新型并联式六维力传感器设计理论与测量性能研究

The six-axis force/torque sensor is one kind of the most important sensors as it can measure the six-dimensional force and moment information in the space, and has broad application prospects in the field of aerospace, robotics, automotive manufacturing and biomedical. In this project, research on performance indicators analysis, structure optimization design, calibration and measuring experiment of novel parallel six-axis force sensor are carried out. The mathematical model of the novel parallel six-axis force sensor is built first, and the static mapping matrix between the six-axis force/torque applied on the sensor and the axial force on the measuring limbs is derived out. The performance indicators of six-axis force sensor are completed based on measuring requirements, and then the structural optimization of the sensor is carried out. Based on the optimized structure parameters, the prototype of the sensor is manufactured. By static calibration experiment, the static performance indices are obtained, which can verify the correctness of the theoretical analysis. The inadequacy of the six-axis force sensor in actual measurement is studied. The contact statics model of surface tracking is established, and the corresponding relationship between the sensor measurement and the state of contact is deduced. Finally, the surface tracking experiment based on six-axis force sensor force feedback control is carried out. The conduct of this project can build the theoretical and experimental basis for the development of six-axis force sensor with independent intellectual property rights and the practical application of six-axis force sensor.

六维力传感器以其能够检测空间六维力和力矩的全部信息而成为非常重要的一类传感器，并在航空航天、机器人、汽车制造、生物医疗等领域都有着广阔的应用前景。本项目针对所提出的新型并联式六维力传感器开展性能指标分析，结构优化设计，标定与测量实验等方面研究。首先建立新型并联式六维力传感器的数学模型，推导作用在传感器上的六维力与测量分支轴向力之间的静力映射矩阵。基于测量需求完善六维力传感器静态性能指标，以此来对传感器结构进行优化设计。依据所优化的结构参数研制六维力传感器样机，并进行静态标定实验，验证理论分析的正确性。研究六维力传感器在实际测量中的局限性，建立曲面跟踪操作任务时接触静力学模型，推导传感器检测值与接触状态的对应关系，开展基于六维力传感器力反馈控制的曲面跟踪实验研究。本项目的开展将为研制具有自主知识产权的六维力传感器及推进六维力传感器的实用化奠定理论和实验基础。

随着高新技术产业智能化进程的加快，传感器技术在其发展中逐渐占有越来越重要的地位。六维力传感器作为一类能够检测空间全力信息的传感器在机器人技术、生物医疗、航空航天、汽车制造等领域中有着广泛的应用。本项目提出一种正交并联式六维力传感器，并对其进行了深入的理论分析、样机研制和试验等研究。项目首先分析了正交并联式六维力传感器的结构及其数学模型，建立了传感器的静力平衡方程，得到该传感器不仅从原理上实现了六维外力的准确测量，而且在一定程度上是解耦的。然后提出了工况函数模型，对并联结构六维力传感器进行结构参数优化。在传感器满足工况函数以及设定参数范围的前提下，以测量分支量程最小为优化目标，最终得到满足以上要求的结构参数及对应的测量分支最小量程。基于工况函数模型的六维力传感器结构参数优化为促进与提高六维力传感器在工程中的实用性提供了行之有效的方法。研制了正交并联式六维力传感器样机，并进行静态标定试验和耦合性能分析。通过静态标定试验，得到传感器的最大I、II类测量误差均低于7%F.S.。采用独立成分分析的方法研究了传感器的解耦问题，得到了基于独立成分分析方法的耦合率要小于传统最小平方线性解耦的耦合率，从而验证了所提出的独立成分分析方法静态解耦的可行性。最后，将六维力传感器安装于工业机器人手腕处，进行曲面跟踪运动实验。实验过程中，机器人能够按照所规划的力控制算法，由六维力传感器的测量值来保持手指与接触曲面垂直，从而实现了机器人对未知环境的力觉以及力控制功能。实验结果验证了所提出方案及力控制算法的可行性和正确性。本项目的研究成果为进一步设计和研制适用于实际需求的高性能六维力传感器提供了一定的理论及试验依据，对拓展六维力传感器的应用场合及解决应用过程中面临的技术问题具有一定的借鉴价值。