激光制导测量机器人几何误差分析

目的: 为了实现对工件进行自动高效地测量,建立了激光制导测量机器人系统,研制了测量机器人样机。对测量机器人的光靶自动跟踪装置旋转轴偏心误差和光靶与两轮中心连线误差进行了研究。方法:首先,介绍了基于“光束运动-光靶跟踪”理论的激光制导测量机器人技术和原理。接着,根据系统原理,研制了实验样机,并给出其理想的几何关系。然后,推出了旋转轴偏心误差和光靶与两轮中心连线误差几何误差数学模型。最后,利用三坐标测量机与激光制导测量机器人系统对样机进行了比对实验。结果：实验结果表明：光靶中心偏离理想位置的误差（x轴）为0.13mm。结论：对激光制导测量机器人移动反馈控制系统的设计和实现具有指导性作用。     

一种基于工具坐标系的机器人运动学参数标定方法

机器人末端执行器位姿误差在基础坐标系中表示时,误差模型中包含姿态误差与位置矢量的乘积项,影响了参数标定识别精度。以工具坐标系为参考系,给出一种基于指数积公式包含关节约束条件的机器人位姿误差标定模型,避免了姿态误差与位置矢量的乘积项对参数标定识别精度的影响。以UR5机器人为标定对象,采用LeciaAT960-MR激光跟踪仪为测量设备,进行参数标定试验。试验结果表明,经参数标定后UR5机器人位置误差模和姿态误差模的平均值分别减小了91.07%和89.16%。     

Elasto-geometrical error modeling and compensation of a five-axis parallel machining robot

Parallel manipulators have the potentials of high efficiency and high precision in the field of machining and manufacturing. However, accuracy improvement of the parallel manipulator is still an essential and challenging issue, encountering two important problems. Firstly, the ignorance of elastic deformation caused by gravity or deviations of static stiffness model restricts further improvement of accuracy. To solve this problem, an elasto-geometrical error modeling method is proposed. The comprehensive effects of structural errors, elastic deformation under gravity and compliance parameter errors on pose deviations are disclosed. On this basis, the identification equation of actual structural errors and compliance parameter errors can be established. Secondly, the ill-conditioned identification matrix and the identification equation with anisotropic residual error can lead to inaccurate identification results. To solve this problem, a weighted regularization method is proposed. The identification equation with isotropic residual error is built, and accurate identification can be realized with the regularization method. Based on the proposed methods, the error compensation experiment is conducted on the prototype of a five-axis parallel machining robot using a laser tracker. Experiment results show that the accuracy of the machining robot is significantly improved after compensation. An M1_160 test piece and an S-shaped test piece are machined and measured to further validate the effectiveness of the proposed methods. The elasto-geometrical error modeling method and the weighted regularization method can be applied to other parallel manipulators’ accuracy improvement.     

神光-Ⅲ精密光学模块侧装机械手运动学分析

为顺利将激光聚变试验所需的光学模块安装至主机试验装置中,设计了一种八自由度侧装机器人。通过D-H法建立机器人各杆件的参考坐标系并获得D-H参数,推导出该侧装机器人运动学正解。提出采用关节变量虚化法构建出一个虚拟六自由度机器人,并利用解析法求解虚拟六自由度机器人运动学逆解。基于关节占用空间最小的原则,结合麦夸特算法利用1stOpt软件对关节3和关节4的位置进行求解,进而求解八自由度侧装机器人运动学逆解,并通过实例验证逆解算法的正确性。对运动学分析求解可以用于机械臂末端执行器的精确定位和运动规划,为实现八自由度侧装机器人的轨迹规划及实时控制等提供理论参考。     

A multilevel calibration technique for an industrial robot with parallelogram mechanism

This paper presents a multilevel calibration technique for improving the absolute accuracy of an industrial robot with a parallelogram mechanism (ABB IRB2400). The parallelogram structural error is firstly modeled based on the partial differential of the position function of a general four-bar linkage and the linearization of the position constraints of the parallelogram mechanism, the model coefficients are fitted from experimental data. Secondly, an absolute kinematic calibration model is established and resolved as a linear function of all the kinematic parameters, as well as the base frame parameters and tool parameters. Finally, contrary to most other similar works, the robot joint space (rather than Cartesian space) is divided into a sequence of fan-shaped cells in order to compensate the non-geometric errors, the positioning errors on the grid points are measured and stored for the error compensation on the target points. After the multilevel calibration, the maximum/mean point positioning errors on 284 tested configurations (evenly distributed in the robot common workspace) are reduced from 1.583/0.420 mm to 0.172/0.066 mm respectively, which is almost the same level as the robot bidirectional repeatability.     

Motion error compensation of multi-legged walking robots

Existing errors in the structure and kinematic parameters of multi-legged walking robots,the motion trajectory of robot will diverge from the ideal sports requirements in movement.Since the existing error compensation is usually used for control compensation of manipulator arm,the error compensation of multi-legged robots has seldom been explored.In order to reduce the kinematic error of robots,a motion error compensation method based on the feedforward for multi-legged mobile robots is proposed to improve motion precision of a mobile robot.The locus error of a robot body is measured,when robot moves along a given track.Error of driven joint variables is obtained by error calculation model in terms of the locus error of robot body.Error value is used to compensate driven joint variables and modify control model of robot,which can drive the robots following control model modified.The model of the relation between robot’s locus errors and kinematic variables errors is set up to achieve the kinematic error compensation.On the basis of the inverse kinematics of a multi-legged walking robot,the relation between error of the motion trajectory and driven joint variables of robots is discussed.Moreover,the equation set is obtained,which expresses relation among error of driven joint variables,structure parameters and error of robot’s locus.Take MiniQuad as an example,when the robot MiniQuad moves following beeline tread,motion error compensation is studied.The actual locus errors of the robot body are measured before and after compensation in the test.According to the test,variations of the actual coordinate value of the robot centroid in x-direction and z-direction are reduced more than one time.The kinematic errors of robot body are reduced effectively by the use of the motion error compensation method based on the feedforward.     

Plane kinematic calibration method for industrial robot based on dynamic measurement of double ball bar

A new calibration method is proposed to improve the circular plane kinematic accuracy of industrial robot by using dynamic measurement of double ball bar (DBB). The kinematic model of robot is established by the MDH (Modified Denavit-Hartenberg) method. The error mapping relationship between the motion error of end-effector and the kinematic parameter error of each axis is calculated through the Jacobian iterative method. In order to identify the validity of the MDH parameter errors, distance errors and angle errors of each joint axis were simulated by three orders of magnitude respectively. After multiple iterations, the average value of kinematic error modulus of end-effector was reduced to nanometer range. Experiments were conducted on an industrial robot (EPSON C4 A901) in the working space of 180 mm × 490 mm. Due to the measuring radius of DBB, the working space was divided into 30 sub-planes to measure the roundness error before and after compensation. The average roundness error calibrated by the proposed method at multi-planes decreased about 21.4%, from 0.4637 mm to 0.3644 mm, while the standard deviation of roundness error was reduced from 0.0720 mm to 0.0656 mm. In addition, by comparing the results of positioning error measured by the laser interferometer before and after calibration, the range values of motion errors of end-effector were decreasing by 0.1033 mm and 0.0730 mm on the X and Y axes, respectively.     

A systematic approach to identify the error motion of anN-degree of freedom manipulator

A generalised calibration technique for identifying the joint geometric parameters of an N-degrees-of-freedom (d.o.f.) robot manipulator model is presented. The technique is analogous to the synthesising calibration method applied in the calibration of coordinate measuring, machines. It describes the state of each joint by six d.o.f. and assumes rigid-body motion. The initial step in the calibration involves locating the axis of motion of each joint; the axes are then used to extract the kinematic parameters, introduced by Denavit-Hartenberg (D-H). In order to derive the generalised manipulator kinematic equation, the robot model is modified to include the six error motion components associated with each axis. The paper also addresses the problem of identifying the error motion components of each joint, on the basis of a set of measurement of three noncollinear points at the robot end-effector at various joint configurations. Because the technique is based on axis-by-axis calibration, other non-geometric errors such as joint backlash and gear transmission error may also be revealed.     

考虑基坐标系误差的机器人运动学标定方法

提出了一种基于机器人几何参数误差与基坐标系位姿误差的六轴串联型机器人误差标定方法.首先基于MD-H方法建立了IRB6700机器人几何参数误差模型,得到机器人连杆几何参数误差到机器人末端位姿误差的映射关系;然后进一步考虑了基坐标系的位姿误差,并建立了考虑基坐标系误差的机器人误差模型;此外,针对传统标定方法操作繁琐、偶然误...     

Error Modeling and Sensitivity Analysis of a Parallel Robot with SCARA（Selective Compliance Assembly Robot Arm） Motions

Parallel robots with SCARA（selective compliance assembly robot arm） motions are utilized widely in the field of high speed pick-and-place manipulation. Error modeling for these robots generally simplifies the parallelogram structures included by the robots as a link. As the established error model fails to reflect the error feature of the parallelogram structures, the effect of accuracy design and kinematic calibration based on the error model come to be undermined. An error modeling methodology is proposed to establish an error model of parallel robots with parallelogram structures. The error model can embody the geometric errors of all joints, including the joints of parallelogram structures. Thus it can contain more exhaustively the factors that reduce the accuracy of the robot. Based on the error model and some sensitivity indices defined in the sense of statistics, sensitivity analysis is carried out. Accordingly, some atlases are depicted to express each geometric error’s influence on the moving platform’s pose errors. From these atlases, the geometric errors that have greater impact on the accuracy of the moving platform are identified, and some sensitive areas where the pose errors of the moving platform are extremely sensitive to the geometric errors are also figured out. By taking into account the error factors which are generally neglected in all existing modeling methods, the proposed modeling method can thoroughly disclose the process of error transmission and enhance the efficacy of accuracy design and calibration.     

电驱动重载六足机器人关节转速分析方法

为合理匹配电驱动重载六足机器人关节的驱动装置和传动装置,提出一种快速、精确获得关节转速的方法。基于某一关节转动以实现机器人最大步行速度指标,建立该关节转角与机器人最大步行速度指标的数学关系式,研究螃蟹型三角步态下的髋关节和膝关节在最小摆角和最大摆角时的相应输出转速以及蚂蚁型三角步态下的跟关节输出转速,并获得跟关节转角和转速随髋、膝关节夹角的变化趋势。根据ADAMS软件和研制的机器人单腿与样机,进行关节转速的仿真验证和试验分析,分别获得机器人承载平台重心的速度曲线和关节伺服电动机脉冲数曲线。仿真和试验结果表明,机器人关节转速分析方法具有合理性和有效性,能够可靠地应用于重载多足机器人的研制。     

Laser tracker-based kinematic parameter calibration of industrial robots by improved CPA method and active retroreflector

Typical approaches to calibrate industrial robots are based on open- and closed-loop methods; the screw–axis measurement methods traditionally receive much less attention. Although the identification process does not guarantee the physical–mathematical link between the robot parameters in the first two groups of techniques, these techniques are generally more effective in reducing the global positioning error compared to the screw–axis methods. The third group of techniques acquires parameters based on the physical reality of the robot, effectively keeping the physical–mathematical link. This group is considered more appropriate than the previous two groups; however, it cannot reduce the overall error when considering the entire workspace of the robot compared to the previous groups. This paper presents a new technique to identify the kinematic parameters of an industrial robot based on a combination of techniques from the aforementioned categories. This new data acquisition technique uses a laser tracker with an active target, which maximises the angle covered by each joint and greatly simplifies the screw–axis measurement process. An identification procedure based on circle point analysis is also proposed, and the procedure evaluates the technique by obtaining initial values with a new formulation of the objective function of error based on mutual distances between the points captured in screw–axis measurements. This type of measurement also allows the eccentricity and backlash of each joint to be characterised independently such that local joint corrections could be made in combination with the identified parameters.     

车铣复合加工中心综合误差检测及补偿策略

根据五轴车铣复合加工中心的结构及其运动链构型特点,设计了综合误差检测方案。检测包括车主轴床身至铣主轴运动链的空间误差检测以及车主轴的热误差检测两部分。由于检测方案使刀具-工件之间构成了完整的运动链,解决了单纯的空间误差检测方法未考虑车主轴运动链误差影响的问题。文中同时提出了车铣复合加工中心综合误差补偿策略以及运用神经网络算法的几何误差和热误差综合补偿模型。采用分步体对角空间误差检测后,实施了空间误差补偿。补偿后四条体对角线的空间误差都明显减小,减小幅度从15.24 μm到50.83 μm,误差补偿效果从39.10%提高到78.06%。本文提出的方法极大地改善了空间误差补偿精度。     

转台误差对数字天顶仪轴系误差的影响

针对数字天顶仪在定位过程中存在的的轴系偏差,研究了如何对光轴与旋转轴、旋转轴与垂直轴之间的角度偏差进行补偿的方法。为了高精度地解算出测站点位置垂直轴的天文坐标,采用对称位置的两幅星图直接解算旋转轴的坐标,从而避免了光轴与旋转轴之间的补偿。采用双轴倾角仪测量倾角,并对旋转轴进行倾角补偿得出垂直轴的位置坐标。考虑进行轴系补偿时,转台误差会对旋转轴坐标和倾角补偿造成影响,分别研究了转台误差对于旋转轴以及倾角补偿的影响,并得出了转台误差的范围。实验结果表明:当测站点纬度的绝对值小于或等于88.3°时,转台误差必须小于或等于35″;当测站点纬度的绝对值大于88.3°时,转台误差值要小于|1 166.8cosδ|″。在对称位置解算测站点位置坐标时,必须提高转台的精度,以减小转台误差对于定位精度的影响。     

基于递归小脑神经网络模型控制的空间机器人关节抗死区及摩擦控制

探讨了存在关节力矩输出死区、摩擦与外部干扰的载体位姿均不受控的漂浮基空间机器人系统的动力学控制问题。设计了一种递归小脑模型关节控制器（CMAC）神经网络与死区估计补偿器,使两关节铰能够跟踪期望运动轨迹。该控制器利用摩擦双观测器估计不可测的内部摩擦状态,利用死区预补偿器消除关节力矩输出死区的影响;应用递归小脑神经网络模型逼近了包含摩擦误差及外部干扰的动力学方程不确定项。仿真结果表明了该控制方法的有效性。     

一种新型三坐标测量机构模型的研究

提出一种非正交三坐标测量机构方案，即三根伸缩测量杆大约垂向、横向、纵向布置，主测杆的上端用十字铰吊挂于机架，测头安装在其下端；两根辅测杆两端分别用球铰与机架及主测杆芯下端连接。建立了该测量机的模型，给出了由测量杆长度求测点坐标的解析式、测量空间及其数字算例，简要分析了测量机的误差，结果表明，机构对多种制造误差不敏感。给出了采用关节式测头架的测量机的数学模型。     

Three-point method for measuring the geometric error components of linear and rotary axes based on sequential multilateration

The linear and rotary axes are fundamental parts of multi-axis machine tools. The geometric error components of the axes must be measured for motion error compensation to improve the accuracy of the machine tools. In this paper, a simple method named the three-point method is proposed to measure the geometric error of the linear and rotary axes of the machine tools using a laser tracker. A sequential multilateration method, where uncertainty is verified through simulation, is applied to measure the 3D coordinates. Three non-collinear points fixed on the stage of each axis are selected. The coordinates of these points are simultaneously measured using a laser tracker to obtain their volumetric errors by comparing these coordinates with ideal values. Numerous equations can be established using the geometric error models of each axis. The geometric error components can be obtained by solving these equations. The validity of the proposed method is verified through a series of experiments. The results indicate that the proposed method can measure the geometric error of the axes to compensate for the errors in multi-axis machine tools.     

下肢外骨骼助力机器人关节驱动设计及试验分析

针对人体下肢关节特点与助行要求,设计了外骨骼机器人关节结构;通过ADAMS软件仿真,分析了外骨骼机器人水平助行过程中关节功率配置需求,根据关节需求设计了外骨骼电液伺服驱动系统;为满足外骨骼机器人对人体下肢关节助力及柔顺性要求,提出了基于关节误差估计的PID控制方法。详细介绍了外骨骼机器人下肢关节结构的运动形式与技术参数,优化配置了关节结构的运动范围与驱动行程,对该机器人进行了运动学分析并通过外骨骼的典型动作进行验证;划分了外骨骼助行过程中步态与关节驱动映射,给出误差估计与补偿PID控制的具体参数;分别从关节跟踪与助力功率的角度,量化分析、对比了基于关节误差估计与常规PID两种控制方法的助力指标参数。试验结果表明,所设计外骨骼关节与驱动系统可实现穿戴者助力行走;对比常规PID控制,抑制了关节驱动控制输出区间的不连续,改善了关节跟踪误差,提升了助力效果与柔顺性。     

基于期望动力学的柔性关节控制器设计

协作机器人具有灵活,安全特点,已广泛应用于自动化领域以及中小企业中。为了保证与人交互的安全性,协作机器人通常采用中空电机与中空减速器配合的设计方案,以降低关节转动惯量,从而获得良好的外力感知与控制能力,这种设计导致协作机器人的关节具有了柔性。针对具有柔性关节的轻量级协作机器人,设计了一种基于期望动力学的柔性关节控制器,提高柔性关节机器人的轨迹跟踪精度和抖动抑制能力。在具有谐波减速器和力矩传感器的柔性关节上,基于连杆侧位置反馈与关节力矩反馈实现了从经典的电机侧控制到连杆侧控制的转变,并借助储存函数建立李雅普诺夫函数证明了该控制器的无源性与渐近稳定性。最后,通过Simulink仿真与单关节实验平台的关节轨迹追踪实验验证了柔性关节控制器的性能,结果显示其与全状态反馈控制相比具有关节力矩波动小、抖动抑制快以及轨迹跟踪误差小等优点。     

机器人逆标定方法研究

在分析传统机器人位姿标定方法的基础上,提出了一种新的机器人标定方法:基于神经网络的逆标定方法。这种标定方法把机器人关节角和相应的误差分别作为前馈神经网络的输入和输出来训练网络,从而实时获得机器人任意关节角的误差值,通过修改关节值来提高机器人的位姿精度。仿真和试验结果均证明了这种方法的有效性。。