A method for grinding removal control of a robot belt grinding system

As a kind of manufacturing system with a flexible grinder, the material removal of a robot belt grinding system is related to a variety of factors, such as workpiece shape, contact force, robot velocity, and belt wear. Some factors of the grinding process are time-variant. Therefore, it is a challenge to control grinding removal precisely for free-formed surfaces. To develop a high-quality robot grinding system, an off-line planning method for the control parameters of the grinding robot based on an adaptive modeling method is proposed in this paper. First, we built an adaptive model based on statistic machine learning. By transferring the old samples into the new samples space formed by the in-situ measurement data, the adaptive model can track the dynamic working conditions more rapidly. Based on the adaptive model the robot control parameters are calculated using the cooperative particle swarm optimization in this paper. The optimization method aims to smoothen the trajectories of the control parameters of the robot and shorten the response time in the transition process. The results of the blade grinding experiments demonstrate that this approach can control the material removal of the grinding system effectively.     

Hybrid active/passive force control strategy for grinding marks suppression and profile accuracy enhancement in robotic belt grinding of turbine blade

Grinding marks and traces, as well as the over- and under-cutting phenomenon are the severe challenges in robotic abrasive belt grinding of turbine blades and it greatly limits the further application of robotic machining technology in the thin-walled blade fields. In the paper, an active force control method consisting of force/positon and PI/PD controller based on six-dimensional force/torque sensor is introduced to eliminate the grinding marks and traces, and a passive force control method including PID controller based on one-dimensional force sensor is proposed to reduce the over- and under-cutting phenomenon in robotic machining system. Then the Kalman filter information fusion methodology is adopted to combine the active and passive force control methods which could improve the controlled force accuracy and efficiency, as well as avoid the control interference. Finally both the test workpiece and turbine blade are employed to examine and verify the reliability and practicality of the proposed hybrid force control method by achieving the desired surface quality and higher profile precision.     

Time-varying isobaric surface reconstruction and path planning for robotic grinding of weak-stiffness workpieces

Severe deformations and vibration usually occur when grinding the weak-stiffness workpieces, then fluctuate the grinding force and damage the surface. In this paper, the time-varying isobaric surface (TVIS) is defined as a virtual surface to generate constant force during robotic grinding. Based on it, a novel robotic grinding method, including contact trial and surface reconstruction, is proposed. In the contact trial process, the robot actively samples the deformation and stiffness of contact point with a force sensor. Then, a TVIS mesh is constructed to replace the original geometry of the workpiece, which is utilized for grinding path planning. Experiments have been conducted to verify the feasibility of this method. The result shows that the proposed method can achieve constant grinding force and is robust to the types of workpieces and the processing techniques. Furthermore, it is considered as an intelligent method for customized robotic machining of the weak-stiffness workpieces.     

A new force-depth model for robotic abrasive belt grinding and confirmation by grinding of the Inconel 718 alloy

Robotic abrasive belt grinding has been successfully applied to the grinding and polishing of aerospace parts. However, due to the flexible characteristics of robotic abrasive belt grinding and the time-varying characteristics of the polishing contact force, as well as the plastic and difficult-to-machine material properties of Inconel 718 alloy, it is very difficult to control the actual removal depth and force of the polished surface, which brings great challenges to robot automatic polishing. Therefore, the relationship between the grinding force and the grinding depth in the robotic abrasive belt grinding is analyzed in detail, the robot machining pose error model considering the deformation of the grinding head is established, and the Inconel 718 alloy machining experiment of the robotic abrasive belt grinding is designed. The mapping relationship between the grinding force and the grinding depth is obtained, and the grinding force ratio in the downgrinding and upgrinding mode is discussed. The experimental and theoretical comparisons results show that with the increase of the grinding depress depth, both the grinding depth and the grinding force show an irregular increasing trend, and the increasing trend of the grinding force (increases by about 344.44%–445.45%) is obviously greater than that of the grinding depth (increases by about 52.94%). When the grinding depress depth is large (greater than 3 mm), the feed direction force and the normal force appear obvious secondary pressure peaks at the beginning and end of grinding, which has not been seen in previous studies. In addition, regardless of whether it is downgrinding or upgrinding, the grinding force ratio decreases with the increase of the depress depth, and the grinding force ratio of downgrinding (average 0.668) is smaller than that of upgrinding (average 0.724). This study provides a reference for robotic abrasive belt grinding, and the surface quality of Inconel 718 alloy of robotic abrasive belt grinding can be further improved through the optimization of force and depth.     

基于曲率优化的机器人砂带磨削轨迹规划

针对复杂曲面零件砂带磨削编程效率低、精度差的问题,基于B样条曲线曲面重构和机器人离线编程技术,提出了一种根据关键接触点曲率值生成工业机器人磨削轨迹的方法.首先,利用零件表面上需要进行砂带磨削的关键接触点和积累弦长参数化法构造节点矢量,从而计算出磨削轨迹的B样条基函数;其次,根据控制顶点反求矩阵得到全部未知控制点和3次B样条加工曲线;然后,分析关键接触点之间的曲率变化率和弧长,对关键点细化生成符合磨削工艺要求的目标点;最后,通过求解双3次B样条插值曲面方程获得目标点的加工姿态.以水龙头磨削为例进行试验,结果表明曲率优化算法磨削的零件表面轮廓形状明显优于截面法,且其粗糙度值能稳定在0.082 μm左右,可以有效提高工件表面加工质量.     

A new calibration method for a dynamic coordinate system in a robotic blade grinding and polishing system based on the six-point limit principle

Automatic robotic grinding and polishing systems have become a developing trend in aerospace parts manufacturing. In a robotic blade grinding and polishing system (RBGPS), the automatic and precise calibration of the dynamic workpiece coordinate frame is the most important process. In this research, a new method that introduces the concept of six-point positioning into the dynamic workpiece coordinate frame calibration process is proposed using a point laser displacement sensor (PLDS). The static coordinate frame calibration process is conducted based on a robot flange and force sensor. The results indicate that the new method can achieve a higher precision calibration result and has improved operational efficiency and cost. Finally, its practicality is verified in the BRGPS, and the results indicate that the polished blade surface after using the new method has good consistency.     

Identification of effective engineering methods for controlling handheld workpiece vibration in grinding processes

The objective of this study is to identify effective engineering methods for controlling handheld workpiece vibration during grinding processes. Prolonged and intensive exposures to such vibration can cause hand-arm vibration syndrome among workers performing workpiece grinding, but how to effectively control these exposures remains an important issue. This study developed a methodology for performing their analyses and evaluations based on a model of the entire grinding machine-workpiece-hand-arm system. The model can simulate the vibration responses of a workpiece held in the worker's hands and pressed against a grinding wheel in order to shape the workpiece in the major frequency range of concern (6.3–1600 Hz). The methodology was evaluated using available experimental data. The results suggest that the methodology is acceptable for these analyses and evaluations. The results also suggest that the workpiece vibration resulting from the machine vibration generally depends on two mechanisms or pathways: (1) the direct vibration transmission from the grinding machine; and (2) the indirect transmission that depends on both the machine vibration transmission to the workpiece and the interface excitation transformation to the workpiece vibration. The methodology was applied to explore and/or analyze various engineering methods for controlling workpiece vibrations. The modeling results suggest that while these intervention methods have different advantages and limitations, some of their combinations can effectively reduce the vibration exposures of grinding workers. These findings can be used as guidance for selecting and developing more effective technologies to control handheld workpiece vibration exposures.     

Position-based force tracking adaptive impedance control strategy for robot grinding complex surfaces system

As a key technology of robot grinding, force control has great influence on grinding effects. Based on the traditional impedance control, a position-based force tracking adaptive impedance control strategy is proposed to improve the grinding quality of aeroengine complex curved parts, which considers the stiffness damping environmental interaction model, modifies the reference trajectory by a Lyapunov-based approach to realize the adaptive grinding process. In addition, forgotten Kalman filter based on six-dimensional force sensor is used to denoise the force information and a three-step gravity compensation process including static base value calculation, dynamic zero update and contact force real-time calculation is proposed to obtain the accurate contact force between tool and workpiece in this method. Then, to verify the effectiveness of the proposed method, a simulation experiment which including five different working conditions is conducted in MATLAB, and the experiment studying the deviation between the reference trajectory and the actual position is carried out on the robot grinding system. The results indicate that the position-based force tracking adaptive impedance control strategy can quickly respond to the changes of environmental position, reduce the fluctuation range of contact force in time by modifying the reference trajectory, compensate for the defect of the steady-state error of the traditional impedance control strategy and improve the surface consistency of machined parts.     

Force control-based vibration suppression in robotic grinding of large thin-wall shells

Vibration suppression is a major difficulty in the grinding of low-stiffness large thin-wall shells. The paper proposes that effective workpiece vibration control can be performed by a novel force-controlled end-effector integrated into a robotic grinding workcell. First, a dynamics model is built to capture the characteristics and vibration suppression mechanism of force control-based robotic grinding, then a novel force control-based vibration suppression method is designed for grinding large thin-wall shells, and three robotic grinding tests are conducted to validate the effects of the new method and the grinding performance of the force control-based robotic grinding workcell. The results are: 75% reduction in the amplitude of workpiece vibration; effective suppression of non-tool passing frequency; stable grinding of large thin-wall shells remarkably enhancing grinding depth up to 0.3 mm per pass, grinding depth error less than ±0.1 mm, and significant improvement of the workpiece surface quality up to Ra=0.762 μm.     

Simulation of micro-patterns engraved by grinding process with screw shaped wheel

Grinding is an important means of realizing precision and ultra-precision machining of workpiece surface. The surface patterning of workpiece directly affects its mechanical properties such as friction, wear, contact stiffness, fitting property. Therefore, prediction of the geometry of the workpiece surface is very important to evaluate the workpiece quality to perform mechanical function accurately. In this paper using MATLAB simulation, prediction for the geometry pattern of the workpiece according to the developed shape of the grinding wheel dressed by thread cutting was studied. The model for the geometry of the grinding wheel surface was first developed and subsequently, a new simulation model for surface pattern by grinding process was established. The simulation results could be used to optimize the grinding process and to improve the workpiece surface quality or predict the surface pattern by given grinding parameters.     

Accuracy analysis in mobile robot machining of large-scale workpiece

Mobile robot machining provides more flexible machining mode compared to the robot machining with a fixed base. However, its machining accuracy is frequently questioned. This paper focuses on the accuracy analysis in mobile robot machining. To evaluate the machining error qualitatively, the tool center point (TCP) error index is defined as the distance between the TCP and the designed machining point. The different error sources acting on the TCP error index are enumerated, and the theoretical accuracy analysis is proposed to eliminate the TCP error. The mobile robot machining strategy is then proposed based on the accuracy analysis. To ensure high machining accuracy, the global measurement system locates the position of the workpiece and the mobile platform. The force-controlled grinding head is used to compensate the TCP error. Experimental results show that the TCP error during mobile robot machining is lower than 40 mm, which mainly introduced by the calibration of the workpiece. The force-controlled grinding head can compensate the TCP error and the fluctuation of the grinding force under the control is lower than ±2 N.     

Non-jamming conditions in multi-contact rigid-body dynamics

This paper addresses an issue related to a multi-rigid-body frictional contact application, the non-jamming condition for the applying force such that the workpiece can move while maintaining existing contacts. The issue arises from the study of fixture loading planning. While rigid-body frictional contacts could restrict workpiece motion in both normal and tangential directions, it is found that the reason for jamming is from the tangential constraints by frictional forces. We first enumerate all the possible contact states for multiple contacts, and the contact constraints are classified into two categories, the configuration constraints and kinematic constraints. We then find an interesting result related with a non-jamming condition. That is, in a general situation, the applying force that can induce all-sliding contacts will never result in jamming. Moreover, a method to find the applied force on the workpiece that results in sliding on all contact points is presented, based on the sufficient condition for non-jamming. Numerical examples are presented and the results of the method are compared with the results of a quasi-static method.     

Updating workpiece geometry using robotic sensor information gathered during contact tasks

During robotic contact tasks, geometric information of the workpiece is used to specify the position of the robot’s hand on the workpiece and the direction of force control. This geometry is idealized in a typical CAD file, but due to manufacturing precision or wear, the actual workpiece geometry is inevitably deviated from the desired geometry. Furthermore, when the workpiece is mounted, position and orientation inaccuracies emerge. In this paper, we investigate two questions: (1) Can the workpiece geometry in the CAD file be used to control a robot in contact with an inaccurately placed workpiece?; and (2) Once the task is performed, how can the robot’s sensor information be used to update the geometry of the workpiece? A methodology is developed to solve robotic control problems with workpiece position and geometry inaccuracies. Once performed, the CAD file image is displaced to fit the sensed trajectory of the robot’s hand. Finally, the workpiece image geometry is modified using a least squares approximation to fit the sensed data more accurately. In the end, the robot performs the contact task while gathering information that is used to update the original CAD file geometry. The methodologies are demonstrated through a simulation experiment that requires a robot to shave a geometrically altered face that is inaccurately positioned.     

Modeling of cutting geometry and forces for 5-axis sculptured surface machining

5-Axis sculptured surface machining is simulated using discrete geometric models of the tool and workpiece to determine the tool contact area, and a discrete mechanistic model to estimate the cutting forces. An extended Z-buffer model represents the workpiece, while a discrete axial slice model represents the cutting tool. Determination of the contact area for a given tool move requires a swept envelope (SWE) of the tool path. The SWE is used to find the intersections of the tool envelope with Z-buffer elements (ZDVs) representing the workpiece. A 3-axis approximation of the 5-axis tool movement is used to simplify the calculations while maintaining a desired level of accuracy. The intersection of the SWE with each ZDV yields segments which are used to find the contact area between the cutter and the workpiece for a given tool path. The contact area is subsequently used with the discrete force model to calculate the vector cutting force acting on the tool.     

On Clamping Planning in Workpiece-Fixture Systems

Deformations of contacts between the workpiece and locators/clamps resulting from large contact forces cause overall workpiece displacement, and affect the localization accuracy of the workpiece. An important characteristic of a workpiece-fixture system is that locators are passive elements and can only react to clamping forces and external loads, whereas clamps are active elements and apply a predetermined normal load to the surface of workpiece to prevent it from losing contact with the locators. Clamping forces play an important role in determining the final workpiece quality. This paper presents a general method for determining the optimal clamping forces including their magnitudes and positions. First, we derive a set of “compatibility” equations that describe the relationship between the displacement of the workpiece and the deformations at contacts. Further, we develop a locally elastic contact model to characterize the nonlinear coupling between the contact force and elastic deformation at the individual contact. We define the minimum norm of the elastic deformations at contacts as the objective function, then formulate the problem of determining the optimal clamping forces as a constrained nonlinear programming problem which guarantees that the fixturing of the workpiece is force closure. Using the exterior penalty function method, we transform the constrained nonlinear programming into an unconstrained nonlinear programming which is, in fact, the nonlinear least square. Consequently, the optimal magnitudes and positions of clamping forces are obtained by using the Levenberg–Marquardt method which is globally convergent. The proposed planning method of optimal clamping forces, which may also have an application to other passive, indeterminate problems such as power grasps in robotics, is illustrated with numerical example.      

火电厂皮带秤的校验方法及误差分析

介绍了火电厂皮带秤校验的三种方法,从不同方面对其进行了分析。从最接近皮带秤的实际受力情况出发,经过现场实践检验证明,在线实物校验是火电厂皮带秤最理想的校验方式。     

Robotic grinding of complex components: A step towards efficient and intelligent machining – challenges,solutions, and applications

Robotic grinding is considered as an alternative towards the efficient and intelligent machining of complex components by virtue of its flexibility, intelligence and cost efficiency, particularly in comparison with the current mainstream manufacturing modes. The advances in robotic grinding during the past one to two decades present two extremes: one aims to solve the problem of precision machining of small-scale complex surfaces, the other emphasizes on the efficient machining of large-scale complex structures. To achieve efficient and intelligent grinding of these two different types of complex components, researchers have attempted to conquer key technologies and develop relevant machining system. The aim of this paper is to present a systematic, critical, and comprehensively review of all aspects of robotic grinding of complex components, especially focusing on three research objectives.For the first research objective, the problems and challenges arising out of robotic grinding of complex components are identified from three aspects of accuracy control, compliance control and cooperative control, and their impact on the machined workpiece geometrical accuracy, surface integrity and machining efficiency are also identified. For the second aim of this review, the relevant research work in the field of robotic grinding till the date are organized, and the various strategies and alternative solutions to overcome the challenges are provided. The research perspectives are concentrated primarily on the high-precision online measurement, grinding allowance control, constant contact force control, and surface integrity from robotic grinding, thereby potentially constructing the integration of “measurement – manipulation – machining” for the robotic grinding system. For the third objective, typical applications of this research work to implement successful robotic grinding of turbine blades and large-scale complex structures are discussed. Some research interests for future work to promote robotic grinding of complex components towards more intelligent and efficient in practical applications are also suggested.     

A biomechanical assessment of hand/arm force with pneumatic nail gun actuation systems

A biomechanical model is presented to estimate user hand/arm force exertion with two pneumatic nail gun trigger systems. The sequential actuation trigger (SAT) is safer than the contact actuation trigger (CAT) but increases the user's exertion of force because the trigger must be actuated after the safety tip is held pressed against the workpiece. Time integrated hand force was calculated for a single user based on direct measurement of nail gun tip force against the workpiece (tip contact) and from estimated force to support the tool weight during transfer between nails and during idle holding. The model shows that hand/arm force increases when nailing with the SAT (relative to CAT) and with a vertically-oriented workpiece (relative to horizontal). Expressed per nail fired, the user exerted 0.13 Ns (horizontal orientation) and 2.88 Ns (vertical orientation) integrated hand force during tip contact with CAT compared to 26.15 Ns (horizontal) and 46.08 Ns (vertical) with SAT. Depending upon idle holding duration, integrated hand force during tip contact was estimated to have been 1–3% of 48–132 Ns total hand force with CAT and 21–44% of 83–167 Ns total hand force with SAT (average of horizontal and vertical orientations). Based on standard time allowances from work measurement systems it is proposed that efficient application of hand force during tip contact with SAT can reduce this contribution to 6–15% of 55–139 Ns total hand force. The model is useful for considering differences in hand/arm force exertion between the SAT and CAT systems     

An adaptive trajectory planning algorithm for robotic belt grinding of blade leading and trailing edges based on material removal profile model

Robotic belt grinding of the leading and trailing edges of complex blades is considered to be a challenging task, since the microscopic material removal mechanism is complicated due to the flexible contact state accompanied with greatly varying curvature that finally affects the machined profile accuracy. The resulting poor accuracy of blade edges, to a great extent, is attributed to the trajectory planning method which less considers the dynamics. In this paper, an iso-scallop height algorithm based on the material removal profile (MRP) model is developed to plan the tool paths by taking into consideration the elastic deformation at contact wheel-workpiece interface. An improved constant chord-height error method considering the influence of elastic deformation is then proposed to adaptively plan the grinding points according to the curvature change characteristics of the free-form surface. Based on these two steps, a MRP model based adaptive trajectory planning algorithm is constructed to enhance the profile accuracy facing the robotic belt grinding operation. Simulation and experimental results demonstrate the effectiveness of the proposed trajectory planning algorithm for the robotic belt grinding of blades from the perspectives of surface roughness, profile accuracy and processing efficiency. Particularly this technology serves to solve the problem of over-cutting at the blade leading and trailing edges.     

Sensor-based force decouple controller design of macro–mini manipulator

A robotic polishing system includes a force-controlled end-effector (mini manipulator) and a position-controlled industrial robot (macro manipulator). This combination mode has a fast response and a large workspace. However, the force-controlled axis component of the macro motions and the geometric of the workpiece surfaces will affect the contact force response rate and tracking accuracy due to the coupling dynamics between the macro and mini, limiting system performance. A new dynamic decoupling method employing dual force sensors (DFSs) is proposed to address these problems. One of the force sensors installed between the endpoint of the macro and the fixed platform of the mini realizes the dynamic decoupling of the macro and mini. The other one is added at the endpoint of the mini to obtain the interaction force in contact with the environment and feed it back to the control loop. When the disturbances produced by the macro trajectories and the uncertainties coming from the workpiece are introduced into the system, the proposed method can improve force response rate and tracking accuracy without knowing the dynamic models and parameters of the macro and the geometric of the workpiece surface. Several experiments are carried out under various conditions. Experimental results indicate that the contact force response rate and tracking error of DFSs are better than those of the conventional force-controlled and impedance matching methods, proving the proposed method’s effectiveness. In addition, the last comparison experiment verifies that the DFSs method applies to different kinds of end-effectors with various dynamics.