Grinding Robot Retrofit Solutions--TREEINCO | Providing Reliable Robotic Grinding Equipment For Foundries

Solution Overview

The market demand is evolving rapidly, and accordingly, the products, processes, and takt times on foundry shop floors are constantly changing. Traditional grinding robots are facing unprecedented challenges — many can no longer simultaneously deliver the required flexibility, precision, and efficiency. Purchasing new equipment entails prohibitively high costs. Building on your existing equipment assets, we retrofit underperforming or idle grinding robots, equipping them with the adaptability to keep pace with change through TREEINCO's proprietary 3D vision-based deviation correction system. This enables your existing equipment to meet new operational requirements while delivering maximum cost-effectiveness.

Business Challenges & Solution Value

Business Challenges

Difficult Changeover

Traditional grinding equipment requires different tooling fixtures for processing various types of castings. Frequent changeovers and tuning not only drive up tooling costs but also result in prolonged downtime, making it difficult to achieve the flexible, high-mix, low-volume production that modern manufacturing demands.
Low Precision

Conventional equipment either lacks the ability to precisely locate castings or relies on fixed grinding paths. When castings experience shrinkage, expansion, or deformation, the system fails to grind accurately — resulting in poor consistency across finished castings and, in some cases, even causing surface damage to the workpieces.
Low Efficiency

Conventional equipment cannot precisely locate castings. As a result, engineers program grinding paths with significant allowances to avoid damaging the workpieces. While this prevents surface damage, the reduced precision leaves excessive residual material after grinding — requiring subsequent manual rework and cleanup.
Prone to Failures

Conventional equipment cannot precisely locate castings. Moreover, the presence of flash and residual roots on castings can induce unexpected posture deviations. When encountering difficult-to-grind areas, the equipment is prone to collisions, overloads, and mechanical damage — leading to frequent breakdowns and unplanned downtime.

Solution Value

Production Flexibility

The 3D vision-based deviation correction system precisely locates and identifies the position, posture, and type of castings, and automatically corrects deviations without relying on fixture-based positioning. A simplified tooling set can accommodate multiple casting types. Frequent changeovers are no longer a concern, and flexible production becomes significantly easier.
Precision Grinding

The 3D vision-based deviation correction system precisely locates and identifies the position and posture of castings. When castings undergo shrinkage or deformation, the intelligent algorithm automatically corrects deviations and generates optimal grinding paths, ensuring consistently high-precision grinding performance.
Efficient Grinding

The 3D vision-based deviation correction system automatically generates optimal grinding paths to ensure consistent, high-precision grinding performance. It achieves a grinding residual accuracy of ≤ 0.5 mm, significantly reducing residual material and eliminating the need for manual rework — delivering a one-pass, highly efficient process.
Reliable and Stable

The 3D vision-based deviation correction system precisely locates and identifies the position and posture of castings. Combined with rigid-flexible grinding tools and a grinding monitoring system, it enables real-time, accurate control of grinding force, effectively handling difficult-to-grind areas while ensuring stable and reliable equipment performance.

Solution Architecture

Core Components

3D Vision Technology

With deep expertise in 3D vision algorithms, self-developed grinding control systems, and rigid-flexible grinding tools, we provide one-stop customized design for non-standard machinery.

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Rigid-Flexible Grinding Tools

Leveraging extensive process data and hands-on field experience, Quanyu Industrial's technical team has independently developed a "rigid-flexible" composite grinding tool.

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Grinding Monitoring and Control System

The grinding monitoring and control system is equipped with a real-time Ethernet bus, enabling comprehensive perception, monitoring, and control throughout the entire grinding process.

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