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.     

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.     

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 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.     

An approach to enhancing the intelligence of a three-fingered automated flexible fixturing system by using adaptive control theory

A new approach to clamping workpieces for the machining process has been developed. The new approach is based on the identification of the workpiece stiffness, during the machining process, which enables the fixturing system to determine whether the clamping force should be changed. Using this approach, a three-fingered intelligent automated flexible fixturing system for planar objects has been successfully designed and implemented. The conventional and traditional clamping methods use a hydraulic vise to clamp workpieces with a fixed amount of clamping forces. This often causes the workpieces to deform under such force, thus contributing to machining error. It is therefore desirable to control the clamping force according to the progress of the machining process. The implementation of this approach to the three-fingered automated flexible fixturing system enhances the system’s ability to achieve intelligent clamping force control and deal with abnormal machining, thus making the system intelligent. A thin ring-shaped workpiece was successfully used as an example to demonstrate the feasibility and validity of this approach. It also demonstrates that the developed system can be used in the highly automated manufacturing system of the future.     

Force Control of Robotic Manipulators Using a Fuzzy Predictive Approach

This paper proposes a force control strategy for robotic manipulators considering a non-rigid environment described by a nonlinear model. This approach uses a fuzzy predictive algorithm to generate, in an optimal way, the reference or virtual position to the classical impedance controller in order to apply a desired force profile on the environment. The main advantage of this control strategy is the possibility of including a nonlinear model of the environment in the controller design in a straightforward way, improving the global force control performance, especially in non-rigid environments. Moreover, in order to reduce the oscillations on the optimized reference position a fuzzy scaling machine is included on the force control strategy. The performance of the force control scheme is illustrated for a two degree-of-freedom PUMA 560 robot, which end-effector is forced to move along a flat surface located on the vertical plane. The simulation results obtained with the fuzzy control scheme reveal significant improvement in the force tracking performance, when compared to the impedance control with force tracking in non-rigid environments.     

快速刀具伺服系统自抗扰控制的研究与实践

快速刀具伺服系统(fast tool servo, FTS)是实现非圆截面和非轴对称表面零件加工的关键部件. 加工过程中,FTS应克服时变切削力负载和自身参数的非线性, 驱动刀具完成高频高精度跟踪运动. 为了解决FTS的快速精密跟踪控制问题, 根据刀具运动参考轨迹已知的特点, 应用自抗扰控制原理和前馈控制策略, 针对基于剪应力和正应力电磁驱动的两种直线执行机构, 分别设计了采用线性和非线性扩张状态观测器的自抗扰控制器, 并利用传递函数和描述函数方法, 分析了线性控制器的跟踪精度和动态刚度特性, 探讨了非线性控制系统的极限环问题. 两种基于自抗扰控制的快速刀具伺服系统已应用于发动机椭圆截面活塞的精密车削和二维正弦微结构表面的超精密车削,满足了加工需求. 研究与应用结果表明: 自抗扰控制思想独特、算法易于工程实现, 具有很好的工程应用价值.     

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.     

Nonlinear robust adaptive Cartesian impedance control of UAVs equipped with a robot manipulator

In this paper, a new nonlinear robust adaptive impedance controller is addressed for Unmanned Aerial Vehicles (UAVs) equipped with a robot manipulator that physically interacts with environment. A UAV equipped with a robot manipulator is a novel system that can perform different tasks instead of human being in dangerous and/or inaccessible environments. The objective of the proposed robust adaptive controller is control of the UAV and its robotic manipulator’s end-effector impedance in Cartesian space in order to have a stable physical interaction with environment. The proposed controller is robust against parametric uncertainties in the nonlinear dynamics model of the UAV and the robot manipulator. Moreover, the controller has robustness against the bounded force sensor inaccuracies and bounded unstructured modeling (nonparametric) uncertainties and/or disturbances in the system. Tracking performance and stability of the system are proved via Lyapunov stability theorem. Using simulations on a quadrotor UAV equipped with a three-DOF robot manipulator, the effectiveness of the proposed robust adaptive impedance controller is investigated in the presence of the force sensor error, and parametric and non-parametric uncertainties.     

Extension of impedance matching to nonlinear dynamics of robotic tasks

The concept of impedance matching for linear electric circuits is extended to nonlinear position-dependent circuits that express nonlinear dynamics of robotic tasks such as holding an object of soft material and handling a rigid object with soft fingers. At the first step, impedance control is realized by negative-feedback connection of two passive (hyper-stable) blocks, one is in the forward path expressing position control of the tool endpoint and the other is in the feedback path expressing force control of pressing the object. This negative-feedback framework is naturally introduced owing to the situation that both the tool mass and the nonlinear characteristics of reproducing force of the soft material are unknown. Extension of the concept of impedance matching to such nonlinear circuits is fulfilled by optimizing the regulation of impedance control and subsequently choosing optimal parameters from the viewpoint of both the transient and stead-state responses. The relations of this extension with the well-known theorem of maximum power supply and the H-infinity tuning for disturbance attenuation are also presented.     

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.     

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.     

Investigation on chatter stability of robotic rotary ultrasonic milling

In recent years, industrial robots with higher flexibility and lower cost have become a hot topic in the manufacturing field. In terms of practical machining applications, they are mainly employed in the situations with low cutting forces such as deburring, chamfering and polishing. However, the weak stiffness of robot induces milling chatter easily. Severe chatter not only damages the dimensional accuracy of parts, but also decreases machining efficiency and tool life. Thus, it is urgent to seek a new method to suppress robotic milling chatter. In this paper, robotic rotary ultrasonic milling (RRUM) technology is used to restrict machining vibration. Meantime, an analytical model of stability is developed. Robotic milling system is considered as a three degrees of freedom (3-DOF) model. After that, based on analysis of dynamic chip thickness, a linear force model is developed through defining an angle γ affected by ultrasonic vibration. Then, the semi-discretization method (SDM) is applied to obtain stability lobe diagrams. The analysis result indicates that stability region of RRUM is improved by 133% compared with robotic conventional milling (RCM). Finally, verification experiments are carried out to prove the rationality and effectiveness of these stability lobe diagrams.     

Decentralized adaptive controller design of large-scale uncertain robotic systems

In this paper, we develop a decentralized neural network control design for robotic systems. Using this design, it is not necessary to derive the robotic dynamical system (robotic model) for the control of each of the robotic components, as in traditional robot control. The advantage of the proposed neural network controller is that, under a mild assumption, unknown nonlinear dynamics such as inertia matrix and Coriolis/centripetal matrix and friction, as well as interconnections with arbitrary nonlinear bounds can be accommodated with on-line learning.     

基于阻抗控制的动态装配过程仿真研究

机器人化装配是一个复杂的动力学过程,在高速装配时不可避免地会对工件造成 损伤.为了寻求解决该问题的有效方法,根据采用阻抗控制方法推导出的装配过程的动力 学方程,提出了一种采用径向基函数网络(RBFN)来学习装配过程动力学的渐进学习机制和 通过梯度下降法调整阻抗参数的强化学习算法.数值仿真结果证明了该方法的有效性和渐 进学习的优越性.     

Accurate robotic belt grinding of workpieces with complex geometries using relative calibration techniques

Robotic belt grinding operations are performed by mounting a workpiece to the end effector and commanding it to move along a trajectory while maintaining contact with the belt grinding wheel. A constant contact force throughout the grinding process is necessary to provide a smooth finish on the workpiece, but it is difficult to maintain this force due to a multitude of installation, manipulation, and calibration errors. The following describes a novel methodology for robotic belt grinding, which primarily focuses on system calibration and force control to improve grinding performance. The overall theory is described and experimental results of turbine blade grinding for each step of the methodology are shown.     

Precise and smooth contact force control for a hybrid mobile robot used in polishing

Contact force is dominant in robotic polishing since it directly determines the material removal. However, due to the position and stiffness disturbance of mobile robotic polishing and the nonlinear contact process between the robot and workpiece, how to realize precise and smooth contact force control of the hybrid mobile polishing robot remains challenging. To solve this problem, the force tracking error is investigated, which indicates that the force overshoot mainly comes from the input step signal and the environmental disturbance causes force tracking error in stable state. Accordingly, an integrated contact force control method is proposed, which combines feedforward of the desired force and adaptive variable impedance control. The nonlinear tracking differentiator is used to smooth the input step signal of the desired force for force overshoot reduction. Through modeling of the force tracking error, the adaptive law of the damping parameter is established to compensate disturbance. After theoretical analysis and simulation verification, the polishing experiment is carried out. The improvement in force control accuracy and roughness of the polished surface proves the effectiveness of the proposed method. Sequentially, the proposed method is employed in the polishing of a 76-meter wind turbine blade. The measurement result indicates that the surface roughness after mobile robotic polishing is better than Ra1.6. The study provides a feasible approach to improve the polishing performance of the hybrid mobile polishing robot.     

Design and control of a three-fingered tendon-driven robotic hand with active and passive tendons

This paper presents a design of a three-fingered robotic hand driven by active and passive tendons and proposes control methods for this hand. The tendon-driven robotic hand consists of the thumb, the index and the middle fingers. The robotic thumb can move all the joints independently. In contrast, the index and the middle robotic fingers are under-actuated using the combination of active and passive tendons, and move the terminal two joints synchronously, which is one of the important features of the human digits. We present passivity-based impedance and force controllers for tendon-driven robotic fingers and discuss how to combine them for fast and secure grasps. We experimentally validate that the robotic hand moves fast and manipulates an object and demonstrate that the robotic hand grasps objects in diverse ways.     

Feedback linearization of differential-algebraic systems and force and position control of manipulators

The question of realization and feedback linearization of a class of differential-algebraic system is considered. Based on nonlinear inversion of an input-output map, an analytical expression for the constraint force vector satisfying the algebraic constraints is derived. In this derivation, certain requirements on the relative degree of the output variables are relaxed. Using a new representation of the system in an extended state space, a control law is derived for the independent control of the chosen output variables satisfying algebraic constraints. These results are applied for the position and force control of robotic manipulators. Simulation results are presented for a three-link robotic arm with revolute joints. It is shown that in the closed-loop system, precise position and force trajectory control is accomplished in spite of uncertainty in the robot parameters.     

面向位控机器人的力/位混合控制

本文提出了一种面向位控机器人的力/位混合控制策略．通过力反馈信息对未知约 束进行估计获得位控和力控方向,根据位控和力控方向对机器人终端的运动轨迹进行规划, 并采用阻抗力控制规律以使机器人获得较好的柔顺性．仿真试验表明,该策略具有较高的力 控制精度和表面跟踪能力．