Robot cell for automatic deburring of generator shafts up to 20 m in length

The contours add up to more than a kilometer and sometimes they have to be machined several times – manually deburring the multitude of grooves, threads, slots and holes on large generator shafts, such as those used in hydroelectric or lignite-fired power plants, is an extremely time-consuming task.

iNDAT Robotics has developed a robot cell for automatic deburring of large rotors. The result: the deburring system enables time savings of more than 50 to 80 % compared to the conventional deburring method. The highlight of the robot system is a powerful software and database concept that allows the robot processing program to be largely created via offline programming and 3D simulation. The machining process can then be configured and adapted directly on the deburring machine via a convenient WinCC interface.

The deburring system enables time savings of more than 50 to 80 % compared to the conventional deburring method.

The precise deburring result achieved using various pneumatically-driven and flexibly-positioned tools (including files, brushes, cutters, countersinks and scrapers) is part of the overall concept, together with the innovative software and database concept for consistent virtual teach-in. With minimum downtimes and tooling times, this enables the system to be set up for machining different shaft models. Furthermore, the machining program can be easily created and simulated on the 3D model until it is absolutely flawless. All parameters and settings are stored in a database. Connecting the database to the process control and process visualization systems is easy. In addition, the deburring process can be flexibly adapted and configured on the machine using a convenient WinCC interface instead of having to enter data via a robot panel.

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