Flexiv’s Automated Material Abrasion Solution

Polishing, sanding, grinding, deburring, and a range of other material abrasion processes are essential steps in countless production environments. Today, most industries still rely on costly human labor to complete these tasks. This dependence on manual input introduces production bottlenecks, increases costs, raises the risk of workpiece damage, and leads to greater variability in product quality.

Flexiv’s material abrasion solution harnesses the power of adaptive robotics to fully automate surface removal tasks through a unique combination of artificial intelligence, industry-leading force control, and standard, non-force-sensing power tools.

What Are Adaptive Robots?

Adaptive robots are engineered to think and react in real time.

Unlike traditional cobots that rigidly follow preset trajectories, Flexiv’s adaptive robots use AI, torque sensors in each of their seven joints, and real-time force control to intelligently respond to variations in products, part positioning, and external interference. This allows them to react to collisions, insert plugs into misaligned sockets, and polish or grind surfaces with complex geometries without sacrificing precision or speed.

Solution Overview

Flexiv’s surface polishing solution combines proprietary force-sensing technology with AI-powered vision (in select applications) to deliver consistent, high-quality results with minimal setup. Thanks to a universal mounting flange, the system is compatible with a wide variety of polishing EOAT tools and materials, enabling it to handle everything from delicate wood veneers to dense granite and marble.

By mimicking the delicate force control of skilled craftspeople, Flexiv’s adaptive robots can perform intricate polishing and grinding tasks while retaining the speed, precision, and repeatability that only automation can offer. This human-like sensitivity eliminates the need for manual labor while improving throughput and consistency.

System Components

• Flexiv Rizon 4 7-Axis Adaptive Robot: Designed for unmatched flexibility, Rizon delivers smooth and precise surface tracking that follows every contour of a workpiece.
• AI-Powered Optimization: Real-time artificial intelligence ensures continuous process optimization to achieve a flawless finish.
• Standard Board Polishing EOAT: Efficient, high-performance end-of-arm tooling for professional-grade surface finishing.
• Board Surface Polishing Module: A user-friendly, dedicated module designed to simplify the polishing process while ensuring exceptional quality.

Key Features

• Real-Time Surface Tracking: Tracks and responds to surface variations at 1kHz for consistent contact and finish across all surface types.
• AI-Driven Optimization: Dynamically adjusts polishing parameters in real time for enhanced efficiency and finish quality.
• Precise Force Control: Multi-axis, real-time force control maintains an optimal pressure throughout the process.
• Complex Surface Mastery: Handles curved, uneven, and irregular surfaces with ease with no manual trajectory pre-programming required.
• Cost-Effective Operation: No need for expensive custom EOAT or force-sensing modules, reducing both capital and commissioning costs.
• Wide Force Range: Adjustable downward force from 1N to 50N, ideal for different materials and abrasion levels.
• High-Speed Efficiency: Reaches speeds of ≥300mm/s with powered tools and ≥1000mm/s with passive tools without compromising quality.
• Hassle-Free Setup: Requires no precision positioning or extensive calibration, saving time and labor.
• Flexible Workpiece Handling: Easily manages oversized or freely positioned workpieces using a mobile base or extended axes.

Applications

• Furniture Manufacturing: Deliver smooth, showroom-ready finishes on wooden and composite furniture.
• Musical Instruments: Ensure a flawless finish on guitars, violins, and other instruments with artisan-level attention to detail.
• Automotive: Process unibody weld seams, wooden trim, leather, and other surfaces with precision and consistency.
• Footwear Production: Achieve perfect surface preparation on soft materials like leather and fabric.
• Medical Devices: Meet the strict regulatory standards for cleanliness and finish on surgical instruments and equipment.
• Any Industry Requiring Precision Surface Finishing: From consumer electronics to aerospace Flexiv delivers the perfect finish.

The Flexiv Advantage

Flexiv’s material abrasion solution is ideal for any application that demands consistent, high-quality surface finishing without the high cost or variability that’s inherent to manual labor. By combining adaptive robotics with off-the-shelf power tools, we empower manufacturers to achieve artisan-quality results at industrial scale.

Ready to transform your surface finishing operations? Submit a “Request a Quote” form on this page!

Flexiv: We help you do more with less.