犄角特征曲面喷涂机器人变倾角喷涂轨迹规划方法研究

In order to solve some problems of spray effect for the horn surface based on the vertical spray technology, a new method for spray trajectory planning is put forward based on the variable slant spray technology. Combine with the spray experiment and the principle of differential geometry, the error rules of parameters between the experiment model and theory model are uncovered, use the error rules to amend the theoretical slant spray model. Make the recognition rule of surface feature which influence vertical spray effect by spray principle, design an automatic identification algorithm for the horn feature. Optimize the slant spray trajectories in four kinds of trajectory planning by optimization theory as goal of coating uniformity and coating utilization rate, explore the influence rules of the horn on coating uniformity and coating utilization rate, the design method of the slant spray trajectory planning mode is studied to achieve the spray effect requirement. According to the horn surface, optimize the slant spray trajectory planning modes which satisfy the spray effect requirement again, achieve automatic planning of the slant spray trajectory which the spray effect is best. Put forward the slant spray trajectory planning method could increase the coating uniformity on in-horn and could increase coating utilization rate on out-horn effectively in this project, and also is good for perfecting the advancement and the reliability of off-line programming for spray painting robot.

针对犄角特征曲面垂直喷涂工艺时的喷涂效果问题，提出采用变倾角喷涂工艺规划犄角特征曲面喷涂轨迹的新方法。结合喷涂实验和微分几何原理，揭示实验模型和理论模型间参数随倾角变化的误差规律，利用误差规律修正理论倾角喷涂模型；采用喷涂理论分析制定影响垂直喷涂效果的曲面特征识别规则，设计曲面犄角特征的自动识别算法；以涂层均匀度和涂料利用率为目标，运用最优化理论优化犄角处四种轨迹规划方式下的倾角喷涂轨迹，探索犄角大小对优化后的涂层均匀度和涂料利用率的影响规律，研究满足喷涂效果要求的倾角喷涂轨迹规划方式设计方法；根据犄角特征曲面形状，以减少喷涂时间为目标，对设计的符合喷涂效果要求的倾角喷涂轨迹规划方式进行二次优选，完成喷涂效果最佳的倾角喷涂轨迹的自动规划。本项目提出的犄角特征曲面变倾角喷涂轨迹规划方法，能显著提高内犄角处的涂层均匀度和外犄角处的涂料利用率，利于完善喷涂机器人离线编程系统的先进性和可靠性。

针对机器人自动喷涂犄角特征曲面存在涂层均匀度和涂料利用率欠佳的问题，项目组提出一种变倾角喷涂轨迹规划方法以解决该问题。通过理论分析和大量的喷涂实验，建立了变倾角静态喷涂时涂层生长率模型的预测方法，该方法可快速预测出一定喷涂倾角时的涂层生长率模型，奠定了变倾角喷涂轨迹规划的基础。针对凹凸面片组合，从喷枪扇形角因素建立了面片组合交界处喷涂不产生涂料浪费和有涂料覆盖的面片组合夹角取值范围，实现犄角特征的初步识别，并通过优化垂直喷涂工艺时不同夹角两面片组合交界处涂层均匀度，建立了夹角对涂层厚度最值的影响规律，以是否满足涂层厚度误差为准则，最终实现了曲面犄角特征的识别。针对形成犄角的两面片组合，分别建立了间断变倾角和连续变倾角时的喷涂路径规划方法及路径上喷枪动态喷涂的涂层厚度模型，并以涂层均匀度和涂料利用率为优化目标分别优化了内外犄角处喷涂轨迹上的相关参数，最终实现了曲面犄角处喷涂效果的提升。通过对不同犄角大小时变倾角喷涂轨迹优化后涂层均匀度进行数值模拟，分析了变倾角喷涂轨迹规划方法的适用范围。通过本项目的研究，为下一步同时考虑喷涂倾角等参数为变量的复杂自由曲面多变量喷涂轨迹规划研究奠定了基础。