面向现场加工的开放式可适应机床设计方法与控制策略

Machine tools designed using existing methods cannot meet requirements of mobility and adaptability as these methods consider unchangeable workshop environments and functions. Open adaptable machine tools （OAMs） are configurable portable machines with common interfaces opened to public, enable the machines to possess the justified functions required for in situ production by integration of process modules from different supplier, which provides a solution for sustainable manufacturing. This research explores design methods for OAMs, investigates relationships of in situ manufacturability and machine structures, and builds quantitative models for measures of in situ manufacturability, mobility and adaptability. The objective is to develop effective methods for in situ machining process innovation based on portable machine tools with open architecture, adaptable function modules, and common interfaces. The proposed method will be applied to the portable friction stitch welding (FSW) machines for repairing of offshore platform structures below sea level, which integrate hole-cutting and solid-phase friction welding process, to verify its feasibility and applicability. The research will form a systematic method to enable designed machine tools with in situ manufacturability to change the working state for different process, and adaptability for the rapid response to changing environments. The research solution will provide a strong support in design methods of machine tool specially for manufacturing, maintaining and repairing of large parts which are performed in situ most of the time. The implementation of OAMs, its intelligent design and control methods can also bring revolutionary effects on other industries, which will be significant in theory and engineering practice.

现有机床设计方法尚未能充分考虑车间之外的现场加工环境和功能多样性而不能满足机床的的机动性和适应性需求，而开放式可适应机床正是一种通过采用开放式接口集成不同工艺模块，使得机床具有可满足复杂多变的现场加工所需功能，符合可持续制造理念。项目旨在探索面向现场加工的开放式可适应机床设计方法，揭示现场可加工性与机床结构的关系，提出定量化的现场可加工性与适应性评价模型，研究适应切削-成形-连接等多样性异构工艺功能集成的可适应机床动力学设计方法与现场运行的可适应控制方法，建立多目标综合优化模型，以形成开放式可适应机床设计与控制技术体系。以集成了制孔和摩擦塞焊功能的开放式可适应摩擦叠焊机床为对象进行验证，针对现场修复作业工况多样性和作业环境的复杂性，应用上述理论对其功能实现、可适应架构和接口设计、模块配置优化和现场运行机理进行研究，以期在现场环境下高效低耗地获得优质焊缝质量。

随着航空、海洋、新能源等新兴产业的发展，在工作作场地对大型零部件的维修始终面临着一些难题。本项目着眼于复杂环境下现场加工装备设计方法与控制策略，主要研究内容包括：基于多能域耦合的现场加工机床功能形成机理，面向多样性的现场加工机床开放式构架演化方法，综合性能、适应性、创新性和开放性的现场加工机床配置智能多目标优化方法，以及面向现场加工的开放式架构机床可适应设计信息物理系统构建。针对传统设计评价的低效和不能适应需求快速变更等问题，提出了基于架构适应性评价的开放式架构机床功能形成机理及架构演化设计方法，基于均衡度和模块度的产品架构适应性评价方法和基于信息熵的设计适应性评价方法，拓展了可适应设计评价方法，为实现高效装备快速应急配置和工程应用提供理论基础，考虑未来野外、水下、太空等特种环境下现场作业加工能源供给的分布式、多样化、自给性和机动性，建立具有高效能源利用的现场加工机床设计方法和技术的理论体系，拓展了已有常规的面向车间的机床设计理论体系；针对现场摩擦叠焊加工装备的复杂性，获取高效高质量稳定精密切削和高速压力摩擦焊接界面稳定性规律，建立了热力耦合解析模型和有限元分析模型，并通过试验验证了其有效性；针对现场加工的环境-工艺及参数与设备耦合的动力学问题，基于信息物理系统建立了动态的“机床模块-工具-工件-环境”物理模块与虚拟仿真模块实时联动的动力学模型，综合考虑适应性和可机动性，实现了加工效率、工艺系统动力学品质及适应性的综合最优。基于云平台和信息物理系统技术，开发了面向现场加工的开放式架构机床智能配置与测控控制系统软件平台，融合理论计算、仿真分析及实时预测与测控系统等，为进一步研究基于搅拌摩擦沉积的增材制造技术与装备打下了良好的基础。项目的研究工作在一定程度上丰富了面向现场加工的可适应装备设计方法及技术，对设计面向现场维修的开放式架构装备具有较好的参考价值。