工业机器人关节非标准薄壁角接触球轴承动态设计与几何结构参数优化研究

The nonstandard thin-wall angular contact ball bearings are the key basic components of a large class of industrial robots for achieving precision transmission. The design of them with high-rigidity, high-precision, high-reliability and lightweight has been a bottleneck for industrial robots to improve the service performance, operation reliability and power to weight ratio. Mastering the method of dynamic design and geometrical parameters optimization of the joint nonstandard thin-wall angular contact ball bearings is the key to solving this problem. For this purpose, a dynamic model of space robot multibody system with joint angular contact ball bearings is proposed firstly based on the theories of multibody dynamics and Hertz contact. Secondly, the dynamic load characteristics of the joint angular contact ball bearings under the influence of the real motion posture and working load of industrial robot are studied relying on dynamic analysis. Finally, on the base of load analysis, the mapping laws between the performance of high-rigidity, high-precision and high-reliability of the angular contact ball bearings when the joint space is limited and their geometric parameters are revealed by finite element analysis. In the end of research, the method of dynamic design and geometrical parameters optimization of the joint nonstandard thin-wall angular contact ball bearings will be mastered and a system of digital design and analysis process will be formed. The research of this project can provide an important theoretical and technical support for improving the independent innovation design level of the joint nonstandard thin-wall angular contact ball bearings of domestic industrial robots.

非标准薄壁角接触球轴承是一大类工业机器人关节实现精密传动的关键基础部件，其高刚性、高精度、高可靠性与轻量化设计已成为决定机器人使役性能、工作可靠性及功重比提高的瓶颈。掌握适于关节非标准薄壁角接触球轴承动态设计与几何结构参数优化的方法是解决这一问题的关键。为此，本项目首先以多体动力学理论和Hertz接触理论为工具，建立含关节角接触球轴承的空间机器人多体系统动力学模型；其次，以动力学分析为手段，研究机器人真实运动姿态及工况载荷下关节角接触球轴承的动态载荷特性；最后，以载荷分析为依据，通过有限元分析揭示关节空间受限下角接触球轴承高刚性、高精度、高可靠性等性能与其几何结构参数之间的映射规律。最终掌握适于关节非标准薄壁角接触球轴承动态设计与几何结构参数优化的方法，形成一套系统的数字化设计与分析流程。该项目研究将为提高我国工业机器人关节非标准薄壁角接触球轴承的自主创新设计水平提供重要的理论与技术支撑。

非标准薄壁角接触球轴承是工业机器人关节减速器实现高刚性、高承载和高精度传动的关键基础部件，为了尽快掌握该类轴承的设计理论和加工制造技术，本项目提出了开展工业机器人关节非标准薄壁角接触球轴承动态设计与几何结构参数优化研究。通过开展项目研究所取得的重要成果包括：提出了含非理想关节轴承铰链机械多体系统动力学建模的基础理论方法，该方法较为全面地考虑了关节轴承几何、结构、动力和工况参数，以及加工误差、形貌缺陷、摩擦磨损和配合间隙等非线性因素的影响；基于动力学分析，揭示了机器人多体系统宏观动力学行为对关节轴承动态载荷变化及其分布特性的影响规律；基于动态载荷特性分析，完成了工业机器人关节非标准薄壁角接触球轴承的几何结构参数设计与优化研究，开展了与国产工业机器人关节减速器之间的匹配设计与虚拟装配，形成了一套系统的数字化设计与分析流程，掌握了适于关节非标准薄壁角接触球轴承性能评价和动态设计的方法；基于上述理论研究成果，开发了关节非标准薄壁角接触球轴承实物样品，寿命可靠性与精度性能达到了预期要求。该项目研究成果为提高我国工业机器人关节轴承基础部件的自主设计与制造水平提供了重要的理论和技术支撑。