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Sanding, Polishing & Finishing

Application Category

OnRobot Sanding, Polishing & Finishing

End-of-arm tooling for cobot surface finishing — OnRobot Sander v2 (200 W, 5-inch random orbital with 1,000–10,000 RPM range), Auto Grit Changer for unattended grit-swap cycles, 3M Hookit-compatible abrasive system, and HEX-E QC 6-axis force/torque sensors for the high-precision force feedback that surface finishing demands. Pairs with Universal Robots UR10e, UR12e, UR16e, and Doosan H-Series cobots.

Surface finishing is where cobot deployment stops being a "pick-and-place upgrade" and starts being a force-control problem. A consistent finish across a curved or contoured surface needs three things that manual operators struggle with: constant contact pressure regardless of part geometry, repeatable orbital speed across full shifts, and abrasive grit changes timed to material removal rate (not operator fatigue). OnRobot's finishing toolkit handles all three. The Sander v2 is a 5-inch random orbital with 200 W output and 1,000–10,000 RPM speed control, using the standard 3M Hookit abrasive system so you're not locked into a single abrasive supplier. The Auto Grit Changer swaps abrasive discs between cycles without operator intervention — a real differentiator for unattended or lights-out sanding cells. And for the force-control layer, the HEX-E QC 6-axis sensor mounts between the cobot flange and the Sander, delivering 0.2 N noise-free Fxy resolution that's specifically called out by OnRobot for sanding and polishing applications. Below: pick the right tools for your finishing profile.

Choose the right finishing EOAT

Finishing Task Profile Best OnRobot Tool Capability Why
Wood, composite, plastic — random orbital sanding OnRobot Sander v2 200 W / 5-inch pad / 1,000–10,000 RPM 5 mm orbit, 3M Hookit pad system (PN 20353); 36 V external supply for full power; 74 dB at max speed (44 dB at 3,000 RPM)
Existing Sander v1 cell — backwards compatibility OnRobot Sander v2 (v1 mode) 150 W (matches v1 output) Connect to original 30 V supply for v1-equivalent performance — green LED indicates v1 mode, blue LED indicates v2 mode; same pad, same orbit
High-mix sanding — multiple grits per cycle Auto Grit Changer Cobot-actuated grit swap Lets the cobot change abrasive discs between cycles without operator intervention — essential for unattended or lights-out sanding cells
High-precision force control — finishing on curved surfaces HEX-E QC force/torque sensor 200 N / 10 Nm Txy / 6.5 Nm Tz 0.2 N noise-free Fxy resolution; OnRobot specifically calls out sanding and pin insertion as canonical HEX-E QC applications; IP67
Heavier deburring, polishing — longer tools or higher payload HEX-H QC heavy-duty F/T sensor 200 N / 20 Nm Txy / 13 Nm Tz Double the torque capacity of HEX-E QC; recommended when payload exceeds ~3 kg or tool length exceeds ~300 mm; IP67
Custom finishing tool (buffer, polisher, custom abrasive head) HEX-E QC or HEX-H QC + custom EOAT 6-axis F/T feedback for any tool Mounts between robot flange and your custom tool — gives the cobot 6-DOF force feedback even when the tool itself has no integrated sensing

Where does the force control come from? The Sander itself is a speed/orbit/power tool — it doesn't sense contact force. Force control for finishing applications comes from either (1) the cobot's native force mode (Universal Robots' force_mode is the most common implementation), or (2) a HEX-E QC sensor mounted between the cobot flange and the Sander. The HEX sensor option gives you finer resolution and works on cobots without native force mode. For aerospace, medical, or other high-precision finishing applications, the HEX-E QC + Sander stack is the recommended configuration.

Browse Sanding, Polishing & Finishing EOAT

OnRobot Sander v2 (200 W) and v1 (150 W) configurations, Sander pad replacement kits and 3M Hookit-compatible abrasive discs (P80, P120, P220, P400 grit profiles), Auto Grit Changer accessory kits, spare pad kits and steel grit changer components. HEX-E QC and HEX-H QC 6-axis force/torque sensors with mounting adapter plates and EtherCAT converter variants.

A complete sanding cell

A typical OnRobot sanding cell pairs five parts:

  1. Cobot: Universal Robots UR10e or UR12e for most flat-and-curved surface work; UR16e when reach matters more than precision; UR20 for larger workpieces. Doosan H-Series and FANUC CRX are strong alternatives for shops standardized on those platforms.
  2. Force/torque sensor: HEX-E QC for high-precision finishing under most conditions; HEX-H QC when payload exceeds ~3 kg or tool length exceeds ~300 mm. The sensor mounts between the robot flange and the Sander.
  3. Sander: OnRobot Sander v2 with 36 V external power supply for full 200 W output. The Sander connects via the standard 24 V tool connector for control signals plus the external 36 V supply for sanding power.
  4. Abrasive system: 3M Hookit-compatible discs (the Sander uses the 3M PN 20353 Clean Sanding Disc Pad). Stock multiple grits — typically P80 for stock removal, P120 for shaping, P220 for finishing, P400+ for pre-polish — and use the Auto Grit Changer if your application needs unattended grit swaps.
  5. Dust extraction: The Sander has dust-extraction porting in the pad; pair with a HEPA-filtered vacuum system at the workcell. This protects sensor lifespan and keeps the cell compliant with finishing-room dust regulations.

Software layer: Universal Robots integration is the deepest, via OnRobot's Unified URCap which provides force-mode programming for the HEX sensor along with the Sander control. Other robot brands integrate via the OnRobot Compute Box and a brand-specific cable kit. Browse the full OnRobot brand catalog →

Sanding, Polishing & Finishing FAQ

What does the OnRobot Sander v2 actually do — and what does it NOT do?

The Sander v2 is a 5-inch random orbital sander with 200 W power output, 1,000–10,000 RPM speed control, and a 5 mm orbit size. It uses the standard 3M Hookit pad system (PN 20353) so any 3M-compatible abrasive disc works. The Sander provides programmable speed and orbit motion — what it does not provide is force sensing. Force control for finishing comes from either the cobot's native force mode (Universal Robots' force_mode is the most common) or from a HEX-E QC sensor mounted between the cobot flange and the Sander. For high-precision finishing on curved or contoured surfaces, the HEX-E QC + Sander stack is the recommended configuration.

Sander v1 vs Sander v2 — which one do I need?

The Sander v2 is the current model — 200 W output (vs 150 W for v1), running on a 36 V external supply. It's the right choice for new deployments and any application with heavier loads. The Sander v1 (150 W on 30 V) is still actively sold and is the right call if you're standardizing on a cell that already runs v1 and need spares. If you've ordered v2 but want it to behave like v1 — for example, to keep cycle times consistent with an existing line — connect the v2 to the original 30 V supply and it runs in v1-equivalent mode (green LED indicates v1 mode, blue indicates v2 mode). Same pad, same orbit, same noise level (74 dB at 10,000 RPM, 44 dB at 3,000 RPM).

What's the Auto Grit Changer and when does it earn its place?

The Auto Grit Changer is a station-mounted accessory that lets the cobot swap abrasive discs between cycles without operator intervention. The cobot programs a movement to the changer, removes the spent disc, picks up a fresh one in the new grit, and continues. It earns its place in three scenarios: (1) multi-grit finishing sequences — when a single part needs progressive sanding from P80 to P400, the cobot can run all grits in one program; (2) unattended or lights-out sanding — when you want the cell to keep running through breaks or overnight; (3) high-mix sanding — when different SKUs need different grits and stopping the cell for manual swaps adds significant cycle time. For single-grit, single-SKU production, manual swaps are usually fine.

HEX-E QC vs HEX-H QC for sanding — which sensor?

For most sanding and polishing applications, the HEX-E QC is the right choice — OnRobot specifically calls it out as the recommended sensor for "high precision applications like Sanding and Pin Insertion." It has finer noise-free resolution (0.2 N for Fxy, 0.8 N for Fz) which translates directly into smoother force-controlled passes across a curved surface. The HEX-H QC is the right call only when payload exceeds roughly 3 kg or tool length exceeds roughly 300 mm — for example, a polishing application using a long custom buffer head or a heavy backing plate. Both have the same 200 N rated force capacity. Both are IP67-rated for finishing-cell dust and incidental splash. Re-calibration interval is 15,000 hours for HEX-E QC vs 7,500 hours for HEX-H QC.

Why use the OnRobot Sander instead of Robotiq Sanding Kit or Mirka AIROS?

Three reasons OnRobot wins on specific deployments. First, 3M Hookit pad compatibility — the Sander uses standard 3M PN 20353 pads, so you're not locked into a single abrasive supplier. Mirka requires Mirka abrasives for warranty support, and Robotiq's media is bundled. Second, integrated ecosystem — the Sander pairs directly with HEX-E QC for force feedback through a single Compute Box, vs. Robotiq's Force Copilot (UR-only) or Mirka (needs separate UR adapter kit). Third, Auto Grit Changer — competitors don't have an equivalent unattended-grit-swap accessory. The trade-off: Mirka AIROS is IP66 (full dust/water rating, capable of wet sanding) vs OnRobot Sander's IP54, so for wet sanding or aggressive washdown environments Mirka wins. For dry sanding and standard finishing, OnRobot is the cleaner deployment.

Can the OnRobot Sander handle polishing as well as sanding?

Yes, with caveats. The Sander accepts polishing pads compatible with the 3M Hookit system, and the speed range (1,000–10,000 RPM) covers both sanding and polishing target speeds. Important: OnRobot's datasheet specifically warns that polishing pads containing polishing agents can increase vibration, and using non-standard pad weights can cause balance issues. If polishing is your primary application (vs. occasional polishing alongside sanding), reduce the rotation speed to minimize vibration and potentially trigger the cobot's protective stop. For dedicated high-volume polishing, a HEX-E QC + custom polishing head may give better long-term reliability than continuous use of the Sander with polishing pads.

Speccing a finishing cell?

Send us your finishing profile (material, surface contour, target finish grade, target cycle time, dust extraction requirements). We'll spec the cobot, Sander v1 or v2, HEX-E QC sensor, Auto Grit Changer if applicable, and dust handling — and price the complete cell.

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