复合材料纤维铺放自动编程技术研究

纤维铺放是近年来发展最快、最有效的复合材料构件成形技术之一。结合所研制的纤维铺放设备,研究复合材料纤维铺放自动编程技术。在已知芯模曲面和纤维铺放路径的基础上,运用机器人学原理建立了纤维铺放机构各杆件坐标系,设计了空间机构运动学逆问题的简化求解算法,针对纤维铺放路径上的每个控制点,得到纤维铺放机构各运动关节位置和姿态。根据传动机构的组成,计算出各驱动步进电机的转角,从而生成纤维铺放机运动控制指令代码。基于CATIA开发平台CAA,开发了复合材料纤维铺放仿真软件模块。     

冗余驱动2SPR-2RPU并联机构的运动静力学 及奇异性研究

针对打磨、抛光等重载机器人的应用需求,提出了一种新型冗余驱动2SPR-2RPU并联机构。运用螺旋理论计算了2SPR-2RPU并联机构的自由度,并求解了其运动学逆解与速度雅克比矩阵。全面考虑2SPR-2RPU并联机构自身重力因素,利用拆杆法对该机构进行静力学分析,并建立了其静力学模型。针对机构驱动冗余的特点,运用拉格朗日乘数法,以驱动力最小为目标构造函数,对驱动力进行分配求解,获得2SPR-2RPU并联机构在给定运动轨迹下的驱动力变化趋势。根据速度雅克比矩阵对2SPR-2RPU并联机构的奇异性进行分析,结果表明该机构没有运动学正解奇异和运动学反解奇异,但具有2个运动学混合奇异,且2个混合奇异位形可通过合理设计机构杆件尺寸进行规避。研究结果可为实际工程应用中冗余驱动并联机构的研究提供一定的理论基础。     

上假肢运动学逆解可视化研究

针对上假肢的结构特点,提出用机构运动等同性条件和代数法相结合的方法来解决上假肢运动关节变量的逆解问题,以避免多次逆矩阵相乘。利用VB对CATIA进行二次开发,在CATIA软件中实现上假肢关节各个解所对应的空间位置姿态图形显示,可直观地判断解的有效性,为上假肢运动控制研究奠定基础。     

3-CRS-S并联机构的运动学分析及仿真

目的 对3-CRS-S并联机构进行运动学分析及仿真,验证该机构是否具有优良的运动学性能.方法 运用修正的Kutzbach-Grübler公式对机构进行自由度计算,并分别采用D-H法和数值算法中的粒子群优化算法(PSO)对该3-CRS-S并联机构的位置正逆解进行分析,运用Adams软件对3-CRS-S并联机构进行角度和角速度分析.结果 得出该机构的位置逆解和正解,以及运动学仿真后的角度、角速度图像,该图像曲线均呈现为有规律、周期性的变化,且曲线没有出现有任何断点和突变点,运动范围相对稳定,说明该机构在运行过程中运行平稳.结论 该机构在运动过程中运行平稳,具有良好的运动学性能,在自动化包装机械领域具有广阔的应用前景.     

新型3T1R并联机器人机构运动学分析与参数优化

目的 针对生产线码垛作业货物搬运需求,设计一种3T1R码垛并联机器人机构.方法 利用方位特征方程分析机器人机构的自由度、耦合度、方位特征集等拓扑结构特性.根据运动副的构型建立运动学逆解模型,考虑到码垛机器人运动范围的精度需求,采用一种新型的数值搜索法实现并联机构工作空间的快速高效搜索,同时,分析结构参数对工作空间体积的影响,选择鲸鱼优化算法对结构参数进行最优化设计.结果 分析得到的机构工作空间较大且连续性较好,新型的数值搜索法可快速有效地搜索,得到准确的工作空间边界.结论 优化后的并联机构具有良好的工作空间和较好的应用前景.     

3-PUPU并联机构的运动学与工作空间分析

目的针对一种六自由度3-PUPU并联机构,对其运动性能和工作空间进行研究。方法利用修正的(G-K)公式对该并联机构动平台的自由度进行计算,并建立机构的逆运动学和正运动学特征方程式,然后利用Matlab/Simulink中的Sim Mechanics功能模块建立3-PUPU并联机构及结构框图,利用杆长的运动范围限制条件编程求得3-PUPU并联机构的工作空间。结果该并联机构的工作空间范围较大,形状规则,结构紧凑,无空洞。结论 3-PUPU机构具有良好的工作空间性能。     

UPS+UPR+S并联机构伴随运动及正逆解分析

目的针对二自由度的UPS+UPR+S并联机构对该并联机构是否具有伴随运动以及对该并联机构的位姿正逆解进行分析。方法通过旋转变化矩阵得到相应向量的表达式,并建立约束方程验证是否具有伴随运动。对该机构进行正逆解分析,通过遗传算法求得机构的部分正解并与逆解相互验证,并通过实例进行验证分析,得到最佳个体、最佳适应度、多样性值和每代个体得分结果。结果该机构不存在伴随运动,正解与逆解所得结果相差较小,数据可以相互吻合。正解实例得到的最佳个体为-0.267和0.31,结果与反解相互验证,最佳适应度逐渐减小,获得了每代得分和每代个体得分情况。结论机构不存在伴随运动,性能较好,由正逆解相互吻合可知正逆解的正确性。     

基于P-Rob六自由度机械臂运动学建模与仿真

目的为实现后续机械臂控制算法研究,检验机械臂运动学模型构建的正确性,基于PersonalRobotics,对六自由度机械臂进行运动学模型构建和轨迹仿真。方法通过标准D-H法建立运动学模型,实现机械臂的正、逆运动学方程求解,根据机械臂的结构特性,对传统逆向运动学求解的解析法进行改进。结果使用仿真软件Matlab验证了运动学模型建立的准确性,改进的逆向运动学求解算法降低了传统求解算法的复杂度。使用仿真软件Matlab验证了运动学模型建立的准确性,并通过Matlab对改进的逆行运动学求解方法进行了验证,结果表明,改进的逆向运动学求解速度是传统逆向运动学求解速度的一半。结论根据六自由度机械臂的运动学研究,对实际机械臂的运动控制具有一定的参考价值。在实际的P-Rob机械臂上进行了仿真数据的测试,再次验证了运动学模型建立的准确性,仿真数据可应用于实际的机械臂控制中。实验现象表明针对此机械结构的机械臂,使用改进解析法求解逆解的方法计算简单、误差小、可行性强。     

空间4R球面机构作为转动副的3RPS并联机构运动学分析

目的设计一种新型3RsPS并联机构,使得机构可以输出3个转动自由度与3个移动自由度耦合的运动。方法根据机构的几何关系,在4R空间机构连杆运动学分析的基础上,建立该机构的运动学方程,使用消元法对其运动学正、逆解进行了求解。使用空间4R机构替换3RPS并联机构的转动副,使得该机构在初始位形下的结构,与3RPS并联机构等效。结果使用Matlab计算得到了运动学方程消元后方程的最高次数,从而得到了运动学正解最多的个数。该机构具有3个自由度,3个移动输出和3个转动输出耦合,机构的运动学正解最多有16个,这与3RPS最多拥有的正解数目一致。结论得到了一种新型的3RsPS机构,该机构的特征为RS副的转动轴线是在空间变化的,该机构的输出为三维移动伴随三维转动,具有此类运动模式的并联机构在不规则形状的产品分拣筛选时,具有一定应用前景。     

七自由度双臂协作机器人操作稳定性分析

为了验证七自由度双臂协作机器人在复杂环境下的操作适应性和稳定性，以及提高机器人工作效率和协调性能，提出一种结合MATLAB和ADAMS的数值分析方法，对七自由度双臂协作机器人的空间运作模式进行分析和计算。首先，在Solidworks中建立七自由度双臂协作机器人的三维模型；然后，运用结合MATLAB和ADAMS的数值分析方法计算七自由度机械臂的运动学逆解；最后，运用基于虚拟动力学模型的控制方法，仿真七自由度双臂协作机器人在复杂环境下的夹取与搬运作业，以验证运动学逆解和分析双臂作业的适应性和稳定性。由仿真结果得到：双臂到达目标位置的X向误差为0.6 mm，Y向误差为0.5 mm，Z向误差为0.9 mm；到达预设位置的平均误差为0.5 mm；双臂协同抓取目标物成功率可达99.1%。由此可见，七自由度机械臂的运动学逆解满足预期要求，七自由度双臂协作机器人在复杂环境下的操作适应性和稳定性有所增强。     

碳纤维束间的摩擦磨损特性

为了对碳纤维束的磨损程度进行定量分析以及探索碳纤维束间摩擦磨损机制,采用自制的摩擦模拟实验装置,研究了摩擦次数、加载力、摩擦角度对碳纤维束摩擦损伤的影响。通过对比摩擦前后碳纤维束的拉伸断裂强力、毛羽量和表面浆膜形态评价了其磨损程度。结果表明:随着摩擦次数、加载力的增大,碳纤维束的磨损程度逐渐加剧;当摩擦角度在90°~30°范围变化时,碳纤维束的拉伸断裂强力随着角度的减小而小幅度下降;而当摩擦角度为0°时,碳纤维束的拉伸断裂强力急剧下降。同时,结合纤维束接触理论和黏性薄膜压痕法揭示了碳纤维束摩擦损伤机制,发现有效接触面积的变化是导致碳纤维束磨损程度改变的主要因素,且纤维束间的有效接触面积随加载力的增大而增大,随摩擦角度的增大而减小。      

Modeling the impact of capillary pressure and air entrapment on fiber tow saturation during resin infusion in LCM

Traditionally, capillary effects have been neglected when modeling the filling stage of Liquid Composite Molding processes. This simplification is justified because the inlet resin pressures are much higher than the capillary pressure. This simplification is also acceptable when impregnating fabrics in which their fiber tows saturate at the same rate as the bulk preform. However, this assumption is questionable for fabrics that exhibit dual scale in which the fiber tows saturate at a much slower rate than the bulk preform. In such cases, the capillary pressure can influence the time to saturate a fiber tow significantly and impact the overall impregnation dynamics. Since the flow front velocity inside the fiber tows is significantly smaller than the flow around them, it is important to include the capillary pressure that may aid the saturation of the tow. In this paper, we modify our existing simulation that can predict the filling of the bulk preform and the saturation of the fiber tows to include the capillary forces at the fiber tow level. Important parameters are identified and grouped in non-dimensional form. A parametric study is conducted to examine the role of these dimensionless parameters on the overall tow saturation levels. The modeling is extended to include the effect of entrapped air inside the tows on the overall saturation of the preform. An experimental technique using the optical properties of vinyl ester and glass fiber was used to qualitatively validate the proposed model.     

纤维铺放轨迹规划的两种方法及其比较研究

为了实现纤维铺放轨迹规划,本文提出了两种方法,即网格化方法和CAD软件的二次开发方法。针对网格化方法,提出了自由曲面的网格化方法和四边形网格铺放轨迹生成算法。针对CAD软件的二次开发方法,基于UG软件,提出了可变计算步长的初始轨迹计算方法、轨迹优化算法和丝束数量计算方法。以某型号的S形飞机进气道为参考模型,利用两种方法分别进行了轨迹规划。最后,对两种开发方法进行了比较研究,发现第二种方法相对于第一种方法具有功能强、开发周期短、与CAD软件的集成度高等优点,得出了其更适合铺放软件开发的结论。     

基于PMAC的激光模切机数控系统设计

开发了由PMAC 运动控制卡和工业PC机组成的开放式多功能激光模切加工数控系统.该系统以通用的Windows 操作系统作为开发平台,同时具有硬件和软件的开放性;可实现数控系统和伺服控制系统间的通讯、加工代码的自动生成、最佳模切顺序和最短空程路径;具有编程专家系统,使用者无需学习G代码和PMAC卡宏指令,即可编程.     

3D-C/SiC复合材料拉伸蠕变损伤和蠕变机理

对3D-C/SiC复合材料进行拉伸蠕变试验,蠕变进行一段时间后,用扫描电子显微镜(SEM)观察试样表面的变化,同时测量试样的共振频率.结果表明,3D-C/SiC除通常CMC所产生的蠕变损伤外,纤维束滑动,纤维束之间的夹角变化,孔隙变形,部分孔隙表面空间位置改变,孔隙表面产生基体微裂纹,损伤在纤维束交叉处更为集中,这些可作为3D-C/SiC蠕变变形的独特机理.电阻和模量的相对变化与蠕变曲线相似,因此电阻和模量都可表征C/SiC材料的蠕变损伤,作为损伤变量.该材料的蠕变属于损伤引起.     

Meso-Scale Progressive Damage Behavior Characterization of Triaxial Braided Composites under Quasi-Static Tensile Load

Based on continuum damage mechanics (CDM), a sophisticated 3D meso-scale finite element (FE) model is proposed to characterize the progressive damage behavior of 2D Triaxial Braided Composites (2DTBC) with 60° braiding angle under quasi-static tensile load. The modified Von Mises strength criterion and 3D Hashin failure criterion are used to predict the damage initiation of the pure matrix and fiber tows. A combining interface damage and friction constitutive model is applied to predict the interface damage behavior. Murakami-Ohno stiffness degradation scheme is employed to predict the damage evolution process of each constituent. Coupling with the ordinary and translational symmetry boundary conditions, the tensile elastic response including tensile strength and failure strain of 2DTBC are in good agreement with the available experiment data. The numerical results show that the main failure modes of the composites under axial tensile load are pure matrix cracking, fiber and matrix tension failure in bias fiber tows, matrix tension failure in axial fiber tows and interface debonding; the main failure modes of the composites subjected to transverse tensile load are free-edge effect, matrix tension failure in bias fiber tows and interface debonding.     

Multi-Scale Progressive Damage Model for Analyzing the Failure Mechanisms of 2D Triaxially Braided Composite under Uniaxial Compression Loads

Based on continuum damage mechanics (CDM), a multi-scale progressive damage model (PDM) is developed to analyze the uniaxial compression failure mechanisms of 2D triaxially braided composite (2DTBC). The multi-scale PDM starts from the micro-scale analysis which obtains the stiffness and strength properties of fiber tows by a representative unit cell (RUC) model. Meso-scale progressive damage analysis is conducted subsequently to predict the compression failure behaviors of the composite using the results of micro-scale analysis as inputs. To research the free-edge effect on the local failure mechanisms, meso-scale models of different widths are also established. The stress-strain curves obtained by numerical analysis are verified with the experimental data. Results show that fiber and matrix compression failure inside the fiber tows are the major failure modes of the composite under axial compression. For transverse compression, the dominated failure modes are recorded for matrix compression failure inside the fiber tows. It is also presented that the free-edge effect plays an important role in the transverse mechanical response of the composite, and the failure behaviors of the internal fiber tows are strongly influenced as well.     

Dry fiber automated placement of carbon fibrous preforms

The superior material properties of carbon fiber-reinforced composites make them especially attractive for applications in aeronautics and aerospace industries. Cost reduction and time saving are continuously driving industry, leading to new industrial challenges which include manufacturing composite structures with optimal mechanical performances using the potential of advanced processes using robotics.To produce complex part shapes, technologies implying fabric draping in a mold imply large waste amount, fabric structure variability and uncertainties concerning local fiber volume fraction amount and thus final mechanical properties. To overcome such issues and comply with cost and time efficiency, automated dry fiber placement for preform manufacturing is proposed. This approach allows to integrate many functions in a complex part thank to the ability of the robot to steer fiber tows at specific locations. The final composite part is obtained by injecting the produced preform with resin using RTM (Resin Transfer Molding) or infusion process.The presented project aims to define the influence of the process driving parameters during fiber placement on the final preform properties range. Preforms were produced using a lab-scale automated placement demonstrator. Three preforms configurations were tested to highlight the influence of the preform structure on permeability and mechanical parameters through characterization of the compression behavior and permeability of the produced preforms. Choice of configuration will affect mechanical properties on the manufactured preforms, whereas creation of open channels to enhance the flow propagation during manufacturing does not necessarily increase the preform permeability.     

Correlation of void distribution to VARTM manufacturing techniques

Vacuum assisted resin transfer molding (VARTM) is a liquid composite molding (LCM) technique used to manufacture large scale composite structures. Fiber preforms are placed on a tool surface and covered by a flow enhancement layer and a plastic bag. A vacuum is drawn on the system to infuse the resin. When the resin does not fully saturate the empty regions in between the fibers, voids are created. The fiber tows in woven and stitched preforms have a much lower permeability as compared to the bulk permeability of the fabric. Hence, fiber tows saturate with resin later than the pores between fiber tows and are more prone to voids.This study explores the impact of extended resin bleeding time and additional flow resistance at the vent on the void content within fiber tows both experimentally and by numerical simulation. Samples were machined from each of the manufactured panels and analyzed using image analysis techniques to obtain a relative void content. The experimental results were compared to results obtained by numerical simulation.The experimental void distribution showed that if resin is not allowed to bleed or if no external resistance is attached at the vent, the void content over the length of the part is not uniform. All void levels reduced when resistance was added or bleeding was allowed. The discrepancy between experimental and numerical results was addressed by including deformable distribution media in numerical model to capture the continuation of resin flow after the injection gate is closed.