Grant: Idea to Innovation

Industrial robots play a pivotal role in modern manufacturing due to their cost-effectiveness, flexibility, and ease of reprogramming. However, over 60% of current robotic systems are limited to tasks like welding and material handling, while about 80% of essential material removal operations-such as grinding, milling, deburring, and polishing-are still predominantly performed manually. Automating these labor-intensive processes can significantly enhance productivity, improve quality consistency, reduce variability, and bolster worker safety. Despite these benefits, automating material removal poses significant challenges. Industrial robots lack the necessary compliance due to the insufficient back-drivability of their actuators. Currently, most robotic material removal applications rely on pneumatic end-of-arm tools that offer passive or active compliance. However, these pneumatic systems fall short in delivering the precision and speed required for high-performance material removal. This project aims to develop a novel end-of-arm tool with a built-in magnetorheological (MR) actuator that provides precise, controllable compliance. Unlike pneumatic tools, our MR-based solution offers superior speed, precision, and lower cost. Building on theoretical and experimental research conducted at Western University, we will create a proof-of-concept prototype with a maximum push force of 100 N and a 20 mm stroke. The tool will be equipped with a bolt circle ISO 9409-1 standard flange, enabling compatibility with a wide range of commercial tools. This prototype will serve as both a technology demonstration and a foundation for securing early-stage investment for subsequent commercialization efforts. Magnetorheological actuation presents a significant competitive advantage in robotic material removal, positioning it as a transformative solution for automating modern manufacturing processes.