弱刚度工件的多机械臂协调加工方法研究

Weak rigidity workpiece has been wildly used in many fields such as aerospace and communication, and is becoming increasingly complex in its shape. Using multi-manipulator in the large scale machining of complex weak rigidity workpiece can bring many benefits such as working space, workpiece clamping and costs. At the same time, it would face many challenges in dynamics, deformation and vibration control.. This project focuses on the key problems of multi-manipulator machining of complex weak rigidity workpiece. Several factors like the material removal of workpiece, joint flexibility and processing force are considered, and dynamic model of the “auxiliary clamping manipulator-weak rigidity workpiece-tool-machining manipulator” collaborative machining system is built. Machining deformation error is analyzed based on the Finite Element, deformation suppression by internal force control and the compensation methods of modification of tool path deformation are studied, based on which to solve the deformation control problems through coordination machining process. By machining parameter optimization, manipulator pose and position optimization, and vibration active control, vibration suppression of the system are discussed. Finally, a preliminary study is given on the synchronizing tracking control method of coordinated machining cooperative manipulators.. The significance of this project is to push on the convert from weak rigidity workpiece machining to multi-manipulator without clamp machining, and to expand the scope of application of multi-manipulation, with corresponding theoretical approach.

弱刚度工件在航空航天、通信等诸多领域有广泛应用，其形状日趋复杂。多机械臂在复杂弱刚度工件大范围加工上具有工作空间、工件夹持、成本等方面优势，但在动力学、变形及振动控制等方面存在诸多挑战。. 项目围绕弱刚度工件多机械臂加工的关键问题，考虑工件材料去除、关节柔性、加工力等因素，研究“辅助机械臂-弱刚度工件-刀具-加工机械臂”协作加工系统动力学模型；研究基于有限元的加工变形误差分析、内力调控的变形抑制以及刀具轨迹修正变形补偿方法，解决协调加工过程中的变形控制问题；通过加工参数优选、机械臂布局位姿优化和主动振动控制等多种手段，研究系统的振动抑制方法；探讨弱刚度工件多机械臂协调加工协同轨迹的同步跟踪控制方法。. 项目意义在于推进弱刚度工件向多机械臂无夹具式加工方式转变、拓展多机械臂协调操作的应用空间，并提供相应的理论方法支持。

弱刚度工件在航空航天、通信等诸多领域有广泛应用，其形状日趋复杂。多机械臂在复杂弱刚度工件大范围加工上具有工作空间、工件夹持、成本等方面优势，但在动力学、变形振动及控制等方面存在诸多挑战。近四年来，按照研究计划，项目组围绕弱刚度工件多机械臂协调加工关键问题，完成研究内容和进展包括：. 1）多机械臂协作加工系统的动力学模型构建，构建了弱刚度工件多机械臂非挤压负载分配协调操控系统动力学模型、任务/关节空间内多未知环境机械臂协调夹持一般性动力学模型，提出了6轴机器人动力学参数辨识方法，为后续变形控制、振动抑制、同步跟踪控制方法研究奠定基础；. 2）提出了弱刚度工件多机械臂协作加工变形控制与变形补偿方法：弱刚度工件受力变形分析、机械臂末端夹持机构设计及位姿优化、多目标加工工艺参数优化、内力调控变形抑制、轨迹修正变形补偿方法，全面提高协调系统加工精度；. 3）提出了弱刚度工件多机械臂协作加工系统振动抑制方法：6R机械臂末端刚度可视化方法、双机械臂协调加工单元布局优化、振动抑制加工参数优选、加工刚度优选、输入成型器设计方法，克服弱刚度工件协调加工系统振动和提高加工质量；. 4）提出了弱刚度工件多机械臂协调加工运动可靠性分析与验证方法：协调加工轨迹可靠性评估与验证、机械臂控制系统参数敏感性分析、机器人基座标协同两点标定、作业/自相交碰撞检测与路径规划方法，综合保证协调加工系统轨迹高可靠性运动精度；. 5）提出了弱刚度工件多机械臂协调加工轨迹同步跟踪控制方法：手势驱动机械手协同控制、神经网络同步内力轨迹跟踪控制、协同反演轨迹跟踪控制、同频鲁棒轨迹跟踪控制、双前馈神内力观测同步滑模控制、自适应模糊规划最优同步控制、间接自适应模糊最优控制方法，提升耦合协作系统的高度稳定性和高质量、高精度的加工控制性能。. 项目取得相关研究成果包括：发表/录用SCI期刊论文9篇，EI期刊论文2篇，在投SCI论文3篇，申请发明专利11项，其中授权4项，培养博士研究生3人，硕士研究生10人。