爬壁加工机器人负压-仿生复合吸附机理与曲面共形顺应

With the outstanding adaptability to special environmental conditions, climbing robots have great potential in applications such as local processing of large components in aerospace and other fields or operations in hazardous environments. However, the existing adsorption technology for climbing robot has difficulties in performing stable adsorption under moving state on complex curved surfaces with variable curvature, and it is difficult to eliminate the effects of desorption and slip caused by the reactive force of the cutting force during processing. This project studies the core scientific issues for the curved-surface machining with climbing robots, such as surface conformation adsorption and robust adsorption enhancement. The main contents include: 1) The analysis and optimization of macro-micro-span scale mechanism for negative pressure adsorption on variable curvature surface, establishing quantitative micro models of negative pressure change and macro-optimal adsorption force; 2) The principle of tactile perception of curved surface shape for flexible lip and its conformal conformity method, realizing surface sensing and conformal control based on finite strain measuring point of fiber Bragg grating; 3) Research and simulation of biological anchoring micro-texture's adsorption-friction strengthening micro-mechanism, proposing design and manufacture methods of strengthening micro-texture which simulates beetles’ and suckerfishes’ adsorption-friction mechanism. The bionic flexible adsorption cavity will be integrated, and the principle verification can be performed by combining the existing climbing robot platform. The related results can provide theoretical and technical support for novel robotic machining mode of large curved components.

爬壁机器人凭借其对特殊环境工况的适应性，在航空、能源等领域大型构件局部加工或危险恶劣环境作业等应用中有着巨大潜力。然而现有的爬壁机器人吸附技术难以在变曲率的复杂曲面上进行稳定的移动吸附，且难以消除加工中切削力反作用带来的脱附、滑移等影响。本项目针对爬壁机器人曲面加工中面临的曲面顺应吸附、鲁棒吸附强化等核心科学问题开展研究。主要内容包括：1）变曲率表面负压吸附的宏-微跨尺度机理分析与优化，建立微观负压变化与宏观最优吸附力的定量模型；2）柔性唇边的曲面形貌触觉感知原理与共形顺应方法，基于光纤布拉格光栅有限应变测点实现曲面感知与共形调控；3) 生物锚固微织构的吸附-摩擦强化微观机理研究与模拟，提出模拟甲虫与䲟鱼吸附-摩擦强化机理的微织构设计与制作方法。项目通过集成仿生柔性吸附腔，并结合已有的爬壁加工机器人平台进行原理验证，相关成果可为大型曲面构件的机器人加工新模式提供理论与技术支撑。

为实现爬壁加工机器人在大型复杂构件的变曲率曲面上稳定吸附移动，并克服加工作用力带来的脱附滑移等影响，本项目围绕负压吸附机理建模、曲面共形顺应吸附、仿生吸附与锚定等核心问题开展了深入研究：1）建立了变曲率曲面负压吸附性能定量评价机制，提出了负压吸附机构接触式感知曲面几何特征的方案，形成了负压吸附腔状态优化调整策略。2）提出了可实现曲面法向感知的柔性6轴力/力矩传感的制备工艺与标定方法，创新了绳驱动-并联约束的轻质重载吸附腔位姿调整机构，实现了吸附机构对曲面的共形顺应；3）发明了仿哺乳动物气管的刚度各向异性柔性负压吸附腔，提出了基于章鱼微吸盘结构仿生的锚固机构原理及其制备工艺，实现爬壁机器人的仿生吸附与锚定。依托上述成果，研制了爬壁加工机器人样机，集成了爬壁机器人大范围自主定位模块与精准运动控制系统，初步实现了爬壁机器人在大型风电叶片、飞机蒙皮表面的磨抛作业。项目执行期内共接收/发表SCI论文8篇，其中在线发表论文2篇，接收待发表论文1篇；申请国家发明专利12项，其中授权3项；登记软件著作权1项。项目负责人获得中国博士后科学基金特别资助，培养硕士研究生2人，在读博士研究生5人，在读硕士研究生2人。