冗余驱动刚柔协作搅拌摩擦焊机器人高能效设计方法与关键技术研究

Friction Stir Welding (FSW) robot equipment with high performance has become an important development direction of friction stir welding technology and high-tech welding equipment, with overpowering demands in the fields of the aerospace, rail transportation, automobile and ship manufacturing. In this project, inertia feed-forward control and high precision welding of FSW robot will be realized by the fusion of the rigid driven and cable driven characteristics, dealing with innovation design and key technology research of redundant driven and rigid-flexible cooperation FSW robot equipment, inventing a kind of adjustable double stationary shoulder stirring head structure, constructing precise dynamics model of redundant driven multi-body system considering the nonlinear dynamic characteristics. One carry out multi-objective dimensional synthesis in coordination with considering both structure system and control system integrated design. A new compound control strategy based on the combination of inertia feed-forward control and PID servo feedback control is proposed, which achieve inertia feed-forward control and high precision welding of FSW robot. Through the above researches on establishing a new and high efficiency design method in term of redundant driven and rigid-flexible cooperative FSW hybrid robot equipment and regarding high-speed rail EMU and other rail vehicle manufacturing as an application objection, which can develop a novel FSW robot equipment experimental prototypes to conduct an experiment and application test as well. It can not only expand the innovative application of robot technology in the field of high-tech equipment manufacturing, but also improve the urgent requirement to the level of welding manufacturing industry.

高性能搅拌摩擦焊机器人装备是搅拌摩擦焊技术与高端焊接装备的重要发展方向，在航空航天、轨道交通、汽车、船舶等制造领域具有强烈的应用需求。本项目融合刚性驱动与柔索驱动的特点，开展冗余驱动刚柔协作搅拌摩擦焊混联机器人装备的创新设计和关键技术研究，发明浮动式双静止轴肩搅拌头新结构，构建考虑非线性动力学特性的冗余驱动多体系统精确动力学模型，开展协同考虑结构系统与控制系统一体化设计的多目标尺度综合，研究基于惯量前馈控制与PID伺服反馈控制相结合的新型复合控制策略，建立一套新型冗余驱动刚柔协作搅拌摩擦焊机器人装备的高能效设计方法，并以高铁动车组等轨道车辆制造为应用领域，开发一台新型FSW机器人样机进行实验及工程应用。该项目研究既能拓展机器人技术在高端装备制造领域的创新应用，也是提升我国焊接制造业水平的迫切需求。

航空航天装备、轨道车辆壁板件以及汽车零部件等铝合金材料构件的推广应用，对搅拌摩擦焊机器人装备的性能提出了更高的要求。基于串联机器人的搅拌摩擦焊设备存在刚度和承载能力低、定位精度差等缺点，一般用于低强度薄壁材料的搅拌摩擦焊接；基于机床的搅拌摩擦焊设备受到动态特性和作业柔性的局限。并联机器人具备定位精度高、刚度大、动态特性和作业柔性好等优势，可以为搅拌摩擦焊装备高精度、高可靠性和柔性制造提供有效解决途径。.本项目创新设计了适用于搅拌摩擦焊机器人焊接的浮动式双静止轴肩搅拌头，建立了摩擦焊搅拌头的受载工作机理、力学模型及产热模型；面向航空航天、轨道车辆壁板件以及汽车零部件8-10mm左右壁厚铝合金构件的焊接要求，提出了搅拌摩擦焊并/混联机器人本体的构型设计及性能优化方法，开展了刚柔协作柔索驱动并联机构、2UPR-UPS-UP+AC摆的五自由度混联机器人等机构的构型综合及性能优化方法研究；构建几类典型混联机器人多体系统的正、逆运动学、动力学模型，建立性能评价指标与多目标集成优化模型，实现了系统的优化及性能评价；开展上述搅拌摩擦焊机器人系统的动力学特性、控制系统及策略研究，建立机器人驱动力优化分配方法和控制策略，提高FSW机器人运行过程中的动态性能和焊接精度；开发一台新型FSW机器人装备实验样机，开展实验研究与分析，验证上述理论和方法的有效性。.在重点解决上述问题基础上，建立一套FSW并联机器人装备的高能效设计方法，涵盖高能效的搅拌头设计、低成本的结构系统与控制系统集成优化设计、轻量化与模块化的机器人本体设计以及机器人本体的动态设计及性能评估等，研制具有高刚度、轻量化、低振动、低能耗的搅拌摩擦焊机器人，既能拓展、深化并混联机构在机器人领域的创新应用，也是提升我国高端制造业水平的迫切需求。