一种大型复杂构件加工新模式及新装备探讨

大型复杂构件是航空航天、能源、船舶等领域装备的核心结构件，此类构件通常具有尺寸大、形状复杂、刚性弱等特点。传统“分体离线加工-在线检测”模式存在工艺不稳定、过程复杂、柔性差、周期长等问题，以龙门式多轴数控机床加工为代表的“包容式”加工模式，难以适应大型复杂构件的高效高质量加工制造需求。提出一种基于移动式和吸附式机器人的多机协同原位加工新模式，通过多机器人系统自主寻位、精确定位加工与加工质量原位检测，实现大型复杂构件多安装面并行铣削、制孔与打磨等作业。多机器人系统包括移动式混联机器人、吸附式并联机器人、移动式串联铣削机器人、移动式双臂加工机器人和移动式打磨机器人。构建多机协同原位加工模式，需要揭示多机器人协同原位加工行为与大型弱刚性结构件质量控制的交互机理，面临着本体、测量、工艺和集成四个方面的挑战，需要设计高灵活、高刚度的移动式和吸附式加工机器人，解决移动机器人自主准确寻位和超大结构件原位高精检测难题，攻克加工变形误差在线补偿和振动抑制技术，通过集成实现多机协同高效高精加工，为大型复杂构件的高效高质量制造提供创新技术及装备，并实现此类构件制造核心技术及装备自主可控。

Novel Mode and Equipment for Machining Large Complex Components

Large complex components are the core parts of equipment in the fields of aerospace, energy, ship, etc. Such components have common features such as large size, complex shape and weak stiffness. The traditional mode of offline processing and online detection has problems such as unstable and complicated process, poor flexibility and long cycle. The inclusive mode represented by gantry multi-axis CNC machine tool can hardly adapt to the requirements of high efficient and quality machining for large complex components. A novel multi-machine cooperative in-situ machining mode based on mobile and adsorptive robots is proposed. The multi-robot system can complete the independent locating, precise positioning and machining, and in-situ detection of machining quality, realizing simultaneously milling, drilling and polishing for multiple mounting surfaces. The multi-robot system includes a mobile hybrid robot, an adsorptive parallel robot, a mobile serial milling robot, a mobile dual-arm machining robot and a mobile grinding robot. In order to build the multi-machine cooperative in-situ processing mode, the interaction mechanism between multi-robots and large thin parts need to be revealed. And the challenges of design, measurement, craft and integration are encountered. It is necessary to design highly flexible mobile and adsorptive robots with high stiffness, solve the problems of accurate autonomous positioning and in-situ measurement, and conquer the deformation error online compensation and vibration suppression technology. Through system integration, multi-machine cooperative machining with high-efficiency and high-precision can be achieved, providing innovative technology and equipment for manufacturing large complex components. Consequently, the core technology and equipment of manufacturing such components can be controlled independently.