work coupon and time duration. Triaxial accelerometer was used to collect the vibration signal and to investigate the most relevant vibration signal direction (x, y, and z) to the surface quality prediction of the aluminum work coupon. The vibration signal was acquired via LabVIEW and NI data acquisition (DAQ) system. The vibration features were extracted and analyzed using Python programming in Google Colab. The SVM algorithm in Python (3.11 and 3.12) is used to classify surface roughness quality into coarse, medium, and fine categories based on the extracted vibration features. Vibration feature parameters such as root mean square (RMS), Peak to RMS, Skewness, and Kurtosis were also investigated to determined which feature pairs are most critical for effective surface roughness monitoring and prediction using SVM classification. The classification model achieved high accuracy across all three vibration axes (x, y, and z), with the z-axis yielding the most consistent results. The proposed system has potential applications in real-time surface quality prediction within smart manufacturing practices aligned with Industry 4.0 principles. Full article

Robotic grinding systems are pivotal in precision manufacturing for their flexibility and cost-effectiveness. However, high-precision online monitoring of robotic grinding state remains challenging due to complex machining mechanisms and unstable environments. Existing deep learning methods, reliant on the assumption of identically distributed data, suffer from poor generalization under domain shifts, such as feature shifts caused by varying processing parameters (cross-condition) or differences between machines (cross-device). To address this issue, this paper proposes a Multi-Scale Attention-Fused Domain Adaptation Network (MADAN) for robust state monitoring in robotic grinding, where an integrated robust transfer framework is constructed by an enhanced signal augmentation module, a multi-scale attention-aware fusion module and an adversarial domain adaptation strategy. The robustness of the monitoring model is greatly improved in processing scenarios involving noise and disturbances with the enhanced signal augmentation module. Based on a Cross-Scale Self-Attention Fusion Network mechanism, the multi-scale attention-aware fusion module adaptively aligns and integrates deep features of vibration signals across different receptive fields. Furthermore, the adversarial domain adaptation strategy is implemented to reduce significant distribution discrepancies between different domains. Two sets of experiments on a robotic grinding platform are carried out including cross-condition and cross-device state monitoring, respectively. Experimental results demonstrate that MADAN achieves superior performance in these two state monitoring tasks. Specifically, the model attains an average accuracy of 96.83% in cross-condition scenarios and 95.68% in cross-device scenarios, significantly outperforming State-of-the-Art transfer learning methods in both detection precision and generalization stability. Full article

Internal wall grinding of pipes constitutes a critical pretreatment procedure in the anti-corrosion repair operations of Prestressed Concrete Cylinder Pipes (PCCP). To address the limitations of low efficiency and poor safety associated with traditional manual internal wall grinding in PCCP anti-corrosion repair, this study presents the design of a support-wheel-type internal wall grinding robot for pipes. The robot’s structure comprises a walking support module and a grinding module: the walking module employs four sets of circumferentially equally spaced (90° apart) independent-support wheel groups. Through an active–passive collaborative adaptation mechanism regulated by pre-tensioned springs and lead screws, the robot can dynamically conform to the inner wall of the pipe, ensuring stable locomotion. The grinding module is connected to the walking module via a slewing bearing and is equipped with three roller-type steel brushes. During operation, the grinding module revolves around the pipe axis, while the roller brushes rotate simultaneously, generating a composite three-helix grinding trajectory. Mathematical models for the robot’s obstacle negotiation, bend traversal, and grinding motion were established, and multi-body dynamics simulations were conducted using ADAMS for verification. Additionally, a physical prototype was developed to perform basic functional tests. The results demonstrate that the robot’s motion characteristics are highly consistent with theoretical analyses, exhibiting stable and reliable operation, excellent pipe traversability, and robust driving capability, thus meeting the requirements for internal wall grinding of PCCP pipes. Full article

In modern shipbuilding, the structural complexity of ship components and the constrained workspace make robotic grinding prone to collisions. To improve safety and stability, this paper proposes a collision-free posture optimization method for ship-component operations. First, forward and inverse kinematic models are established, and postures along the path are organized into a directed graph. Feasible postures are then identified under joint-limit and singularity constraints. Directed bounding boxes and the GJK collision detection algorithm are applied to construct a collision-free posture set. An improved A* algorithm is then introduced. It incorporates a multi-source heuristic based on joint-space geometric distance and a safety-distance penalty to compute an optimal posture sequence with minimal joint deviation. This design promotes smooth transitions between consecutive postures. Simulation results show that the proposed method avoids robot–workpiece interference in constrained environments and improves obstacle avoidance and motion smoothness. Compared with the standard A* algorithm, the proposed approach reduces search time by 15.8% and increases the minimum safety distance by nearly fivefold. Compared with a non-optimized posture sequence, cumulative joint variation is reduced by up to 92.5%. The joint amplitude range decreases by an average of 41.2%, and the standard deviation of joint fluctuations decreases by 37.8%. The proposed method provides a generalizable solution for robotic measurement, assembly, and machining in complex and confined environments. Full article

Robot grinding requires a constant interaction force between the tool and the workpiece, even under inclination changes. This paper proposes a compact single-axis pneumatic constant-force floating compensator (CFFC) to achieve constant force output. The proportional pressure valve and pressure sensor are used to regulate the cylinder’s pressure. Pneumatic components and sensors are integrated into the narrow space between the cylinder and the slide rail. Embedded controller, power, and communication modules are developed and integrated into a control box and interact with the operator by a touch screen. The mathematical models of the compensator are established and the stability and response dynamics are analyzed through transfer functions. A dual-loop force controller based on active disturbance rejection control (ADRC) is designed to address bias load, inclination change, friction, and the sealing cover spring effect. The outer loop is compensated by displacement, tilt, and pressure sensors, and the unmodeled dynamics are estimated by an extended state observer (ESO) and a recursive least square (RLS). Finally, the CFFC is installed on a testing platform to simulate grinding conditions. The experimental results show that even under large floating stroke, inclination changes, and biased load, the CFFC can still quickly and stably output the desired grinding force. Full article