Automated Abrasive Finishing Systems

A3L specialise in delivering robotic and bespoke automated abrasive finishing systems into the UK and global markets.

Finishing refers to a variety of treatments or processes that range from polishing to processes that affect a material’s molecular structure. It includes a variety of abrasive and polishing processes, and other operations designed to improve and enhance the surface characteristics of a given product.

Why Automate?

Finishing operations are generally horrible operations to complete manually, they tend to generate a lot of dirt and debris which make them and the environment where they are performed dirty and unpleasant. The actual finishing process itself is often nasty with large amounts of vibration, noise and airborne particulates which lead to various kinds of health and safety concerns.  Hand-arm vibration (HAV) often known as ‘vibration white finger’ and bronchial conditions can develop with excessive exposure. On top of all these issues they can be mind numbingly dull to perform manually. Finishing is generally a bad job to do and nobody wants to do it.

By law, as an employer, you must assess and identify measures to eliminate or reduce risks from exposure to hand-arm vibration so that you can protect your employees from risks to their health.

HAV’s is covered by the Control of Vibration at Work Regulations 2005, which aim is to make sure that people do not suffer damage to their health from hand-arm vibration. They do this by focusing on controlling the risks associated with exposure to hand-arm vibration. The key measures are:

• Eliminate the vibration through alternative work methods.
• Ensure the use of suitable equipment.
• Workstation design, ensure weighted and loads are minimised by design.
• Work schedules, limit the exposure through regular breaks and work rotation.
• Clothing, use the right PPE to minimise affects and maximise protection.

All these risks should be carefully monitored and recorded as part of the management process.

Automation offers a clear and effective means to protect workers from HAV’s and other H&S issues, as well as further eliminating a boring and dirty job.

Where do you start in automating a finishing operation?

The first stage is to fully map out the current manual process and understand all the key characteristics and variables. For example, is the part put to the grinding wheel or does it remain stationary, and the tool moved around it?

The next step is to then identify the hardware needed to automate the operation. Is everything available ‘off the shelf’ or do bespoke items need to be designed and built? What robot is required and what tooling.

erification work, any assumptions made need to be, where possible, verified. For example, will the finishing machine achieve the required finish, will the fixturing work…

The risks for the project both in terms of safety and project success should be fully assessed and measures taken to minimise their severity and impact.

Build / Program; The system needs to be built and programmed. Once built everything needs to be pulled together and orchestrated into the final system.

Testing and Development will be iterative with changes made based on the results obtained.  Many cycles of development may be needed until the system has reached the desired capability.

What operations can be automated?

Most finishing operations can be automated, and the business case built through savings from efficiency, health and safety, staffing, (it is getting incredibly difficult to employ people to do this kind of work), quality and other things. 

Typical operations that lend themselves to automation are:

• Grinding / linishing
• Polishing/Buffing
• Blasting
• Brushing
• Painting

Summary

Generally finishing applications make a lot of sense to automate because of all the health and welfare benefits on top of the efficiency and quality aspects. If you like to find out more or discuss your finishing needs, please get in touch.