Precision robotic deburring with Simultaneous Registration and Machining for improved accuracy, quality, and efficiency

This paper extends and validates our recently developed Simultaneous Registration and Machining (SRAM) framework for robotic deburring applications. SRAM enhances contact stability and machining quality in planar robotic contouring tasks with uncertain registration. The framework estimates workpiece-tool contact points and utilizes them to improve registration accuracy and reduce path error in real-time, while modulating force controller tuning for optimal edge -finding ability or contact stability as required. We propose SRAM -D, an enhanced deburring-specific SRAM controller that addresses practical shortcomings in the original framework for improved workpiece quality and contact stability. Added virtual spring modulation ensures more effective burr removal, while a novel feedrate modulation strategy improves contact stability and optimizes cycle times. SRAM -D is implemented in a custom robotic deburring workcell and validated in extensive experimental testing against nominal SRAM and nominal admittance (ADMIT) controllers with varying registration accuracy. Tests demonstrate that SRAM -D outperforms both nominal controllers in all tested metrics. Path error is minimized and contact stability is improved, enhancing workpiece quality. SRAM -D improves large burr removal by 34% over the nominal SRAM and 45% over ADMIT. Furthermore, SRAM -D reduces tool wear by 29% compared to ADMIT, significantly decreasing ongoing tool costs. SRAM -D improves the feasibility of precision robotic deburring in industry by enhancing workpiece quality while enabling the use of lower accuracy yet faster and less costly registration methods-ultimately reducing workcell costs and boosting process efficiency.