Normal trajectory generation for robotic-based machining on curved surfaces: a contact-based depth-pose correction tool

Robotic-based machining has significant potential and will be an essential component of Industry 4.0/5.0. However, machining complex workpieces with curved surfaces continue to be challenging. Due to the intricacies involved, one of the key difficulties to be solved in real-time is making the cutting tool normal to the curved surface to be machined. The proposed technique in this work is a revolutionary strategy that incorporates an intrinsically compliant tool and controls via a simple yet cutting-edge algorithm to automate pose correction on curved surfaces. The proposed technique in this research is mostly based on the force/torque detected by the compliant tool’s 3-axis force/torque sensor. When the passively compliant tool makes contact with the workpiece surface, the measured force is used to compute the depth and angle adjustments required to make the tool normal to the surface. This computational algorithm is performed in the 3-axis force/torque sensor and is transmitted to the master computer, where it is used to update the robot trajectory. The suggested approach has been proven effectively on curved surface tracking using a 6-DoF robot arm. The tool’s performance was determined by the absolute average errors on depth (Z) of 0.46mm and angles (Rx, Ry) of 0.53∘ and 0.83∘. These findings indicate a significant improvement in contact-based depth-pose correction methods.