相贯线切割机器人作业单元关键技术研究
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摘要
本文密切结合新型5自由度混联机器人TriVariant-B的钢管相贯线切割应用,系统的研究了该机器人运动学与工作空间分析、空间连续轨迹规划、控制系统开发及钢管相贯线切割工艺等相关理论、方法和关键技术,论文取得如下创造性成果:
采用矢量法建立TriVariant-B混联机器人机构的运动学模型,并基于避免干涉和奇异位形的考虑,在末端执行器逆解多解中正确选择了合理解。采用Newton-Raphson法构造出2自由度球面并联机构的位置正解数值算法,并用C语言和LabVIEW环境开发了用于机器人末端位姿实时监控的位置正解软件模块。计算结果表明,在本文开发的控制系统中,位置正解运算时间为35μs,满足了实时性要求。在此基础上,建立了混联机器人的速度映射模型,进而为后续轨迹规划与运动控制提供了运动学基础。
根据机器人尺度参数和铰链运动范围约束条件,建立了工作空间边界约束方程,得到TriVariant-B机器人的可达位置空间。在此基础上,应用极坐标描述方法,构造出可达位置空间内部任意点的姿态空间模型。利用上述模型可保证末端执行器在工作空间内的运动连续性,进而为轨迹规划提供了重要依据。
在独立规划点和矢量轨迹的基础上,提出了一种基于点矢复合运动的时间同步规划算法和轨迹段间过渡算法,保证了末端执行器位姿运动的同步和轨迹过渡问题。针对任意空间曲线和参数化空间曲线,提出一种基于耦合速度曲线的连续运动轨迹规划方法和轨迹插补算法,在二阶近似条件下可获得理想的轨迹精度,进而将操作空间轨迹映射到关节空间后,利用分段三次样条函数可得到C2连续的高精度实时控制轨迹。
基于PC+Motion Controller构建出TriVariant-B混联机器人控制系统核心硬件平台,并结合切割、焊接、喷涂、轻型加工、装配及搬运等多种应用场合,利用可重构思想设计了控制软件的逻辑架构。应用图形化编程环境LabVIEW实现了机器人控制软件的模块化与层次化设计,开发了控制系统回零、轨迹控制、点动控制、在线仿真、网络通讯等核心功能。这种基于数据流的编程方式可有效缩短软件开发和测试周期,提高开发效率。
以TriVariant-B机器人为核心构建机器人相贯线切割作业单元,系统地研究了快速零点标定方法、钢管在机器人工作空间中的最优摆放位姿与定位方法和预留坡口角相贯线切割动态轨迹规划等关键技术,基于上述关键技术开发的机器人相贯线切割作业单元成功应用于钢结构生产企业并完成多项石化用火炬塔架相贯线切割任务。
This dissertation presents a theoretical package for kinematics and workspace analysis, continuous path planning, development of the PC based control system for a new 5-DOF hybrid robot known as the TriVariant-B, out of which a pipe intersecting curve cutting machine has been developed. The following contributions have been made.
The inverse kinematic analysis of the 5-DOF hybrid robot is carried out using vector based method and the interference and singularity free solution is selected. By using Newton-Raphson method, the numerical algorithm is developed to solve the forward displacement problem of the 2-DOF spherical parallel module. It takes less than 35μs to solve the forward displacement problem using this algorithm and thereby can be used for the real time applications. The Jacobian matrix of the hybrid robot is formulated, which is useful for the tool path planning and motion control.
Given the dimensional parameters and the joint limits, a geometrical constraint method is presented to determine the boundary of the reachable workspace. In addition, the project orientation workspace of the end-effector at any arbitrary point within the position workspace is achieved by using polar coordinate systems. As a result, the continuity of the motion of the end-effector within these workspaces can be ensured
A novel path planning method for generating point-vector trajectory is proposed and algorithms of time synchronization and the transitions between different path segments are developed. On the basis of velocity profile analysis, an approach for trajectory planning and interpolation is proposed for generating parametric and implicit space curves. Computer simulations show that the ideal trajectory accuracy up to the second order approximation can be obtained. The real-time trajectory in joint space is also obtained using piecewise cubic splines to achieve C2 continuity.
The hardware platform of the TriVariant-B robot control system is developed based on PC and motion controller and the reconfigurable of the software architecture is designed to meet demands in various applications such as cutting, welding, light machining, assembly, pick-and-place, etc. The graphical programming environment LabVIEW is employed to develop the key control functions such as homing, trajectory control, JOG control, online simulation, network data communications, etc. and great efficiency has been achieved in the development and testing procedure due to the special manner of data flow diagram.
The TriVariant-B robot has been used to develop a pipe intersecting curve frame cutting unit and the techniques to improve its accuracy, efficiency and applicability are investigated, such as fast home position calibration, quick localization of the steel pipe in the world coordinate systems, trajectory planning of intersecting curve cutting with bevel angles, etc. As a result, the products have been widely used in the construction of flare stack tower pylons in petrochemical enterprises.
采用矢量法建立TriVariant-B混联机器人机构的运动学模型,并基于避免干涉和奇异位形的考虑,在末端执行器逆解多解中正确选择了合理解。采用Newton-Raphson法构造出2自由度球面并联机构的位置正解数值算法,并用C语言和LabVIEW环境开发了用于机器人末端位姿实时监控的位置正解软件模块。计算结果表明,在本文开发的控制系统中,位置正解运算时间为35μs,满足了实时性要求。在此基础上,建立了混联机器人的速度映射模型,进而为后续轨迹规划与运动控制提供了运动学基础。
根据机器人尺度参数和铰链运动范围约束条件,建立了工作空间边界约束方程,得到TriVariant-B机器人的可达位置空间。在此基础上,应用极坐标描述方法,构造出可达位置空间内部任意点的姿态空间模型。利用上述模型可保证末端执行器在工作空间内的运动连续性,进而为轨迹规划提供了重要依据。
在独立规划点和矢量轨迹的基础上,提出了一种基于点矢复合运动的时间同步规划算法和轨迹段间过渡算法,保证了末端执行器位姿运动的同步和轨迹过渡问题。针对任意空间曲线和参数化空间曲线,提出一种基于耦合速度曲线的连续运动轨迹规划方法和轨迹插补算法,在二阶近似条件下可获得理想的轨迹精度,进而将操作空间轨迹映射到关节空间后,利用分段三次样条函数可得到C2连续的高精度实时控制轨迹。
基于PC+Motion Controller构建出TriVariant-B混联机器人控制系统核心硬件平台,并结合切割、焊接、喷涂、轻型加工、装配及搬运等多种应用场合,利用可重构思想设计了控制软件的逻辑架构。应用图形化编程环境LabVIEW实现了机器人控制软件的模块化与层次化设计,开发了控制系统回零、轨迹控制、点动控制、在线仿真、网络通讯等核心功能。这种基于数据流的编程方式可有效缩短软件开发和测试周期,提高开发效率。
以TriVariant-B机器人为核心构建机器人相贯线切割作业单元,系统地研究了快速零点标定方法、钢管在机器人工作空间中的最优摆放位姿与定位方法和预留坡口角相贯线切割动态轨迹规划等关键技术,基于上述关键技术开发的机器人相贯线切割作业单元成功应用于钢结构生产企业并完成多项石化用火炬塔架相贯线切割任务。
This dissertation presents a theoretical package for kinematics and workspace analysis, continuous path planning, development of the PC based control system for a new 5-DOF hybrid robot known as the TriVariant-B, out of which a pipe intersecting curve cutting machine has been developed. The following contributions have been made.
The inverse kinematic analysis of the 5-DOF hybrid robot is carried out using vector based method and the interference and singularity free solution is selected. By using Newton-Raphson method, the numerical algorithm is developed to solve the forward displacement problem of the 2-DOF spherical parallel module. It takes less than 35μs to solve the forward displacement problem using this algorithm and thereby can be used for the real time applications. The Jacobian matrix of the hybrid robot is formulated, which is useful for the tool path planning and motion control.
Given the dimensional parameters and the joint limits, a geometrical constraint method is presented to determine the boundary of the reachable workspace. In addition, the project orientation workspace of the end-effector at any arbitrary point within the position workspace is achieved by using polar coordinate systems. As a result, the continuity of the motion of the end-effector within these workspaces can be ensured
A novel path planning method for generating point-vector trajectory is proposed and algorithms of time synchronization and the transitions between different path segments are developed. On the basis of velocity profile analysis, an approach for trajectory planning and interpolation is proposed for generating parametric and implicit space curves. Computer simulations show that the ideal trajectory accuracy up to the second order approximation can be obtained. The real-time trajectory in joint space is also obtained using piecewise cubic splines to achieve C2 continuity.
The hardware platform of the TriVariant-B robot control system is developed based on PC and motion controller and the reconfigurable of the software architecture is designed to meet demands in various applications such as cutting, welding, light machining, assembly, pick-and-place, etc. The graphical programming environment LabVIEW is employed to develop the key control functions such as homing, trajectory control, JOG control, online simulation, network data communications, etc. and great efficiency has been achieved in the development and testing procedure due to the special manner of data flow diagram.
The TriVariant-B robot has been used to develop a pipe intersecting curve frame cutting unit and the techniques to improve its accuracy, efficiency and applicability are investigated, such as fast home position calibration, quick localization of the steel pipe in the world coordinate systems, trajectory planning of intersecting curve cutting with bevel angles, etc. As a result, the products have been widely used in the construction of flare stack tower pylons in petrochemical enterprises.
引文
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