Enhancing Robotic-Based Propeller Blade Sharpening Efficiency with a Laser-Vision Sensor and a Force Compliance Mechanism

The edge sharpness of a propeller blade plays a vital role in improving energy transmission efficiency and reducing the power required to propel the vehicle. However, producing finely sharpened edges through casting is challenging due to the risk of breakage. Additionally, the blade profile of the wax model can deform during drying, making it difficult to achieve the required edge thickness. To automate the sharpening process, we propose an intelligent system consisting of a six-DoF industrial robot and a laser-vision sensor. The system improves machining accuracy through an iterative grinding compensation strategy that eliminates material residuals based on profile data from the vision sensor. An indigenously designed compliance mechanism is employed to enhance the performance of robotic grinding which is actively controlled by an electronic proportional pressure regulator to adjust the contact force and position between the workpiece and abrasive belt. The system’s reliability and functionality are validated using three different workpiece models of four-blade propellers, achieving accurate and efficient machining within the required thickness tolerances. The proposed system provides a promising solution for finely sharpened propeller blade edges, addressing challenges associated with the earlier robotic-based grinding studies.