Systems and methods for automated sanding

Abstract

A sanding system for sanding a surface of a part includes a scanner and a sander. The scanner scans the part to obtain a three-dimensional (3D) surface model of the surface of the part to be sanded. The sander sands the surface of the part. The sander includes a sanding effector that engages and sands the surface of the part and a robot coupled to the sanding effector. The robot moves the sanding effector into engagement with and across the surface of the part based on the 3D surface model to sand the surface of the part.

What is claimed is: 
     
         1 . A sanding system for sanding a surface of a part, the system comprising:
 a scanner configured to scan the part to obtain a three-dimensional (3D) surface model of the surface of the part to be sanded; and   a sander configured to sand the surface of the part, the sander including:
 a sanding effector configured to engage and sand the surface of the part; and 
 a robot coupled to the sanding effector and configured to move the sanding effector into engagement with and across the surface of the part based on the 3D surface model to sand the surface of the part. 
   
     
     
         2 . The sanding system of  claim 1 , further comprising a controller communicatively coupled to the scanner and the sander and configured to guide the movement of the robot based on the 3D surface model. 
     
     
         3 . The sanding system of  claim 1 , further comprising a platform configured to support the part, the scanner disposed above the platform. 
     
     
         4 . The sanding system of  claim 3 , wherein the platform includes a plurality of clamps configured to hold the part in place on the platform. 
     
     
         5 . The sanding system of  claim 4 , wherein the clamps are negative pressure clamps, the negative pressure clamps configured to be coupled to a negative pressure source. 
     
     
         6 . The sanding system of  claim 1 , wherein the sanding effector includes a sanding head configured to engage and sand the surface of the part and a force adjuster operatively connected to the sanding head and configured to adjust a contact force applied by the sanding head against the surface of the part. 
     
     
         7 . The sanding system of  claim 1 , wherein the robot includes a robotic arm, the sanding effector attached to the robotic arm. 
     
     
         8 . The sanding system of  claim 7 , wherein the sander includes a mobile gantry, the robotic arm attached to the mobile gantry, the mobile gantry configured to move the robotic arm during the sanding of the surface of the part. 
     
     
         9 . The sanding system of  claim 8 , wherein the robotic arm is a six-axis robotic arm. 
     
     
         10 . The sanding system of  claim 1 , wherein the sander is a first sander, the sanding system further comprising a second sander configured to sand the surface of the part, the second sander including:
 a sanding effector configured to engage and sand the surface of the part; and   a robot coupled to the sanding effector and configured to move the sanding effector into engagement with and across the surface of the part based on the 3D surface model to sand the surface of the part.   
     
     
         11 . A method for sanding a surface of a part, the method comprising:
 scanning the surface of the part with a scanner to obtain a three-dimensional (3D) surface model of the surface of the part to be sanded; and   sanding the surface of the part with a sanding effector of a sander, wherein the sanding includes moving the sanding effector with a robot of the sander into engagement with and across the surface of the part based on the 3D surface model.   
     
     
         12 . The method of  claim 11 , further comprising generating a first sanding route with a controller based on the 3D surface model, wherein sanding the surface of the part includes moving the sanding effector along the first sanding route. 
     
     
         13 . The method of  claim 12 , wherein the first sanding route directs the sanding effector over the entire surface of the part. 
     
     
         14 . The method of  claim 12 , further comprising generating a second sanding route with the controller based on the 3D surface model, wherein sanding the surface of the part includes moving the sanding effector along the second sanding route after the sanding effector has finished moving along the first sanding route. 
     
     
         15 . The method of  claim 11 , further comprising securing the part in place before scanning the surface of the part. 
     
     
         16 . The method of  claim 15 , wherein securing the part in place includes clamping the part in place with a plurality of clamps. 
     
     
         17 . The method of  claim 16 , wherein clamping the part in place includes activating a negative pressure source fluidly coupled to the clamps so that the clamps hold the part in place with suction. 
     
     
         18 . The method of  claim 17 , further comprising operating the negative pressure source simultaneously and continuously with said scanning and said sanding to hold the part in place during said scanning and said sanding. 
     
     
         19 . The method of  claim 11 , wherein sanding the surface of the part includes adjusting the contact force applied by a sanding head of the sanding effector against the surface of the part as the sanding effect moves over the surface. 
     
     
         20 . The method of  claim 11 , wherein the sander is a first sander and the method further comprises:
 sanding the surface of the part with a sanding effector of a second sander, wherein the sanding with the second sander includes moving the sanding effector of the second sander with a robot of the second sander into engagement with and across the surface of the part based on the 3D surface model.