CNC Root Cleaning Robot

I. Machining Requirements

This specialized all-position machining robot is capable of machining the outer bevel of ribs inside a cylinder with a diameter of 7600 mm, as required by the project owner.

Pipe Outer Diameter Bevel Dimensions:

Groove Cleaning Width: 26-30 mm, Depth: 16-20 mm, Angle: 60-62.5 degrees.

After groove cleaning, the bevel must be smooth, uniform, and consistent in width, with a width variation of less than 2 mm. The cleaning must be precisely aligned with the bevel gap to ensure complete penetration. The workpiece material is Indian HV400, with a yield strength of 1000 N/mm².

As the workpiece itself remains stationary during processing, the equipment is required to be lightweight, easy to install, remotely operable, and capable of on-site machining. It must also feature strong environmental adaptability, high machining precision, stable accuracy, and high cost-effectiveness.

The equipment must be suitable for the following operating and working environments:

1. Operating Environment Requirements: Temperature -10°C to 45°C, Humidity: Maximum relative humidity 100%.

2. Power Supply: AC380V±10% mains, 220V±10% 50Hz

3. Equipment Operating Space Dimensions: Capable of circumferential movement around the cylinder. Equipment width ≤ 900 mm, equipment height 1200 mm.

4. Equipment Operational Safety: Safety devices must be designed, such as fall prevention ropes or chains, power loss/magnetic failure protection devices, etc., to ensure safe and reliable operation on the outer edge of the cylinder.

5. The equipment must possess good rigidity while being lightweight and easy to assemble/disassemble. The bid document should specify the total weight of the equipment and provide a detailed description of the installation plan.

II. Design Philosophy

Through in-depth communication with the user, the overall equipment design needs to adhere to the following principles:

Ø On-Site Machining Design

As the workpiece is immobile on-site and remains stationary, the requirement is that the workpiece does not move; instead, the machining equipment processes the workpiece by moving itself.

Ø Portable, Modular Design

Achieve portability, ease of installation, remote operation, and on-site machining functionality through modular design.

Ø Automation, High Efficiency, High Precision Design

Primarily through CNC machining to complete the overall processing of a section in a single operation. Features include strong environmental adaptability, high machining efficiency, high machining precision, and stable accuracy.

Ø Lightweight Design

The gantry bed unit and beam unit are manufactured using integrated, lightweight construction. The equipment utilizes high-strength aluminum alloy 7075, subjected to stabilization heat treatment processes. The structural components ensure stability while maintaining strength, significantly reducing weight, improving installation efficiency and equipment safety, and ensuring machining precision.

Ø Safety Design

This solution incorporates left and right annular protection devices, working in conjunction with magnetic adsorption fixation units and rib/flange auxiliary wheel safety mechanisms to create multiple layers of protection, ensuring safety during travel and machining processes.

Ø Design for Adaptability to Different Pipe Sizes

While meeting the project owner's requirement for machining the outer bevel of a 7600 mm diameter pipe, the equipment can be adapted for milling outer bevels on pipes of different diameters (within 7000-10000 mm), significantly reducing production costs.

III. Main Components of the All-Position Machining Robot

The all-position machining robot mainly consists of four parts:

1. Robot Travel Unit: Enables the robot to move along the outer wall of the pipe, maintaining travel straightness and ensuring passability in different orientations such as sideways and inverted positions.

2. CNC Machining Unit: A lightweight CNC machine tool for bevel groove cleaning. Machining precision is ensured by the accuracy of the CNC machine tool.

3. Electromagnets: Adheres the lightweight CNC machine tool to the surface of the workpiece, ensuring stability during machining.

4. Lifting Unit: Enables the lifting and lowering of the CNC machining unit, allowing switching between the robot's machining and travel states.