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2020 Vol. 63, No. 9
Published: 2020-05-01
FEATURE
FORUM
RESEARCH
C0NTENTS
COVER STORY
APPROACHING SCIENCE
 
       FEATURE
14 Research on Stiffness Characteristics and Load Control Method of Friction Stir Welding Robot
FANG Lijin,ZHANG Yue,XU Xiaohui
DOI: 10.16080/j.issn1671-833x.2020.09.014
Based on the mathematical model of the force on the mixing head in friction stir welding, the static model of the mixing head was established by using Ansys Workbench. The influence of forward resistance, lateral force, axial force and torque on the strain of the mixing head is analyzed. Suitable welding methods and processes are of great help to improve the stability of robot friction stir welding, and the load control methods such as friction stir spot welding, optimizing mixing head design and welding process parameters, heat source and ultrasonic-assisted, feedback measurement and compensation friction stir welding, as well as the improvement of robot structural stiffness and accuracy are described in detail. In combination with the weak overall rigidity of industrial robot, easy to cause flutter during processing, and large internal tooth gap of joint reducer, a high rigid mechanical arm with non-clearance drive based on dual motor drive is proposed, and the stiffness characteristics of the mechanical arm are discussed.
2020 Vol. 63 (9): 14-20 [Abstract] ( 247 ) HTMLNew PDF (6164 KB)  ( 365 )
       COVER STORY
22 Research Status and Prospects of External Force Perception and Interaction Control Methods for Collaborative Robots
MEI Xuesong，LIU Xing， ZHAO Fei，SUN Zheng，TAO Tao
DOI: 10.16080/j.issn1671-833x.2020.09.022
Collaborative robot (cobot) is a kind of robot system which can realize physical human-robot interaction and perform cooperative tasks in shared workspace. Collaborative robots are gradually integrated into human society, and interact with human beings, other robots or unstructured environment closely and complicatedly. For the physical robot-environment interaction process, external force perception and interaction control are very important to ensure its safety and improve its interaction performance. In this paper, the research status of collaborative robot is summarized from three aspects: external force perception, collaborative control and cognitive control, and the research prospect of collaborative robot perception and control is also discussed.
2020 Vol. 63 (9): 22-32 [Abstract] ( 282 ) HTMLNew PDF (2344 KB)  ( 1273 )
       FORUM
36 Review of Robot Mobile Machining System in Aviation Manufacturing
ZHENG Wei,DU Kunpeng,CHEN Hang,LIN Wei,WANG Gang,ZHANG Yiming,WANG Zhanxi
DOI: 10.16080/j.issn1671-833x.2020.09.036
The mobile robot machining system is widely used in the field of aeronautical large parts assembly. Because the mobile robot machining system is separated from fixed-point operation mode for mobile machining, in actual machining process, the high-precision positioning of large parts to be machined and the machining stability of machining process must be studied and solved. Based on the review of the research on advanced mobile robot machining system at home and abroad, this paper focuses on the high-precision positioning technology of large parts in the mobile state and vibration suppression in the process of machining, in order to realize the stable machining of mobile robot, and discusses and prospects the problems to be solved and future research direction.
2020 Vol. 63 (9): 36-41/49 [Abstract] ( 256 ) HTMLNew PDF (1949 KB)  ( 905 )
42 Robot Positioning System for Assembly of Thin-Walled Rotating Composite Components of Aero-Engine
ZHANG Yunzhi, SUN Nianjun, LIU Jiandong, ZHAO Fulong, JIANG Qian
DOI: 10.16080/j.issn1671-833x.2020.09.042
There are some important thin-walled rotary composite components in aero-engine, the manufacturing and assembly process of which include positioning, drilling-riveting, glue coating and other processes. The positioning efficiency and accuracy are related to the production capacity and assembly quality. In order to improve assembly quality and efficiency, the authors have developed a positioning system for the automatic assembly of the composite components which applies a 4-DOF manipulator based on RV transmission. It is proven to realize the automatic grasping and highprecision positioning of the composite components, as well as to solve the problem of low accuracy and efficiency of the manual posture alignment in the assembly of the composite components. This article could establish the foundation for further realizing the intelligent manufacturing of the aero-engine composite components.
2020 Vol. 63 (9): 42-49 [Abstract] ( 290 ) HTMLNew PDF (12520 KB)  ( 494 )
50 A Method of Edge Milling for Industrial Robots Guided by Binocular Vision
LIU Yu, PI Xinglai, ZHOU Zhijun
DOI: 10.16080/j.issn1671-833x.2020.09.050
A method of edge milling for industrial robots guided by binocular vision is proposed, which is suitable for machining workpieces composed of 3D planes. Firstly, the Zhang Zhengyou’s calibration method and the Tsai-Lenz hand-eye calibration method are used to calculate the internal/external parameters of binocular cameras and the hand-eye transition matrix between binocular cameras and an industrial robot. Then edges of workpieces are detected by binary processing of the binocular images. And corresponding relationships of points sampled from edges in the binocular images are established based on some preset ArUco markers. Finally, the 3D points on edges of workpieces are calculated according to the hand-eye transition matrix and the matched edge points. And robot milling trajectories are generated and sent to the robot controller so that the robot can execute edge milling processes. In the experiments of milling circular and straight edges, the results show that smooth edges are produced by our method and the maximum edge error is less than 0.5mm.
2020 Vol. 63 (9): 50-56/62 [Abstract] ( 237 ) HTMLNew PDF (24332 KB)  ( 554 )
57 Trajectory Following Method of Multi-Joint Robot Under Safe Torque Constraints
ZHANG Shaolin,WANG Ying,WANG Shuo
DOI: 10.16080/j.issn1671-833x.2020.09.057
To reduce the effects of collision between the robot and environment, it is generally required to limit the maximum torque of each joint while the robot follows the command trajectory. For keeping the Cartesian path unchanged and following quickly under the dynamic constraints of a multi-joint robot, the effects of joint space torque constraints on the velocity and acceleration of Cartesian space are analyzed. The maximum acceleration allowed is analyzed in real time, and the corresponding velocity and position are calculated while the robot keeps the Cartesian path unchanged. The purpose of safe operation is achieved. The method was verified on a self-developed six-degree-of-freedom lightweight manipulator. The result shows that the method can constrain the torque to a set range, the replanned trajectory keeps the Cartesian path unchanged, and the command trajectory is followed quickly.
2020 Vol. 63 (9): 57-62 [Abstract] ( 217 ) HTMLNew PDF (3996 KB)  ( 299 )
63 Robotic Belt Grinding Accuracy Control Technology of Aero-Engine Blade Based on Grey Correlation Method
XIAO Guijian, ZHANG Youdong, HUANG Yun, Lü Chong, HE Yi
DOI: 10.16080/j.issn1671-833x.2020.09.063
The surface integrity and structural characteristics of titanium alloy blades have a great impact on the aerodynamic performance of aero-engines. Abrasive belt grinding is widely used in the surface polishing of titanium alloy blades, which plays an important role in improving its surface integrity. However, it is still difficult to process the surface of workpieces with complex curved surfaces. Industrial robots are widely used in various fields due to the advantages of high flexibility and general versatility. Therefore, robotic belt grinding technology can take advantage of the flexibility of robots and the advantages of abrasive belt polishing to greatly improve the surface quality. However, in the current grinding and polishing of robots, there is still a problem that the machining accuracy cannot be controlled well, which will eventually affect the surface integrity and machining quality of the workpiece. In order to solve this problem, a robotic belt grinding accuracy control based on gray correlation method was proposed, and experimental research was carried out on this method. It can be obtained that the surface roughness can reach 0.38μm and meet the requirement that the surface roughness of belt grinding is less than 0.4μm, the precision of titanium alloy blade can reach about 0.04mm.
2020 Vol. 63 (9): 63-70 [Abstract] ( 221 ) HTMLNew PDF (11973 KB)  ( 287 )
       RESEARCH
74 Research on 3D Milling of Honeycomb Sandwich Structure High-Precision Panel
LI Dongsheng, YOU Jiaqi, WANG Mingming
DOI: 10.16080/j.issn1671-833x.2020.09.074
  The 3D milling finite element simulation model of honeycomb sandwich structure high-precision panel is established. The influence of the spindle speed, the feed speed and the milling depth on the surface roughness and the temperature of the honeycomb sandwich panel are analyzed. The orthogonal milling experiment and non-destructive testing of water ultrasonic pulse reflection method have been carried out, in company with optimizing the milling parameters. Based on the simulation analysis and experiment, the 400mm×400mm double-curvature high-precision sandwich panels with focal lengths of 5500mm, 2750mm, and 1090mm are milled, as well as non-destructive testing of ultrasonic pulse penetration method. Meanwhile both the surface precision and roughness are inspected before and after forming. The results show that the experimental results are consistent with the finite element simulation. The surface roughness of the sandwich plate after milling is negatively correlated with the spindle speed, and is positively correlated with the milling depth and feed rate. Plus, the panel temperature is mainly determined by the milling depth. When the single milling depth exceeds 300μm, the panel temperature exceeds the glass transition temperature of the epoxy resin (313K), and the sandwich structure is slightly debonded. Eventually the precision value, the peak-to-peak value (crest-to-valley value) and the surface roughness value of the double-curvature panels are significantly reduced. No debonding phenomenon occurs simultaneously. It is verified that milling can improve the surface quality of the panel on the basis of ensuring structural stability.
2020 Vol. 63 (9): 74-82 [Abstract] ( 187 ) HTMLNew PDF (11026 KB)  ( 144 )
83 Research Status and Prospect of Invar Alloy Welding Technology
LIU?Hongbing,?XUAN?Yang,?YANG?Jin
DOI: 10.16080/j.issn1671-833x.2020.09.083
 Invar alloy is widely used in the manufacture of large-scale aircraft composite molds and LNG ships due to its extremely low coefficient of thermal expansion. It has broad application prospects. The key to the wide application of Invar alloy are the quality of the weld and the matching of the thermal expansion coefficient between the weld and the base metal. This article mainly introduces the most widely used traditional welding methods of Invar alloy, MIG and TIG, and the new welding methods including laser welding, laser arc hybrid welding and friction stir welding. Meanwhile, this paper summarizes the welding status of Invar alloy, and proposes a new high-quality, high-efficiency welding method: K–TIG welding.
2020 Vol. 63 (9): 83-88/102 [Abstract] ( 262 ) HTMLNew PDF (6482 KB)  ( 452 )
89 Research on differences of Automatic Tape Laying Trajectory Design Based on Hand-Laid Tooling of Curved Surface
REN Weian, MA Jun, YANG Qianqian, XIA Li, WAN Mingyan
DOI: 10.16080/j.issn1671-833x.2020.09.089
 Automatic tape laying technology is widely used in the field of aviation manufacturing because of its high efficiency, high quality and high material utilization rate. But there is still a big gap between domestic and foreign in the application of automatic tape laying technology. One of the main factors affecting the promotion of tape laying technology is that the existing composite manufacturing system is mostly based on manual laying, and the corresponding tooling is difficult to meet the requirements of automatic tape laying, while the cost of reinvestment in tooling suitable for automatic tape laying is too high for the enterprise. Through advanced automatic tape laying programming technology, laying adaptability analysis, simulation and optimization are carried out for existing hand-laid tooling. Finally, the problem of adaptability of existing hand-laid tooling was solved, and the application of automatic tape laying technology was developed and promoted.
2020 Vol. 63 (9): 89-93 [Abstract] ( 207 ) HTMLNew PDF (5370 KB)  ( 259 )
94 Research on Efficient Milling Technology of TC21 Titanium Alloy Shaft Beam Double Closed Angle Deep Groove Cavity
LING?Ping,?WEI?Yuping,?HU?Xianming
DOI: 10.16080/j.issn1671-833x.2020.09.094
Aiming at the low milling efficiency of TC21 titanium alloy shaft beam double closed angle deep groove cavity parts, this article studies the high-efficiency cutting of deep groove cavity and double closed angle region of TC21 titanium alloy shaft beam from the aspects of zero point system, fixture design, part process boss design, tooling scheme, cutting parameters, tool change method, et al, based on the production practice, material and structure analysis. It summarizes a complete set of zero point positioning and large overhang fast feed milling solutions. Compared with the original plan, the processing cycle is shortened by more than 50%.
2020 Vol. 63 (9): 94-102 [Abstract] ( 170 ) HTMLNew PDF (7448 KB)  ( 113 )
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