并/混联式汽车涂装输送机构创新设计与控制研究

The conveyor is the key equipment in electrophoretic painting line for automobiles, which determines the layout of electrophoretic painting line and the electro-coating quality. New conveyors such as RoDip-3 and vario-shuttle, due to the adoption of cantilever structure, can not bear heavy loads and have the complicated structures and high requirements for the process of manufacture and installation. Parallel/hybrid mechanism is consistent with the requirements of electrophoretic painting process because of its advantages of having high stiffness, high load and multi-degree-of-freedom and multi-mode movement. In this project, a novel parallel/hybrid conveying mechanism is proposed to overcome the defects and technical difficulties of the existing conveyors by combining the kinematic principle of the parallel/hybrid mechanism with automobile electrophoretic painting process and to explore the new development trend of the conveyors for automobile electrophoretic painting. The creative principle of building the heavy-load and multi-mode movement equipment based on parallel/hybrid mechanism is researched so as to expand the application fields of parallel/hybrid mechanism. Using modern mathematical tools, the evaluation method and evaluation system of the characteristics of mechanical behavior for the new mechanism are explored in order to meet the demand for the engineering application and achieve the global optimization of the new mechanism. For the synchronized coordination control problem of the novel mechanism with symmetrical lifting on both sides, large span, variable large-load and multi-mode movement, the smooth sliding-mode real-time control theory and method based on a synchronization error and dynamic model are developed. Research results would be helpful for enriching the mechanism theory and control technology applications and improving the self-dependent innovation capability of China's automobile manufacturing equipment.

汽车涂装输送机决定电泳涂装生产线布局及车身涂装质量。目前涂装生产线上采用的新一代RoDip输送机和多功能穿梭机等采用悬臂梁结构，难以承受重载荷，且结构复杂，制造安装工艺要求高。并/混联机构具有高刚度、高承载优点，能实现多自由度、多模式运动，与汽车电泳涂装工艺要求相吻合。拟将并/混联机构运动原理与电泳涂装工艺相结合，提出新型并/混联式输送机构，以期克服现有输送机缺陷和技术难点，探索涂装输送机发展新趋势；研究以并/混联机构构建重载荷、多模式运动装备的创新原理，以期拓展其应用领域；采用现代数学工具探寻建立切合工程应用需求的力学行为特性评价方法和体系，实现新机构全局优化；针对两边对称升降、大跨距、可变大载荷、多模式运动的特异型新机构的同步协调控制问题，探寻建立基于同步误差和动力学模型的光滑滑模实时控制理论与方法。研究成果有助于丰富机构学理论及控制技术应用，有利于提高我国汽车制造装备的自主创新能力。

现有汽车电泳涂装输送机在结构、制造和应用上仍存在一定程度上的缺陷和技术难点。项目面向汽车涂装输送机的工程应用需求，基于以并/混联式机构克服现有输送机采用悬臂梁串联结构的结构缺陷、突破其在制造和应用上的技术难点的创新设计思路，以力图解决其关键问题为契机，着重研究了新型并/混联式输送机构的构型设计、性能分析、性能评价、参数优化设计及同步协调控制等问题。研究结果主要分为以下三个方面：（1）通过分析汽车电泳涂装工艺，并对国际先进水平输送机进行功能分解，确定了新型输送机构及其控制系统的功能和性能要求，通过系统构型综合的方法，得到了可工程实现的若干种并/混联式机构新构型；（2）为解决新构型机构性能分析、评价与参数优化设计问题，提出了结合解析几何法、旋量理论与虚功原理的机构动力学建模方法、表征新型并/混联式机构从机构输入端到机构输出端的运动/力传递效率的分析评价方法，建立了考虑最大动载荷能力、能量和条件数的性能评价指标体系及其机构优化设计方法；（3）针对两边对称升降、大跨距、可变大载荷、多模式运动、存在支路间耦合的新构型并/混联式机构特点，建立了有效的同步滑模控制理论与方法。在理论研究、MATLAB仿真及虚拟样机仿真分析的基础上，研制了新构型并/混联式样机机构及其分布式计算机控制系统实验平台，完成了满足汽车电泳涂装输送要求的样机机构系统运行实验。该研究丰富了机构学理论及控制理论的研究内容，对拓宽并/混联式机构应用领域、提高我国汽车制造装备的自主创新能力具有积极意义。