面向中大型铸造件的主从机器人系统及其遥操作加工方法  

Master-slave Robot System and Its Teleoperation Machining Approach for Medium and Large Casting Parts

作　　者：王猛 宋轶民[1,2] 王攀峰[1,2] 赵学满[1,2] 连宾宾[1,2] 陈跃程 孙涛[1,2] WANG Meng;SONG Yimin;WANG Panfeng;ZHAO Xueman;LIAN Binbin;CHEN Yuecheng;SUN Tao(School of Mechanical Engineering,Tianjin University,Tianjin 300350;Key Laboratory of Mechanism Theory and Equipment Design,Ministry of Education,Tianjin University,Tianjin 300350;Tianjin Zhongyiming Technology Co.,Ltd.,Tianjin 300400)

机构地区：[1]天津大学机械工程学院,天津300350 [2]天津大学机构理论与装备设计教育部重点实验室,天津300350 [3]天津中屹铭科股份有限公司,天津300400

出　　处：《机械工程学报》2022年第14期93-103,共11页Journal of Mechanical Engineering

基　　金：国家自然科学基金(51875391,51875392);天津市新一代人工智能科技重大专项(18ZXZNGX00350)资助项目。

摘　　要：中大型铸造件合模线、浇冒口等残留特征具有尺寸随机、形貌随机、分布随机的特点,其安全高效高质量去除存在巨大挑战。对于此,提出以兼备高刚度和高灵活性的五自由度混联机器人为从动加工机器人、以具有力反馈信息的三平动并联机器人为主动操控机器人、以及基于主动和从动机器人的遥操作加工方法。首先,通过构造参数化、在线可调的禁止型虚拟夹具(Forbidden region virtual fixture,FRVF),解决了遥操作过程中由于抖动、通讯延迟等因素导致的过度加工问题。其次,建立了基于增量式位置跟随与人工势场法的遥操作控制模型,以便对主动和从动机器人进行约束与引导。最后,进行仿真分析与试验验证。结果表明,FRVF对空间复杂曲面的贴合度高,遥操作控制模型可确保加工区域不越过虚拟夹具表面,2.32 m×1.65 m×1.24 m灰铸铁铸造件残留特征的去除率达95%以上,一次加工后的表面粗糙度2.1μm,加工效率较人工方式提升了4倍。所提出的主从机器人系统及其遥操作加工方法,可有效实现中大型铸造件残留特征的高质量高效率去除加工,为其他中大型零部件高效加工提供新的解决思路。The residual features such as mould closing lines and pouring risers of medium and large castings are random in size,morphology and distribution,so there are great challenges in safe,efficient and high-quality removal.For this difficulty,a teleoperation machining method based on master and slave robots is proposed.A five degrees of freedom hybrid robot with both high stiffness and high dexterity is used as the slave machining robot and a three-translational parallel robot with force feedback is utilized as the master control robot.Firstly,the parametric,online adjustable forbidden region virtual fixture(FRVF)is constructed to solve the problem of excessive machining caused by shake,communication delay and other factors during the teleoperation process.Secondly,a teleoperation control model based on incremental position following and artificial potential field is established,which is convenient for constraining and guiding the master robot and slave robot.Finally,the simulation analysis and experimental verification are carried out.The results show that FRVF has a high degree of fit to the complex surface,and the teleoperation control model can ensure that the machining area does not exceed the boundary of FRVF.The removal rate of residual features of gray cast iron casting part with a size of 2.32 m×1.65 m×1.24 m is more than 95%,the surface roughness after one-time machining is 2.1μm,and the machining efficiency is increased by 4 times.The proposed master-slave robot system and its teleoperation machining approach can effectively realize the high-quality and high-efficiency removal of the residual features of medium and large casting parts,and provide a new solution for the efficient machining of other medium and large parts.

关 键 词：中大型铸造件 机器人加工 遥操作 虚拟夹具 人工势场法 

分 类 号：TP242[自动化与计算机技术—检测技术与自动化装置]