Studying effects of screw-fastening process on assembly accuracy

The screw-fastening assembly process is one of the most widely used fastening methods in industrial assembly. However, little research has been conducted in this area in terms of the effect of the screw-fastening process on the assembly accuracy. In this paper, statistical experimental design and data analysis have been performed to study the effect of the screw-fastening process on the assembly accuracy using a multi-dimensional high-resolution optical position monitoring system in a controlled environment. In our study, we observe that an order of magnitude difference (ranging from about 1 μm to over 10 μm) in the assembly accuracy may result using different screw-fastening conditions, and our analysis shows that, number of screws, datum pins, washer and holding force are the important factors affecting assembly accuracy during the screw-fastening process.     

空间太阳电池片封装机器人及温度控制系统设计

提出了一种新的空间太阳电池自动封装系统,能够实现太阳能电池与抗辐射玻璃盖片的自动封装过程,并在封装过程中对胶体的温度进行精确控制以提高封装质量。系统由三自由度直角坐标移动机构、封装机构、电池片和玻璃盖片定位平台以及恒温滴胶器组成。实验验证表明,系统在长时间工作中表现稳定,并由于对温度的控制,有效地延长了封装用盖片胶的使用时间,并降低了封装过程中气泡的产生和边缘错位的发生几率。     

基于多基站IMMKF-DOA辅助车辆协同定位算法研究

针对传统卡尔曼滤波算法在进行车辆实时运动过程中难以精准定位问题,提出一种基于运动状态自适应的交互多模型卡尔曼滤波(Interacting multiple model Kalman filter,IMMKF)与多基站到达方向(Direction-of-arrival,DOA)相融合进行车辆位置实时估计算法。基于无偏估计器对测量噪声协方差进行实时更新并将其嵌入标准卡尔曼滤波算法中实现自适应交互多模型卡尔曼滤波。针对车辆不同运动状态及动态行驶环境对车辆定位估计精度的影响,构建自适应交互多模型卡尔曼滤波器与多基站信息融合算法进行车辆位置实时估计,考虑不同车速与不同基站数等行驶工况下车辆定位精度的变化趋势,实现车辆实时位置的准确估计。利用PreScan-Simulink联合仿真平台进行虚拟仿真验证和实车试验验证。结果表明,基于交互多模型卡尔曼滤波与到达方向角的融合算法相对标准的卡尔曼滤波估计精度高,较好地改善了传统单一模型的卡尔曼滤波算法在进行车辆实时运动状态估计过程中精准定位问题,实车试验验证了提出算法对车辆定位精度较传统卡尔曼滤波算法的精度提高了一个数量级,实现了更精确的车辆位置估计。     

瓦楞纸板涂胶贴面机的结构设计

涂胶贴面机是瓦楞纸板生产线贴面机组中的核心设备,它在展示包装物精美造型的彩色纸盒与纸箱的生产中起着重要的作用,为了保证瓦楞纸板涂胶均匀,粘合强度好,同时又满足该设备的工艺要求,对该设备的结构各项参数加以精心设计和计算,特别是在涂胶辊与定厚辊之间、涂胶辊与加压托辊之间根据不同的性能和要求设计了不同的线速度差以达到擦抹涂胶均匀的作用,得到了良好效果。     

pL级超微量点胶笔的开发及其在封孔中的应用

狭小空间内pL级超微量点胶是胶接技术的难点,针对这个问题,开发了pL级超微量自动点胶笔。基于转印式点胶分液原理,通过移液针穿过装有胶液的玻璃微管,获取胶滴,利用胶滴在点胶面上的转移分离,实现超微量点胶。开发的点胶笔全长仅为65 mm,最小分辨率0.24μm/step,最大行程7 mm,点胶笔通过USB接口连接到上位机上,可以实现对点胶过程的控制。通过大量实验,研究了点胶笔的性能,并将其应用到直径170 mm,长度350 mm小空间密封腔内,直径5~20μm的微孔胶封上。实验结果表明开发的点胶笔,装夹方便,重复精度高,即适用于覆盖式封孔,也适用于插入式封孔。通过调整点胶笔移液针的种类、尺寸、移动速度和封胶方式,可以在密闭小空间内,压力环境变化的工况下,实现微孔的pL级密封,最小封胶量为4.4 pL,满足工程需要,为小空间内的封胶提供了有效技术途径。     

A simple sixth order numerical method for solving the Reynolds equation

A numerical iterative method is given for the solution of the Reynolds equation subject to separable boundary conditions. The iteration error for a given eigenfunction is sixth order in the step size. The method has been tested in the case of the finite exponential bearing pad for which exact analytical solutions are available. The dimensionless load capacity per unit width, W, can be calculated to 0.1% accuracy if ten terms are used in the sum for W. Only the first five terms need be calculated using the iteration, thereafter, analytical approximations given in the article may be used. Not more than twenty steps are needed in any given iteration to obtain the accuracy stated above.Calculations of the dimensionless load capacities of plane bearings show that the method is at least one order of magnitude faster than the method based on a two-dimensional rectangular array of points. The superiority is even more marked when calculations are made for a family of plane bearings having the same inclination but different breadth/length ratios.     

汽车传感器电路板涂胶质量视觉检测系统研究

提出了基于视觉检测技术的车用传感器电路板涂胶质量视觉检测系统,采用多次模板匹配对目标图像进行定位和计算角度,并将图像平移和旋转,从而使零件图像与最初选定的图像位置和角度基本一致。然后,将从最初选定的图像获得的电路板应该有胶和无胶区域坐标应用到零件图像上,截取出相应区域的图像,利用图像分割等算法计算各个区域中涂胶部分的面积占总面积的百分比,与给定的面积百分比限制值进行比较,要求有胶区域的面积百分比大于对应的限制值,无胶区域的面积百分比小于对应的限制值则认为零件涂胶合格。结果表明,系统控制自动定位精度达到像素级,保证了检测精度,解决了目前在现场检测过程中人工操作工作量大、判断不准确以及效率低等问题。     

跨尺度微管微球三维半自动装配点胶系统

设计和搭建了一个3D半自动装配点胶系统,用于完成跨尺度零件微管与微球的三维装配点胶任务。系统主要由体视显微镜、变焦金相显微镜、发光二极管(LED)背光源、pL级点胶机、微操作手和零件夹持器组成。采用显微镜高低倍转换的方式实现了零件跨尺度特征的检测。基于提出的半自动装配点胶策略,并配合人工引导和显微视觉伺服技术,快速完成了跨尺度零件的半自动高精度对准和插入点胶。在搭建完成的系统上开展微管与微球的装配点胶实验,对提出的方法和装配精度进行了实验验证。结果表明,系统的位置对准误差优于1μm,角度对准误差优于0.5°,可以实现末端直径10μm的微管与孔径12μm的微球之间的装配和胶接,基本满足对该组件的装配精度和成功率要求。     

Development of a continuous fabrication system for a metallic sandwich plate with a three-dimensional truss core

In this paper, the concept of the continuous fabrication of a metallic sandwich plate with a three-dimensional truss core is introduced. The method consists of three processes as a fabrication system: metallic mesh manufacture, truss core making, and bonding. A process that fabricates rhombic-shaped metal meshes without material loss is introduced. In order to construct the truss core, a crimping process is employed. Bonding is carried out using multipoint resistance welding with a pair of roll electrodes. To realize the proposed process, a prototype apparatus was assembled. Sandwich plates with a pyramidal truss core are fabricated on an integrated system for continuous fabrication, and various experimental verifications are performed in order to investigate the applicability of the proposed process. As a result, it has been shown that the proposed process is an efficient and practical manufacturing process for continuous fabrication of truss-cored sandwich plates.     

基于偏置正交测量臂逆解算法的构型位置精度预测研究

结构参数误差使得测量臂在不同位置、不同构型下的精度呈现一定的规律。以六关节测量臂为研究对象,采用定积分法分析末端执行器位置精度与结构参数误差之间的关系,构建测量臂位置精度预测模型;并提出一套偏置正交测量臂前四关节的逆解算法,用于确定特定工作点下测量臂各种构型的位置精度分布情况,并给出构型灵活性、构型位置精度权重等评价指标。验证试验包括:比较不同工作点下构型灵活度情况;统计工作点下构型位置精度分布状况;利用其分布特性,对不同工作点下不同构型进行单点测量。实验结果表明:本方法能更直观、全面地描述特定工作点下构型的位置精度分布情况,进而指导实际操作中对测量臂工作点以及测量构型的选择。     

Ultra-flat and ultra-smooth Cu surfaces produced by abrasive-free chemical–mechanical planarization/polishing using vacuum ultraviolet light

The new bonding technologies utilizing intermolecular bonding forces have been developed and attracting attention recently. Cu is known to be a suitable material for the bonding substrate due to its excellent physical properties. And an ultra flatness and an ultra smoothness over a relatively large area are strongly required for the Cu substrate surface.Chemical–mechanical planarization/polishing (CMP) with abrasives is widely adopted for planarizing and smoothing Cu surfaces. But this method has serious problems resulting from abrasives in CMP slurry. Hence, we have developed an abrasive-free polishing (AFP) method that utilizes vacuum ultraviolet (VUV) light in the previous study and an ultra-smooth Cu surface was achieved. However, the problems about a low removal rate and a small finished area remained.To overcome the problem, a new manufacturing process, namely, the process of combining CMP with abrasives and the AFP method was newly developed. First, an ultra-flat surface is achieved using CMP with abrasives. Next, the AFP method is applied for the final polishing step in order to achieve an ultra-smooth surface. As a result, utilizing VUV in situ irradiation and electrolyzed reduced water in the AFP process, the ultra-flat and the ultra-smooth surface produced has a roughness average of <1 nm with a peak value of <10 nm over a relatively large area of 700 μm × 500 μm.     

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.     

螺栓联接件的微动损伤及其涂胶防护试验研究

通过试验分析 ,提出了螺栓联接件的两种不同类型的疲劳破坏形式 ,即孔口应力集中破坏和微动疲劳破坏 ,并研究了不同的螺栓预紧力矩对螺栓联接件微动损伤的影响情况。试验结果表明 ,螺栓预紧力矩大小的改变会引起螺栓联接件不同程度的微动损伤 ,而在联接板面间进行涂胶防护是防止其产生微动损伤的一种较好的方法。最后对涂胶和未涂胶两种螺栓联接件的微动振幅、板面应力、以及由于微动摩擦而产生的板面温升等参数进行了对比测试 ,得出了初步的结论。     

接收机位置误差对GNSS定时的影响分析

不准确的接收机位置信息将会影响用户的定时结果。从理论推导和试验两方面研究了接收机位置误差对定时结果的影响。首先理论上通过对伪距观测方程求一阶微分推导得出定时接收机位置误差对定时的最大影响量;为排除卫星位置误差的影响,利用IGS提供的卫星精确位置,通过引入不同量级的接收机位置误差开展试验,对理论分析结果进行了验证;再通过接收机坐标置偏试验分析不同方向置偏不同量级的位置误差下GPS/GLONASS接收机的观测数据,分析了实际运行环境中的位置误差对接收机定时结果的影响。试验结果表明接收机的纬度、经度分量误差均会对定时结果的准确度和稳定度产生影响,纬度误差每增大1″,对GPS和GLONASS定时准确度的影响分别小于5、15 ns,对稳定度的影响分别小于10和15 ns;经度误差每增大1″,对GPS和GLONASS准确度的影响均小于1 ns,对稳定度的影响均小于10 ns;高程坐标分量误差每增加1 m,会出现约3 ns的定时偏差,对定时稳定度的影响则最大约0.3 ns/m。在实际应用中,用户可参考本文的结论根据所需定时精度的需求,考虑定时接收机输入坐标的精确度。     

An integrated system for setting the optimal parameters in IC chip-package wire bonding processes

The wire bonding process is the key process in an IC chip-package. It is an urgent problem for IC chip-package industry to improve the wire bonding process capability. In this study, an integrated system is proposed to identify and control parameters in the wire bonding process in order to achieve high level performance and quality. First, an experimental design with Taguchi method is applied to identify the critical parameters in the wire bonding process. Then, an ANN is used to establish the nonlinear multivariate relationships between wire boning parameters and responses. Finally, a GA is adopted to find the most desired parameter settings by using the output of ANN as the fitness measure. Another popular method, response surface method, for parameter design problems is conducted for comparison purpose. Results of this comparison demonstrate the effectiveness of the proposed approach.     

A novel curvature circle iterative algorithm for contour error control of multi-axis CNC machine tools

High-precision real-time estimation of contouring errors is a prerequisite for contouring errors control of multi-axis CNC machine tools. This paper focuses on developing a nearest point projection curvature circle iterative (NPP–CCI) algorithm to achieve real-time estimation of multi-axis contouring errors. It is found that the traditional curvature circle iterative (CCI) method has two major shortcomings. The first is that the iterative process may terminate incorrectly at the local contour position, and the other is that the actual tool position and local curvature circle are not necessarily coplanar in three-dimensional space, which would lead to inaccurate calculation of the delay time parameter and eventually affect the estimation accuracy. In order to address the problem of false termination, an index method is used to find the closest reference position with respect to the actual position. At the same time, the projection technology is proposed to overcome the problem met in extending the planar curvature circle iterative method to the spatial applications. The proposed NPP-CCI algorithm is more suitable for spatial contouring errors estimation in tracking complex trajectories and has higher estimation accuracy than the traditional CCI algorithm. Various experiments with different tool paths are conducted on an in-house developed multi-axis experimental platform to verify the effectiveness of the proposed algorithm. The experimental results show that the NPP-CCI algorithm can estimate the contouring errors with higher accuracy than the traditional CCI algorithm, and with the help of real-time computation and compensation, the contouring errors are reduced by more than 44% in terms of the MAX and RMS values.     

Accuracy improvement in nanographite powder-suspended dielectric fluid for micro-electrical discharge machining processes

Micro-electric discharge machining (??-EDM) is an important manufacturing process that is able to produce components and tools with micro-features. Improvement to this process has resulted in the use of powder mixed dielectric (PMD), which results in better surface quality and faster machining time. However, the presence of conductive powder in the dielectric fluid negatively affects the accuracy of the machining depth. This paper presents a novel method of suspending nanographite powder in dielectric fluid, using ultrasonic vibration of dielectric fluid, and using the number of discharge pulses in order to improve the accuracy of the PMD-??-EDM process. As a result, machining time has been significantly reduced up to 35%, accuracy increased, and the appearance of micro-cracks on the workpiece surface has been reduced.     

磨料有序排布电镀砂轮的制备及其把持力研究

为解决电镀砂轮磨削加工中容屑空间不足的问题，采用点胶微粘接的方法制备了磨料有序排布的电镀砂轮，分析了磨料粘接效果和镀层力学性能。通过SEM分析了磨料/镀层/导电胶的结合界面，并进行了干磨削试验。研究结果表明，直径约为磨料粒径40%的胶点可粘接住磨料，单个胶点上粘接多颗磨料的占比小于6%；双脉冲电镀工艺制备的镀层显微硬度大于500HV，表层残余应力小于100MPa，磨料/镀层/导电胶之间的界面贴合紧密，无明显缺陷；砂轮在磨削时没有出现磨料脱落现象。