机电液耦合的搬运机械手虚拟样机研究
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摘要
核环境对人体的伤害是致命的,然而人类对能源的巨大需求又不得不依靠核能发电来满足,遥操作机器人是解决这一矛盾的突破口。目前国际上正在大力发展核环境下的遥操作机器人与自动运装车。最为典型的实例就是由中国、美国、日本、欧盟、俄国、韩国、印度七方联合发起的ITER(International ThermonuclearExperimental Reactor)计划,七方将投资约50亿欧元研制大型核聚变实验反应堆,探索磁约束核聚变发电的技术途径。该项目将建造15种机器人自动运装车,这些运装车是3米宽、5米高、8米长的气垫车,其主要功能是实现重型密封塞在ITER装置的真空室和热室(维修室)之间的往返运输,车箱内装有遥操作搬运机械手,完成在真空室和热室端口处对重型密封塞的安装、拆卸、搬运等操作。
本文研究对象就是上述机电液耦合的搬运机械手,其自身重约5吨,操作对象为45吨的密封塞。机械手的精确定位是其实现对重型密封塞准确、精确、安全可靠操作的前提,而精确定位又涉及到机械手的位姿调整、轨迹规划、摩擦补偿、跟踪控制等一系列的问题,这些问题都将是机械手顺利实现对45吨密封塞操纵的研究重点和难点所在,另外,由于该系统的造价昂贵,需要一次制造成功,因此对机电液耦合的搬运机械手的虚拟样机研究是实现其高效设计开发的必要手段。本文对搬运机械手的虚拟样机进行了研究,其中包括虚拟样机模型的建立、运动学和动力学建模、位姿调整、轨迹规划、液压关节的摩擦补偿、轨迹跟踪控制、联合仿真平台的搭建、联合仿真研究以及动态有限元分析等。本论文的重点研究工作、创新及其特色如下:
1、搬运机械手的运动学与动力学分析与建模
搬运机械手的倾斜提升机制是实现其精确抓取和搬运重型密封塞的最关键运动部件,为此研究分析它的运动特性非常有必要。本文建立了倾斜提升机制的平面7连杆复杂机构的模型,利用其中的两个耦合四连杆结构,并通过一系列周密的推导,得出倾斜提升架的倾斜角度θ与液压缸位移间、提升高度△h与液压缸位移间、以及提升高度△h与水平位移△s间的数学模型,最后通过对比运动学仿真的结果和模型计算结果,验证了模型的准确性。另外,对该机制动力学模型以及动态静力分析等也进行了相关的研究,所有这些研究工作为实现搬运机械手的智能控制奠定了坚实的理论基础,并提供了重要的数学依据。
2、搬运机械手的轨迹规划研究与实现
考虑到机器人传统轨迹规划方法中存在的运动学逆解不唯一,计算量大、实时性差等缺点,本文利用“逆向”仿真的思想,即主动关节与被动关节对调进行仿真的策略,并结合虚拟样机的建模仿真技术提出了一种基于逆向仿真的轨迹规划方法,而且明确阐明了此方法中选择被动关节或者虚拟关节作为主动关节的规则,该方法不仅能克服传统方法的多种弊端,而且还能保证末端轨迹和各个关节的位移、速度、加速度的连续性,求解过程形象、直观。最后通过搬运机械手的运动学仿真验证了该轨迹规划方法的可靠性及精确性,并有效实现了机械手的轨迹规划。另外,本文通过周密的分析和精确的几何作图,将搬运机械手复杂位姿调整问题转化为液压缸的复位,很好地解决了机械手的精确位姿调整给控制带来的难题,最后也通过仿真验证了该方法的正确性及有效性。
3、搬运机械手的关节摩擦补偿与精确轨迹跟踪研究
关节摩擦是机器人实现高精度操作的主要制约因素之一,因此为了消除搬运机械手液压关节的摩擦给精确控制带来的影响,本文在充分分析了摩擦现象、摩擦模型、传统摩擦补偿方法及其缺点后,提出了一种基于模糊滑模智能控制的摩擦补偿方法,这种将模糊和滑模集成的控制方法不仅能够保持滑模控制的快速响应、对参数变化及扰动不灵敏、物理实现简单等种种优点,而且通过模糊规则,根据滑模到达条件对切换增益进行有效的估计,并利用切换增益消除干扰项,从而克服了滑模控制中常见产生抖振的缺点。最后应用MATLAB/Simulink模块,以搬运机械手中的阀控缸为研究对象,并建立关节摩擦的LuGre模型,对提出的模糊滑模集成控制方法进行了仿真验证,仿真结果表明将模糊和滑模控制相集成、传统摩擦补偿与智能补偿方法相结合的研究策略,能够很好地实现机械手的液压摩擦补偿和精确轨迹跟踪。
4、机械手的机电液耦合联合仿真研究策略与实现
本文分析探索了CATIA、ADAMS、MATLAB之间的集成接口,然后根据软件间的数据接口并结合搬运机械手为机电液耦合系统的特点,搭建了机电液耦合系统的联合仿真虚拟实验平台,并在该平台下对机械手进行联合仿真研究。通过联合仿真不仅验证了提出的控制算法的有效性,实现了搬运机械手的精确轨迹跟踪及并联液压缸的同步控制,而且获得了机械手运动过程中液压缸的各种性能参数和指标。在机-液耦合中,提出了利用ADAMS的自动求解能力和精确虚拟样机模型,预先模拟出运动过程中液压缸活塞杆的载荷变化,然后在联合仿真时将此载荷变化曲线实时输入给液压缸,从而保证液压系统仿真与机器人位姿变化的一致性,克服了机器人位姿变化给液压仿真带来的误差。
Nuclear radiation does harm to the human deadly, but we have to depend on nuclear energy to meet our great demands for energy resource. Remote handling manipulator is a good solution to solve the contradiction between radiation and needs, so the research and development of remote handling manipulator and automatic transfer vehicle under nuclear environment are regarded as a key technology by many countries in the world. The most typical example is the ITER (International Thermonuclear Experimental Reactor) program launched by seven sides including China, America, Japan, Russia, Korea, India and Europe union. The seven sides will invest about fifty hundred million euros to construct a large-scale reactor of nuclear fusion, and further to explore the technique approach of generating electricity by nuclear fusion of magnetism restriction. Fifteen kinds of automatic transfer vehicles will be employed in the ITER. These vehicles are air cushion vehicles with 8-meter length, 5-meter height and 3-meter width. Their main function is to transport heavy parts between the vacuum vessel of ITER building and hot cell (maintaining room). There is a manipulator inside the vehicle to realize the operations of installation, uninstallation and transit of the seal plug at the port of vacuum vessel and hot cell.
The study object of this dissertation is just the manipulator driven by hydraulic cylinders. The deadweight of the manipulator is about 5 tons, and weight of the manipulated object is about 45 tons. The accurate orientation of the manipulator is the precondition to operate the heavy-load seal plug precisely, safely and reliably. The accurate orientation is based on the adjustment of position and pose, trajectory planning, friction compensation and track control, so these points are the key research topics to manipulat the 45-ton seal plug successfully. Since the manipulator is heavy and expensive, virtual prototyping of the manipulator is developed to verify the design. The research content of this thesis includes the modeling of virtual prototyping, the analysis and modeling of kinematics and dynamics, the adjusting of position and post, trajectory planning, friction compensation of hydraulic joints, trajectory track control, the establishment of co-simulation experimental platform of mechanical-electrical-hydraulic coupling system, the co-simulation of the manipulator, the dynamic finite element analysis of the manipulator. The main research achievements of the dissertation are as follows:
1. The analysis and modeling of kinematics and dynamics of manipulator
Tilting and lifting mechanism of manipulator is the most important movement component, so it is very necessary to research and analyze the movement trait of this mechanism. At first a model of 7-linkage complicated plane mechanism is built, and then the mathematic relations between the tilting angle 9 of tilting and lifting frame and the displacement of hydraulic cylinders, between the lifting heightΔh of frame and the displacement of hydraulic cylinders, between the lifting heightΔh and horizontal displacementΔs of frame are all concluded by a series of close deducing and calculation, finally the above established mathematical models were proved to be accurate and valid by comparing the calculated results with kinematics simulation resuluts of mechanism. Besides the dynamics characteristic and dynamic statics analysis of the tilting and lifting mechanism were also studied. All these analysis and modeling will provide theoretic guidance and numerical basis for the intelligent control of hydraulic cylinders of manipulator.
2. The implementation of the trajectory planning of manipulator
In view of the disadvantage of traditional trajectory planning method such as no only kinematics converse solution, the great computation, and the bad characteristic of real time, a new method of trajectory planning was proposed by using converse simulation idea and combining the modeling and simulation technology of virtual prototyping, moreover the definition rule of the driving, passive, or virtual joints was also recited in the dissertation. Not only were some shortcomings of the traditional planning method conquered, but also the continuity of displacement, velocity and acceleration of the end trajectory and each joint was guaranteed. Finally the validity and accuracy of this method were confirmed by the converse kinematics simulation of manipulator. In addition the complicated adjustment of position and pose of manipulator was translated to the reposition of hydraulic cylinders by comprehensive analysis and accurate geometrical constructing. Not only was the control system simplified, but also the precise orientation of manipulator was guaranteed easily by this method. At last the accurate trajectory planning and precise orientation of manipulator were both obtained.
3. Joint friction compensation and accurate trajectory track of thr manipulator
Joint friction is one of the major limitations to make manipulator perform high precision tasks. Friction compensation of hydraulic joint is particularly important for manipulator driven by hydraulic cylinders to implement the accurate position and speed control. So in order to eliminate the friction made by the hydraulic joints, a friction compensation method based on fuzzy and sliding intelligent control was proposed after analyzing the complicated friction phenomena, friction modeling, traditional friction compensation method and its excellence and shortcoming. This method integrating the fuzzy control with sliding mode control not only keeps the merit of sliding mode control such as the speediness response, the characteristic of strong anti-jamming, but also can eliminate the high frequency input by the fuzzy rule. At last system simulation model of manipulator was established by the MATLAB/Simulink according to the actual parameter of hydraulic system, and the LuGre model of friction was also built. The results of simulation proved the efficacy of control algorithm based on fuzzy and sliding mode control, and that the friction of hydraulic joints of manipulator can be compensated perfectly, and the accurate trajectory track can be achieved.
4. The strategy and implementing of co-simulation of manipulator
The integration interfaces among CATIA, ADAMS and MATLAB were studied and explored in the dissertation, and the virtual experimental platform of co-simulation of mechanical-electrical-hydraulic complicated coupling system was established by the integration interfaces between different software, moreover the co-simulation of manipulator was carried out under this virtual platform. The validity of proposed control algorithm was proved, and the accurate trajectory track and the synchronization control of parallel hydraulic cylinders of manipulator were also implemented by the co-simulation of manipulator. A new method was presented in the mechanical-hydraulic coupling aspect. This method made use of the ability of automatic computation of ADAMS and the accurate virtual prototyping models to simulate the load change of piston rod of hydraulic cylinder during the movement process beforehand, and then the load change curve was input to the hydraulic cylinder while performing the hydraulic simulation to get the actual motion parameters of hydraulic cylinder. In this way the consistency between the change of the position and poise of manipulator and the hydraulic simulation of manipulator was guaranteed, and the mechanical-hydraulic coupling was achieved indeed.
本文研究对象就是上述机电液耦合的搬运机械手,其自身重约5吨,操作对象为45吨的密封塞。机械手的精确定位是其实现对重型密封塞准确、精确、安全可靠操作的前提,而精确定位又涉及到机械手的位姿调整、轨迹规划、摩擦补偿、跟踪控制等一系列的问题,这些问题都将是机械手顺利实现对45吨密封塞操纵的研究重点和难点所在,另外,由于该系统的造价昂贵,需要一次制造成功,因此对机电液耦合的搬运机械手的虚拟样机研究是实现其高效设计开发的必要手段。本文对搬运机械手的虚拟样机进行了研究,其中包括虚拟样机模型的建立、运动学和动力学建模、位姿调整、轨迹规划、液压关节的摩擦补偿、轨迹跟踪控制、联合仿真平台的搭建、联合仿真研究以及动态有限元分析等。本论文的重点研究工作、创新及其特色如下:
1、搬运机械手的运动学与动力学分析与建模
搬运机械手的倾斜提升机制是实现其精确抓取和搬运重型密封塞的最关键运动部件,为此研究分析它的运动特性非常有必要。本文建立了倾斜提升机制的平面7连杆复杂机构的模型,利用其中的两个耦合四连杆结构,并通过一系列周密的推导,得出倾斜提升架的倾斜角度θ与液压缸位移间、提升高度△h与液压缸位移间、以及提升高度△h与水平位移△s间的数学模型,最后通过对比运动学仿真的结果和模型计算结果,验证了模型的准确性。另外,对该机制动力学模型以及动态静力分析等也进行了相关的研究,所有这些研究工作为实现搬运机械手的智能控制奠定了坚实的理论基础,并提供了重要的数学依据。
2、搬运机械手的轨迹规划研究与实现
考虑到机器人传统轨迹规划方法中存在的运动学逆解不唯一,计算量大、实时性差等缺点,本文利用“逆向”仿真的思想,即主动关节与被动关节对调进行仿真的策略,并结合虚拟样机的建模仿真技术提出了一种基于逆向仿真的轨迹规划方法,而且明确阐明了此方法中选择被动关节或者虚拟关节作为主动关节的规则,该方法不仅能克服传统方法的多种弊端,而且还能保证末端轨迹和各个关节的位移、速度、加速度的连续性,求解过程形象、直观。最后通过搬运机械手的运动学仿真验证了该轨迹规划方法的可靠性及精确性,并有效实现了机械手的轨迹规划。另外,本文通过周密的分析和精确的几何作图,将搬运机械手复杂位姿调整问题转化为液压缸的复位,很好地解决了机械手的精确位姿调整给控制带来的难题,最后也通过仿真验证了该方法的正确性及有效性。
3、搬运机械手的关节摩擦补偿与精确轨迹跟踪研究
关节摩擦是机器人实现高精度操作的主要制约因素之一,因此为了消除搬运机械手液压关节的摩擦给精确控制带来的影响,本文在充分分析了摩擦现象、摩擦模型、传统摩擦补偿方法及其缺点后,提出了一种基于模糊滑模智能控制的摩擦补偿方法,这种将模糊和滑模集成的控制方法不仅能够保持滑模控制的快速响应、对参数变化及扰动不灵敏、物理实现简单等种种优点,而且通过模糊规则,根据滑模到达条件对切换增益进行有效的估计,并利用切换增益消除干扰项,从而克服了滑模控制中常见产生抖振的缺点。最后应用MATLAB/Simulink模块,以搬运机械手中的阀控缸为研究对象,并建立关节摩擦的LuGre模型,对提出的模糊滑模集成控制方法进行了仿真验证,仿真结果表明将模糊和滑模控制相集成、传统摩擦补偿与智能补偿方法相结合的研究策略,能够很好地实现机械手的液压摩擦补偿和精确轨迹跟踪。
4、机械手的机电液耦合联合仿真研究策略与实现
本文分析探索了CATIA、ADAMS、MATLAB之间的集成接口,然后根据软件间的数据接口并结合搬运机械手为机电液耦合系统的特点,搭建了机电液耦合系统的联合仿真虚拟实验平台,并在该平台下对机械手进行联合仿真研究。通过联合仿真不仅验证了提出的控制算法的有效性,实现了搬运机械手的精确轨迹跟踪及并联液压缸的同步控制,而且获得了机械手运动过程中液压缸的各种性能参数和指标。在机-液耦合中,提出了利用ADAMS的自动求解能力和精确虚拟样机模型,预先模拟出运动过程中液压缸活塞杆的载荷变化,然后在联合仿真时将此载荷变化曲线实时输入给液压缸,从而保证液压系统仿真与机器人位姿变化的一致性,克服了机器人位姿变化给液压仿真带来的误差。
Nuclear radiation does harm to the human deadly, but we have to depend on nuclear energy to meet our great demands for energy resource. Remote handling manipulator is a good solution to solve the contradiction between radiation and needs, so the research and development of remote handling manipulator and automatic transfer vehicle under nuclear environment are regarded as a key technology by many countries in the world. The most typical example is the ITER (International Thermonuclear Experimental Reactor) program launched by seven sides including China, America, Japan, Russia, Korea, India and Europe union. The seven sides will invest about fifty hundred million euros to construct a large-scale reactor of nuclear fusion, and further to explore the technique approach of generating electricity by nuclear fusion of magnetism restriction. Fifteen kinds of automatic transfer vehicles will be employed in the ITER. These vehicles are air cushion vehicles with 8-meter length, 5-meter height and 3-meter width. Their main function is to transport heavy parts between the vacuum vessel of ITER building and hot cell (maintaining room). There is a manipulator inside the vehicle to realize the operations of installation, uninstallation and transit of the seal plug at the port of vacuum vessel and hot cell.
The study object of this dissertation is just the manipulator driven by hydraulic cylinders. The deadweight of the manipulator is about 5 tons, and weight of the manipulated object is about 45 tons. The accurate orientation of the manipulator is the precondition to operate the heavy-load seal plug precisely, safely and reliably. The accurate orientation is based on the adjustment of position and pose, trajectory planning, friction compensation and track control, so these points are the key research topics to manipulat the 45-ton seal plug successfully. Since the manipulator is heavy and expensive, virtual prototyping of the manipulator is developed to verify the design. The research content of this thesis includes the modeling of virtual prototyping, the analysis and modeling of kinematics and dynamics, the adjusting of position and post, trajectory planning, friction compensation of hydraulic joints, trajectory track control, the establishment of co-simulation experimental platform of mechanical-electrical-hydraulic coupling system, the co-simulation of the manipulator, the dynamic finite element analysis of the manipulator. The main research achievements of the dissertation are as follows:
1. The analysis and modeling of kinematics and dynamics of manipulator
Tilting and lifting mechanism of manipulator is the most important movement component, so it is very necessary to research and analyze the movement trait of this mechanism. At first a model of 7-linkage complicated plane mechanism is built, and then the mathematic relations between the tilting angle 9 of tilting and lifting frame and the displacement of hydraulic cylinders, between the lifting heightΔh of frame and the displacement of hydraulic cylinders, between the lifting heightΔh and horizontal displacementΔs of frame are all concluded by a series of close deducing and calculation, finally the above established mathematical models were proved to be accurate and valid by comparing the calculated results with kinematics simulation resuluts of mechanism. Besides the dynamics characteristic and dynamic statics analysis of the tilting and lifting mechanism were also studied. All these analysis and modeling will provide theoretic guidance and numerical basis for the intelligent control of hydraulic cylinders of manipulator.
2. The implementation of the trajectory planning of manipulator
In view of the disadvantage of traditional trajectory planning method such as no only kinematics converse solution, the great computation, and the bad characteristic of real time, a new method of trajectory planning was proposed by using converse simulation idea and combining the modeling and simulation technology of virtual prototyping, moreover the definition rule of the driving, passive, or virtual joints was also recited in the dissertation. Not only were some shortcomings of the traditional planning method conquered, but also the continuity of displacement, velocity and acceleration of the end trajectory and each joint was guaranteed. Finally the validity and accuracy of this method were confirmed by the converse kinematics simulation of manipulator. In addition the complicated adjustment of position and pose of manipulator was translated to the reposition of hydraulic cylinders by comprehensive analysis and accurate geometrical constructing. Not only was the control system simplified, but also the precise orientation of manipulator was guaranteed easily by this method. At last the accurate trajectory planning and precise orientation of manipulator were both obtained.
3. Joint friction compensation and accurate trajectory track of thr manipulator
Joint friction is one of the major limitations to make manipulator perform high precision tasks. Friction compensation of hydraulic joint is particularly important for manipulator driven by hydraulic cylinders to implement the accurate position and speed control. So in order to eliminate the friction made by the hydraulic joints, a friction compensation method based on fuzzy and sliding intelligent control was proposed after analyzing the complicated friction phenomena, friction modeling, traditional friction compensation method and its excellence and shortcoming. This method integrating the fuzzy control with sliding mode control not only keeps the merit of sliding mode control such as the speediness response, the characteristic of strong anti-jamming, but also can eliminate the high frequency input by the fuzzy rule. At last system simulation model of manipulator was established by the MATLAB/Simulink according to the actual parameter of hydraulic system, and the LuGre model of friction was also built. The results of simulation proved the efficacy of control algorithm based on fuzzy and sliding mode control, and that the friction of hydraulic joints of manipulator can be compensated perfectly, and the accurate trajectory track can be achieved.
4. The strategy and implementing of co-simulation of manipulator
The integration interfaces among CATIA, ADAMS and MATLAB were studied and explored in the dissertation, and the virtual experimental platform of co-simulation of mechanical-electrical-hydraulic complicated coupling system was established by the integration interfaces between different software, moreover the co-simulation of manipulator was carried out under this virtual platform. The validity of proposed control algorithm was proved, and the accurate trajectory track and the synchronization control of parallel hydraulic cylinders of manipulator were also implemented by the co-simulation of manipulator. A new method was presented in the mechanical-hydraulic coupling aspect. This method made use of the ability of automatic computation of ADAMS and the accurate virtual prototyping models to simulate the load change of piston rod of hydraulic cylinder during the movement process beforehand, and then the load change curve was input to the hydraulic cylinder while performing the hydraulic simulation to get the actual motion parameters of hydraulic cylinder. In this way the consistency between the change of the position and poise of manipulator and the hydraulic simulation of manipulator was guaranteed, and the mechanical-hydraulic coupling was achieved indeed.
引文
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