CN105643399A - Automatic lapping and polishing system for complex surface of compliant control-based robot and machining method - Google Patents
Automatic lapping and polishing system for complex surface of compliant control-based robot and machining method Download PDFInfo
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B24—GRINDING; POLISHING
- B24B—MACHINES, DEVICES, OR PROCESSES FOR GRINDING OR POLISHING; DRESSING OR CONDITIONING OF ABRADING SURFACES; FEEDING OF GRINDING, POLISHING, OR LAPPING AGENTS
- B24B19/00—Single-purpose machines or devices for particular grinding operations not covered by any other main group
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B24—GRINDING; POLISHING
- B24B—MACHINES, DEVICES, OR PROCESSES FOR GRINDING OR POLISHING; DRESSING OR CONDITIONING OF ABRADING SURFACES; FEEDING OF GRINDING, POLISHING, OR LAPPING AGENTS
- B24B45/00—Means for securing grinding wheels on rotary arbors
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B24—GRINDING; POLISHING
- B24B—MACHINES, DEVICES, OR PROCESSES FOR GRINDING OR POLISHING; DRESSING OR CONDITIONING OF ABRADING SURFACES; FEEDING OF GRINDING, POLISHING, OR LAPPING AGENTS
- B24B47/00—Drives or gearings; Equipment therefor
- B24B47/20—Drives or gearings; Equipment therefor relating to feed movement
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B24—GRINDING; POLISHING
- B24B—MACHINES, DEVICES, OR PROCESSES FOR GRINDING OR POLISHING; DRESSING OR CONDITIONING OF ABRADING SURFACES; FEEDING OF GRINDING, POLISHING, OR LAPPING AGENTS
- B24B49/00—Measuring or gauging equipment for controlling the feed movement of the grinding tool or work; Arrangements of indicating or measuring equipment, e.g. for indicating the start of the grinding operation
- B24B49/16—Measuring or gauging equipment for controlling the feed movement of the grinding tool or work; Arrangements of indicating or measuring equipment, e.g. for indicating the start of the grinding operation taking regard of the load
- B24B49/165—Measuring or gauging equipment for controlling the feed movement of the grinding tool or work; Arrangements of indicating or measuring equipment, e.g. for indicating the start of the grinding operation taking regard of the load for grinding tyres
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B19/00—Programme-control systems
- G05B19/02—Programme-control systems electric
- G05B19/18—Numerical control [NC], i.e. automatically operating machines, in particular machine tools, e.g. in a manufacturing environment, so as to execute positioning, movement or co-ordinated operations by means of programme data in numerical form
- G05B19/19—Numerical control [NC], i.e. automatically operating machines, in particular machine tools, e.g. in a manufacturing environment, so as to execute positioning, movement or co-ordinated operations by means of programme data in numerical form characterised by positioning or contouring control systems, e.g. to control position from one programmed point to another or to control movement along a programmed continuous path
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- Manufacturing & Machinery (AREA)
- Physics & Mathematics (AREA)
- General Physics & Mathematics (AREA)
- Automation & Control Theory (AREA)
- Manipulator (AREA)
- Finish Polishing, Edge Sharpening, And Grinding By Specific Grinding Devices (AREA)
Abstract
The invention relates to an automatic lapping and polishing system for a complex surface of a compliant control-based robot and a machining method. The automatic lapping and polishing system comprises an industrial robot, a worktable, a force sensor, a flexible lapping and polishing cutter, a signal conversion amplifier, a computer and a robot controller; the method comprises the following steps: performing machining trace planning before lapping and polishing a complex surface workpiece to obtain cutter contact point trace of the lapping and polishing cutter to obtain a surface machining cutter location point trace; converting the surface machining cutter location point trace into a code format program file which can be identified by the robot controller, and inputting the code format program file into the robot controller; positioning and clamping the workpiece to complete coordinate labeling and unification of a process system; and driving the robot to move according to a machining trace planning program file to drive the lapping and polishing cutter arranged on an end executor of the robot to perform contact machining on a machined surface. According to the automatic lapping and polishing system and the machining method disclosed by the invention, manual operation at a finish machining stage of the complex surface workpiece, especially a large-sized complex surface workpiece, can be replaced; labor strength and machining cost are reduced; and quality stability and quality consistency of a machined molded surface are increased.
Description
Technical Field
The invention relates to the technical field of industrial robot machining application, in particular to a robot complex curved surface automatic grinding and polishing system based on compliance control and a machining method.
Background
In the process of machining a complex curved surface, the surface of a workpiece meeting the requirements can be obtained by rough machining, semi-finish machining and then grinding, polishing and high-precision (finishing) machining. In the future, with the rapid development of high-end intelligent automatic control technology, the flexible processing using a numerical control machine as a platform has basically realized the automatic processing of complex curved surface workpieces, but the polishing processing mainly depends on manual operation of workers. The manual polishing and burnishing time of the complex curved surface accounts for about 1/3% of the total time in developed industrial countries such as the United states, and reaches more than 80% in China. The intelligent and automatic finishing processing of complex curved surfaces is taken as an important link for realizing high-quality, high-efficiency and low-cost manufacturing, and increasingly receives attention from the industry and academia. The flexible characteristic of the industrial robot makes it very suitable for the automatic grinding and polishing processing of complex curved surfaces.
In the polishing process, the polishing pressure between the polishing tool and the workpiece surface is a main factor influencing the processing quality, not the polishing force. The polishing pressure can change in real time along with the curvature radius of the complex curved surface, the polishing force applied to the surface of the curved surface and the pose (pose and posture) of a polishing cutter. In order to obtain high curved surface processing quality, the polishing tool in the automatic polishing system platform is required to have certain flexibility in addition to good cutting ability. Compliance is generally classified into active compliance and passive compliance. The active compliance control is force control, the posture and the position of a grinding and polishing cutter are automatically adjusted by adopting a certain control strategy according to feedback information of a force sensor, the polishing pressure is actively controlled, so that the robot can generate real-time feedback on the grinding and polishing pressure and adjust the generated pressure, the mixed control of the position, the posture and the force is realized, the reasonable and stable contact force can be ensured, and the robot can actively conform to the change of the external environment to meet the requirement of a processing task. The passive compliance control is that the grinding tool can naturally conform to external acting force when contacting with the environment by means of auxiliary compliance mechanisms (mainly comprising mechanical devices capable of absorbing or storing energy such as springs, dampers and the like), and the grinding tool forms passive compliance through elastic changes of different positions of the grinding tool according to changes of curvature of a curved surface in the machining process.
Based on the previous theoretical analysis, the industrial robot is very suitable for the automatic grinding and polishing processing of complex curved surfaces due to the specific flexible characteristic of the industrial robot. However, an automatic polishing system and a processing method for realizing the complex curved surface of the robot based on the compliance control are not reported yet.
Disclosure of Invention
Aiming at the defects that the grinding and polishing processing depends on manual operation of workers, the production efficiency is low, the processing quality is unstable, the modern processing and manufacturing requirements of low cost, short period and high quality are difficult to meet and the like in the prior art, the invention aims to solve the technical problem of providing the automatic grinding and polishing system and the processing method for the complex curved surface of the robot based on the flexible control, which can ensure the uniformity and consistency of the processing and removing amount, improve the processing efficiency and the processing quality and effectively reduce the labor intensity of the processing workers and the production cost.
In order to solve the technical problems, the invention adopts the technical scheme that:
the invention relates to a robot complex curved surface automatic polishing system based on compliance control, which comprises: the device comprises an industrial robot, a workbench, a force sensor, a flexible polishing cutter, a signal conversion amplifier, a computer and a robot controller, wherein the flexible polishing cutter is mounted on the industrial robot, the computer is in bidirectional communication connection with the robot controller through a robot communication interface, the robot controller controls the industrial robot to act, and the flexible polishing cutter is used for polishing a workpiece fixed on the workbench; the force sensor sends the acquired polishing force data as a closed loop feedback signal to a computer for processing.
The flexible grinding and polishing tool comprises an L-shaped support, a grinding and polishing head, an elastic taper chuck and a motor, wherein the grinding and polishing head is arranged on the elastic taper chuck through a clamping elastic rubber disc, the elastic taper chuck is connected with a main shaft of the motor, the motor is fixedly arranged on the L-shaped support, and the L-shaped support is connected with an end effector of an operating arm of the industrial robot through a connecting flange.
The flexible grinding and polishing tool is further provided with a right-angle trapezoidal support, the motor is supported on the upper bottom surface of the right-angle trapezoidal support, the lower bottom surface of the right-angle trapezoidal support is abutted to the stress surface of the force sensor, and the bottom of the force sensor is fixedly arranged on the L-shaped support.
The bottom surface of the clamping elastic rubber disc is bonded with back fluff emery cloth or sand paper.
The invention relates to a processing method of a robot complex curved surface automatic polishing system based on compliance control, which comprises the following steps:
planning a machining track before grinding and polishing a complex curved surface workpiece to determine a tool machining track and pose parameters, acquiring a tool contact track of a grinding and polishing tool, and further acquiring a tool locus track of a machined curved surface;
converting the locus of the tool position of the machined curved surface into a code format program file which can be recognized by a robot controller and inputting the code format program file into the robot controller;
mounting the workpiece on a workbench, positioning and clamping the workpiece, and completing coordinate calibration unification of a process system;
the robot plans the program file according to the processing track input by the controller, drives the robot to move according to the program file formed by the track planning, and drives a grinding and polishing cutter arranged on an end effector of the robot to contact with the processing surface for processing.
Planning a machining track before grinding and polishing a complex curved surface workpiece to determine a tool machining track and pose parameters, acquiring a grinding and polishing tool bit point track, and further acquiring the machining curved surface tool bit point track, wherein the method comprises the following steps:
the robot and the workbench positioning block are used for tool setting and positioning, so that the calibration of the base coordinate of the robot and the coordinate of the workbench is completed, and the unification of the calibration of the coordinates is realized;
importing a three-dimensional model of a complex curved surface workpiece into path generation software of the system, and setting a concave surface feed mode or a convex surface feed mode; under a workpiece coordinate system, automatically calculating the center line of the workpiece by software according to the three-dimensional model and calibrating; then, a symmetrical row cutting processing feed path generation method is applied to obtain a processing cutter row cutting path;
discretizing the three-dimensional model of the line cutting path of the obtained machining tool according to the rules of a Hilbert curve, discretizing a curved surface into a series of control point sets, point-dividing the discrete control points into a series of point sets, rearranging the point sets through recombination and deletion operations, and obtaining a tool contact path point set in a real number domain through parameter mapping;
and obtaining the tool location point track of the processing curved surface according to the tool location point track obtaining method of the grinding and polishing tool.
The method for generating the feed path for the symmetrical row cutting processing comprises the following steps: and selecting a central line of the complex curved surface three-dimensional model by adopting a line cutting feed mode under a workpiece coordinate system, and symmetrically extending on two sides according to the set line cutting feed distance and the workpiece central line as a symmetry axis and the set feed distance until all the curved surfaces finish the generation of the line cutting path of the machining tool.
The method for obtaining the tool location point track of the grinding and polishing tool comprises the following steps:
mining deviceThe vector A and the vector O represent position vectors of a contact point and a tool position point, respectively, and the arbor vector can be expressed asThe distance from the tool contact point to the tool location point is R-W, the direction from the point A to the point O is expressed by a unit vector v, and then v is expressed asThen the position vector O of the tool location point is expressed as O ═ a + (R-W) v and the tool location trajectory vector is generated to include the tool
Position vector O and arbor vector a, expressed as CO＝(Oa)；
Wherein a is the cutter shaft vector direction of the grinding and polishing cutter, n is the curved surface normal vector direction, u is the cutter feeding direction, theta is the reverse direction deflection angle value of the cutter shaft vector direction a of the grinding and polishing cutter relative to the curved surface normal vector direction n in the feeding direction u, and a, n and u are unit vectors.
The robot plans the program file according to the processing orbit that the controller was input, and the program file motion that the drive robot formed according to the orbit planning drives the polishing cutter of installing at end effector and processing surface contact processing includes:
when the grinding and polishing tool and the processed curved surface are in mutual contact processing, strain signals are acquired and measured through a force/torque sensor, and digital signals which can be identified are output and transmitted to a computer after signal conversion, amplification and filtering processing;
the computer processes the collected digital signals, performs weight compensation calculation according to a weight compensation algorithm, and converts the measurement result into actual polishing force Fc；
The computer will measure the actual polishing force FcAnd a set polishing force FdPerforming comparative calculation to obtain a force compensation value delta F; converting the force compensation value delta F into a position compensation value delta X, and adjusting the compensation value delta X and the polishing track planning value XpMake compensation changeCalculating to obtain the actual polishing position XdThe same process gives Yd、ZdValue of (A), Xd、Yd、ZdAre each in the base coordinate system OBPosition values of the lower X, Y, Z three coordinate directions.
The computer feeds back the adjusted Xd，Yd、ZdAnd transmitting the attitude angle data of the three grinding and polishing workpieces to a robot controller, controlling the robot to perform feedback adjustment by the robot controller, and performing corresponding position and attitude adjustment on the grinding and polishing workpieces in a robot motion belt to realize constant and controllable grinding and polishing force in the machining process.
Performing weight compensation calculation according to a weight compensation algorithm comprises:
in-system robot base coordinate system OBIn the following, the polishing tool gravity is expressed as:BFg＝[00-G]the expression of the gravity of the grinding and polishing tool measured by the force/moment sensor isSFg＝[FgXFgYFgZ]The conversion relationship between the two isIn the formula,for end effector coordinate system OETo base coordinate system OBThe transformation matrix of (a), determined by the robot body;as sensor coordinate system OSTo end effector coordinate system OEThe transformation matrix of (2) is determined by the installation mode of the sensor and the end effector of the robot,as sensor coordinate system OSTo base coordinate system OBTransformation moment of (F)gXIs the gravity magnitude of the tool in the X direction under the sensor coordinate system, FgYIs the gravity magnitude of the tool in the Y direction under the sensor coordinate system, FgZThe gravity value of the tool in the Z direction under the sensor coordinate system is obtained.
Obtaining a system robot base coordinate system O through coordinate matrix transformationBDownward grinding and polishing force
Converting the measured value in the force sensor coordinate system to the base coordinate system to eliminate the interference of gravity on the grinding and polishing force and obtain the base coordinate OBActual polishing forceBFc＝BFm-BFg；
Wherein,BFmin order to provide a system robot with a base coordinate system for lower polishing force,sFmis the polishing force under the sensor coordinate system,BFgthe base coordinate is the gravity of the lower polishing tool itself,BFithe inertial force generated for the feed movement.
The invention has the following beneficial effects and advantages:
1. the invention can replace manual operation in the finishing processing stage of complex curved surface parts, particularly large complex curved surface workpieces, and can reduce the manual strength, reduce the processing cost and improve the stability and consistency of the quality of the processed molded surface.
2. The robot automatic grinding and polishing processing system based on the compliance control can control the grinding and polishing force of the grinding and polishing cutter and the surface contact area of the processed workpiece, effectively compensate and adjust the position and the attitude precision of the grinding and polishing cutter, apply corresponding control to the grinding and polishing pressure according to the change of the curvature of the complex curved surface, ensure reasonable grinding and polishing pressure and constant force processing, realize the uniformity and consistency of the removal amount of the workpiece and improve the processing quality of the workpiece.
3. The grinding and polishing tool in the system has an inclination angle of contact with the curved surface of the workpiece, so that high processing efficiency can be obtained, zero-rotation-speed grinding and polishing processing is avoided, and heat dissipation and chip removal of a processed area are facilitated.
4. The system of the invention designs the selected flexible grinding and polishing cutter, realizes passive compliance with the processing curved surface, ensures the consistency of grinding and polishing pressure intensity of a contact processing area, and realizes the controllability and continuity of removal amount; the robot can simulate manual operation, and overcomes the contradiction between the rigidity and the flexibility of the robot.
5. The method for generating the symmetrical cutting processing feed path and processing the one-side feed sequence in the method can reduce idle travel of the processing path and improve processing efficiency.
Drawings
FIG. 1 is a schematic diagram of the overall structure of the system apparatus of the present invention;
FIG. 2 is a block diagram of a flexible polishing tool in the system of the present invention;
FIG. 3 is a diagram of a communication scheme in the system of the present invention;
FIG. 4 is a schematic view of the contact angle between the polishing tool and the curved surface to be machined in the system of the present invention;
FIG. 5 is a schematic diagram of a force measurement analysis of a sensor in the system of the present invention;
FIG. 6 is a schematic diagram of a cutting path in the system of the present invention;
FIG. 7 is a diagram of the position relationship between the knife contacts and the knife locations in the system of the present invention;
FIG. 8 is a diagram of a position based force outer loop control methodology in accordance with the present invention;
FIG. 9 is a schematic view of an automatic polishing process in the method of the present invention.
The device comprises an industrial robot 1, a positioning block 2, a six-dimensional force/moment six-dimensional sensor 3, a flexible polishing tool 4, a connecting flange 41, an L-shaped support 42, a motor 43, an elastic taper chuck 44, an elastic rubber clamping disc 45, abrasive cloth 46, a right-angle support 47, a workbench 5, a signal conversion amplifier 6, a computer 7, a robot controller 8 and a workpiece machining curved surface 9.
Detailed Description
The invention is further elucidated with reference to the accompanying drawings.
The invention relates to a compliance control-based automatic grinding and polishing system device and a processing method for a complex curved surface of a robot, which are used for realizing constant grinding and polishing force processing in the automatic grinding and polishing processing process of the complex curved surface and ensuring the uniformity and stability of processing and removing. The invention mainly comprises the components of a complete system device and an active and passive control mode based on compliant machining. Compensation calculation of the gravity of the grinding and polishing cutter is carried out, and the interference of the gravity of the grinding and polishing cutter on the grinding and polishing force is eliminated; the description of the contact form and state of the grinding and polishing tool and the workpiece during machining is carried out, and the full contact and chip removal and heat dissipation of a machining contact area are ensured; the process and the content of tool path planning are described, and the workpiece three-dimensional model is automatically converted into a machining program file which can be identified by a robot; a force control closed-loop control mode based on position control is explained, position-attitude-force decoupling control in the machining process is realized, a communication mode and a format among components are explained, and control and feedback closed-loop control of a system device are realized.
As shown in fig. 1, the present invention provides a robot complex curved surface automatic polishing system based on compliance control, which includes: the device comprises an industrial robot 1, a workbench 5, a force sensor 3, a flexible polishing cutter 4, a signal conversion amplifier 6, a computer 7 and a robot controller 8, wherein the flexible polishing cutter 4 is installed on the industrial robot 1, the computer 7 is in bidirectional communication connection with the robot controller 8 through a robot communication interface, the robot controller 8 controls the industrial robot 1 to act, and the flexible polishing cutter 4 is used for polishing a workpiece fixed on the workbench 5; the force sensor 3 sends the acquired polishing contact force data as a closed loop feedback signal to the calculation 7. In this embodiment, the industrial robot 1 is a six-axis, and the force sensor 3 is a six-dimensional force/moment sensor.
As shown in fig. 2, the flexible polishing tool 4 includes an L-shaped bracket 42, a polishing head 46, an elastic taper chuck 44 and a motor 43, wherein the polishing head 46 is mounted on the elastic taper chuck 44 by clamping an elastic rubber disc 45, the elastic taper chuck 44 is connected with a main shaft of the motor 43, the motor 43 is fixedly mounted on the L-shaped bracket 42, and the L-shaped bracket 42 is connected with an end effector of an operation arm of the industrial robot 1 by a connecting flange 41; the flexible grinding and polishing tool 4 is also provided with a right-angle ladder-shaped support 47, the motor 43 is supported on the upper bottom surface of the right-angle ladder-shaped support 47, the lower bottom surface of the right-angle ladder-shaped support is abutted against the stress surface of the force sensor 3, and the bottom of the force sensor 3 is fixedly arranged on the L-shaped support 42.
In this embodiment, the flexible polishing tool mainly includes 7 parts, wherein the connecting flange 41 is used for connecting the L-shaped bracket and the end shaft of the 42 robot, the L-shaped adapter bracket 42 is used for connecting the connecting flange 41 and the sensor 3, the right-angle bracket 47 is used for connecting the sensor 3 and the pneumatic motor 43, the pneumatic motor 43 is fixedly connected to the right-angle bracket 47 (the mounting hole for mounting the pneumatic motor 43 on the right-angle bracket 47 is a cross long hole, the center line of the pneumatic motor is coincident with the center line of the sixth axis of the robot during mounting and adjusting), the pneumatic motor main shaft is connected to the elastic taper chuck 44, the chuck is connected to and clamps the elastic rubber disk 45, and the bottom surface of the rubber disk can be bonded with a piece of sandpaper (or. This embodiment employs a six-axis industrial robot.
As shown in fig. 3, the communication scheme adopted by the present invention includes two working threads: the control computer-robot motion controller working thread and the control computer-sensor working thread are used for realizing real-time communication connection among the control computer-robot motion controller working thread and the control computer-sensor working thread, and simultaneously, the throwing power is controlled on line and the off-line path planning of the robot is realized. The robot controller and the computer communicate in an Ethernet mode, a high-reliability TCP/IP (Transmission control protocol/Internet protocol) communication protocol is adopted, the real-time performance of communication between the two protocols is high, communication is carried out in a data stream mode, communication is carried out by an xml file, a track control command of the surface of a polishing workpiece is output and transmitted to the robot controller every 12ms, and the robot executes corresponding polishing processing according to a track command planned by an upper computer CAD/CAM system. The communication mode between the force sensor and the computer uses Ethernet communication, and adopts UDP (user Datagram protocol) protocol of high-speed transmission to carry out communication, and can provide transmission frequency as high as 7000 Hz.
The invention relates to a processing method of a robot complex curved surface automatic polishing system based on compliance control, which comprises the following steps:
planning a machining track before grinding and polishing a complex curved surface workpiece to determine a tool machining track and pose parameters, acquiring a tool contact track of a grinding and polishing tool, and further acquiring a tool locus track of a machined curved surface;
converting the locus of the tool position of the machined curved surface into a code format program file which can be recognized by a robot controller and inputting the code format program file into the robot controller 8;
mounting the workpiece on a workbench 5, positioning and clamping the workpiece, and completing coordinate calibration unification of the process system;
the robot plans the program file according to the processing track input by the controller, drives the robot to move according to the program file formed by the track planning, and drives a grinding and polishing tool 4 arranged on an end effector of the robot to contact with the processing surface for processing.
Planning a machining track before grinding and polishing a complex curved surface workpiece to determine a tool machining track and pose parameters, acquiring a grinding and polishing tool bit point track, and further acquiring the machining curved surface tool bit point track, wherein the method comprises the following steps:
A1. the center hole at the tail end of the sixth shaft of the robot and the workbench positioning block 2 are used for tool setting and positioning, so that the base coordinate of the robot 1 and the coordinate of the workbench 5 are calibrated, and the coordinate calibration is unified;
A2. importing a three-dimensional model of a complex curved surface workpiece into path generation software of the system, and setting a concave surface feed mode or a convex surface feed mode; under a workpiece coordinate system, automatically calculating the center line of the workpiece by software according to the three-dimensional model and calibrating; then, a symmetrical row cutting processing feed path generation method is applied to obtain a processing cutter row cutting path;
A3. discretizing the three-dimensional model of the line cutting path of the obtained machining tool according to the rules of a Hilbert curve, discretizing a curved surface into a series of control point sets, point-dividing the discrete control points into a series of point sets, rearranging the point sets through recombination and deletion operations, and obtaining a tool contact path point set in a real number domain through parameter mapping;
in step a2, the method for generating the symmetrical row-cutting processing feed path includes: and selecting a central line of the complex curved surface three-dimensional model by adopting a line cutting feed mode under a workpiece coordinate system, and symmetrically extending on two sides according to the set line cutting feed distance and the workpiece central line as a symmetry axis and the set feed distance until all the curved surfaces finish the generation of the line cutting path of the machining tool.
As shown in fig. 6. In actual machining, the workpiece is fed from the one-side (set) production path, and machining is performed in accordance with the formed feed path.
The invention relates to a method for grinding and polishing a curved surface contact angle between a tool and a workpiece. During grinding and polishing, the cutter shaft vector direction a of the grinding and polishing cutter deflects for an angle relative to the normal vector direction n of the curved surface in the reverse direction of the feeding direction u, and a, n and u are unit vectors. As shown in fig. 4, 9 is a workpiece machining curved surface.
The tool location point trajectory of the machining curved surface obtained according to the tool location point trajectory acquisition method of the grinding and polishing tool is shown in fig. 7, point a represents the contact point position (tool contact point) where the cutter head of the tool starts to contact with the machining surface, point O represents the tool location point position of the tool, point B represents the outermost side point of the cutter head,r is the radius of the cutter head, and W is the passive flexible deformation length. For convenience of description, the position vectors of the contact point and the knife position point are respectively represented by a vector A and a vector O. The arbor vector can be expressed asThe distance between a tool contact point and a tool position point is R-W, the direction from the point A to the point O is expressed by a unit vector v, a is the cutter shaft vector direction of the grinding and polishing tool, n is the normal vector direction of a curved surface, u is the feeding direction of the tool, theta is the reverse direction deflection angle of the cutter shaft vector direction a of the grinding and polishing tool relative to the normal vector direction n of the curved surface in the feeding direction u, and a, n and u are unit vectors;
v can be expressed asThe position vector O of the tool location point can be expressed as O ═ a + (R-W) v, and the resulting tool location trajectory vector includes the tool position vector O and the arbor vector a, which is expressed as CO＝(Oa)。
According to the set requirement, the tool path vector is converted into a program file of a numerical value code (three displacement and three angles) of a point set which can be identified by a robot controller, so that all tool contacts on the three-dimensional model processing path of the processed workpiece are converted into a vector point set of the automatic grinding and polishing processing path of the robot to form a processing program file, the processing program file is transmitted to the robot controller, the robot is controlled to move, and the tail end tool and the workpiece are driven to grind and polish.
The robot plans the program file according to the processing orbit that the controller was input, and the program file motion that the drive robot formed according to the orbit planning drives the polishing cutter of installing at end effector and processing surface contact processing includes:
A7. when the grinding and polishing tool and the processed curved surface are in mutual contact processing, a six-dimensional force/torque sensor is used for collecting and measuring strain signals, the signals are in a sensor coordinate system, signal conversion, amplification and filtering processing are carried out through a signal conversion amplifier (NetF/T)6, identifiable digital signals are output, and information is transmitted to a computer through an Ethernet;
A8. the computer processes the collected digital signals, performs weight compensation calculation according to a weight compensation algorithm, and converts the measurement result into actual polishing force Fc；
A9. The computer measures the polishing force F through the force controller modulecAnd a set polishing force FdCarrying out comparison calculation to obtain a compensation value delta F; converting the force compensation value delta F into a position compensation value delta X through a position controller module algorithm, and performing compensation conversion on the adjustment compensation value delta X and the polishing track planning value Xp to obtain an actual polishing processing position XdA value of (d); (the feedback adjustment method in the X-axis direction is described here, and the Y-axis direction and the Z-axis direction are the same).
A10. The computer feeds back the adjusted Xd，Yd、ZdAnd the attitude angle data of the three grinding and polishing workpieces are transmitted to the robot controller 8, the robot controller 8 controls the robot 1 to perform feedback adjustment, and the grinding and polishing workpieces 4 in the motion belt of the robot 1 perform corresponding position and attitude adjustment, so that the grinding and polishing force in the machining process is constant and controllable.
Performing weight compensation calculation according to a weight compensation algorithm comprises:
in the system device base coordinate system OB(XB，YB，ZB)(XB、YB、ZBAre each a base coordinate system OBThree coordinate axes of) the polishing force vectorBFmThe device consists of three parts: polishing force of polishing tool and workpieceBFcGravity of the polishing tool itselfBFgAnd the inertia force generated by the feed movementBFi，BFm＝BFc+BFg+BFiAs shown in fig. 5. Because the robot moves according to the planned continuous path, the feed speed of the grinding and polishing cutter changes little, the weight of the cutter is light, the inertia force caused by the movement can be ignored, and the grinding and polishing cutter can grindVector of throwing powerBFmExpressed as:BFm＝BFc+BFg. The output value of the six-dimensional force/torque sensor is in a sensor coordinate system OS(XS，YS，ZS)(XS，YS，ZSRespectively sensor coordinate system OSThree coordinate axes) of the measurement. The attitude of the grinding and polishing tool at the tail end of the robot changes along with the surface shape of the workpiece, and a sensor coordinate system OS(XS，YS，ZS) The attitude of the grinding and polishing tool changes, so that the gravity Fg of the grinding and polishing tool is in a sensor coordinate system OSThe component of the gravity compensation device changes, and the gravity of the grinding and polishing tool is compensated. In the base coordinate system OBThe lower polishing tool gravity is expressed as:BFg＝[00-G]the expression of the gravity force of the load of the grinding and polishing tool measured by the force sensor isSFg＝[FgXFgYFgZ]The conversion relationship between them isIn the formula,for end-sensor coordinate system OETo base coordinate system OBThe transformation matrix of (a), determined by the robot body;as sensor coordinate system OSTo end sensor coordinate system OEThe transformation matrix of (2) is determined by the mounting manner of the sensor and the tail end of the robot. Through coordinate matrix transformation, a base coordinate system O can be obtainedBNumerical values of As sensor coordinate system OSTo base coordinate system OBThe transformation matrix of (2). Values to be measured by the force sensorConverting the reference coordinate system to a basic coordinate system, eliminating the interference of gravity on the grinding and polishing force, and obtaining the actual grinding and polishing force vector under the basic coordinate systemBFc＝BFm-BFgWhereinBFmthe vector of the polishing force is the vector of the polishing force,sFmis the polishing force measured value under the sensor coordinate system,BFgin order to grind and polish the gravity of the cutter,BFithe inertial force generated for the feed movement.
The invention relates to a force outer ring active compliance control method based on positions. As shown in FIG. 8, the polishing force F is given according to the process requirements according to the curved surface material characteristics of the workpiecedMeasurement by force sensors in active compliance control systemsSFcCompensating the gravity interference caused by the grinding and polishing tool to obtain the current grinding and polishing force FcWith a given force FdComparing, obtaining position correction quantity delta X by force controller, the position controller executing corrected position command XdAnd the control of the polishing force of the outer ring of the inner ring force of the position based on the active compliant structure is realized.
The whole polishing process involved in the method of the present invention is shown in fig. 9.
The robot based on the flexible control can simulate manual operation, when a grinding and polishing cutter is in contact with the surface of a workpiece, the cutter always keeps stable grinding and polishing pressure in a contact area with the surface of the workpiece, pressure fluctuation between the grinding and polishing cutter and the workpiece can be measured and displayed in real time, effective position and attitude precision can be improved, corresponding control can be applied to the grinding and polishing pressure according to changes of curvature of a complex curved surface, reasonable grinding and polishing pressure is guaranteed, constant-force processing is achieved by controlling the grinding and polishing pressure, uniformity and consistency of workpiece removal amount are achieved, and workpiece processing quality is improved.
Claims (10)
1. The utility model provides an automatic system of polishing of complicated curved surface of robot based on gentle and agreeable control which characterized in that includes: the device comprises an industrial robot, a workbench, a force sensor, a flexible polishing cutter, a signal conversion amplifier, a computer and a robot controller, wherein the flexible polishing cutter is mounted on the industrial robot, the computer is in bidirectional communication connection with the robot controller through a robot communication interface, the robot controller controls the industrial robot to act, and the flexible polishing cutter is used for polishing a workpiece fixed on the workbench; the force sensor sends the acquired polishing force data as a closed loop feedback signal to a computer for processing.
2. The automatic lapping and polishing system for complex curved surfaces of a robot based on compliance control as claimed in claim 1, wherein: the flexible grinding and polishing tool comprises an L-shaped support, a grinding and polishing head, an elastic taper chuck and a motor, wherein the grinding and polishing head is arranged on the elastic taper chuck through a clamping elastic rubber disc, the elastic taper chuck is connected with a main shaft of the motor, the motor is fixedly arranged on the L-shaped support, and the L-shaped support is connected with an end effector of an operating arm of the industrial robot through a connecting flange.
3. The automatic lapping and polishing system for complex curved surfaces of a robot based on compliance control as claimed in claim 2, wherein: the flexible grinding and polishing tool is further provided with a right-angle trapezoidal support, the motor is supported on the upper bottom surface of the right-angle trapezoidal support, the lower bottom surface of the right-angle trapezoidal support is abutted to the stress surface of the force sensor, and the bottom of the force sensor is fixedly arranged on the L-shaped support.
4. The automatic lapping and polishing system for complex curved surfaces of a robot based on compliance control as claimed in claim 2, wherein: the bottom surface of the clamping elastic rubber disc is bonded with back fluff emery cloth or sand paper.
5. The method for processing the complicatedly-controlled robot complex curved surface automatic polishing system according to claim 1, which comprises the following steps:
planning a machining track before grinding and polishing a complex curved surface workpiece to determine a tool machining track and pose parameters, acquiring a tool contact track of a grinding and polishing tool, and further acquiring a tool locus track of a machined curved surface;
converting the locus of the tool position of the machined curved surface into a code format program file which can be recognized by a robot controller and inputting the code format program file into the robot controller;
mounting the workpiece on a workbench, positioning and clamping the workpiece, and completing coordinate calibration unification of a process system;
the robot plans the program file according to the processing track input by the controller, drives the robot to move according to the program file formed by the track planning, and drives a grinding and polishing cutter arranged on an end effector of the robot to contact with the processing surface for processing.
6. The method for processing the automatic grinding and polishing system for the complex curved surface of the robot based on the compliance control as claimed in claim 5, wherein: planning a machining track before grinding and polishing a complex curved surface workpiece to determine a tool machining track and pose parameters, acquiring a grinding and polishing tool bit point track, and further acquiring the machining curved surface tool bit point track, wherein the method comprises the following steps:
the robot and the workbench positioning block are used for tool setting and positioning, so that the calibration of the base coordinate of the robot and the coordinate of the workbench is completed, and the unification of the calibration of the coordinates is realized;
importing a three-dimensional model of a complex curved surface workpiece into path generation software of the system, and setting a concave surface feed mode or a convex surface feed mode; under a workpiece coordinate system, automatically calculating the center line of the workpiece by software according to the three-dimensional model and calibrating; then, a symmetrical row cutting processing feed path generation method is applied to obtain a processing cutter row cutting path;
discretizing the three-dimensional model of the line cutting path of the obtained machining tool according to the rules of a Hilbert curve, discretizing a curved surface into a series of control point sets, point-dividing the discrete control points into a series of point sets, rearranging the point sets through recombination and deletion operations, and obtaining a tool contact path point set in a real number domain through parameter mapping;
and obtaining the tool location point track of the processing curved surface according to the tool location point track obtaining method of the grinding and polishing tool.
7. The machining method of the automatic grinding and polishing system for the complex curved surface of the robot based on the compliance control as claimed in claim 6, wherein the method for generating the symmetrical row cutting machining feed path comprises the following steps: and selecting a central line of the complex curved surface three-dimensional model by adopting a line cutting feed mode under a workpiece coordinate system, and symmetrically extending on two sides according to the set line cutting feed distance and the workpiece central line as a symmetry axis and the set feed distance until all the curved surfaces finish the generation of the line cutting path of the machining tool.
8. The machining method of the automatic grinding and polishing system for the complex curved surface of the robot based on the compliance control as claimed in claim 6, wherein the tool location point track of the machined curved surface obtained according to the tool location point track obtaining method for the grinding and polishing tool is as follows:
the vector A and the vector O are adopted to respectively represent position vectors of a contact point and a cutter point, and a cutter shaft vector can be expressed asThe distance from the tool contact point to the tool location point is R-W, the direction from the point A to the point O is expressed by a unit vector v, and then v is expressed asThe position vector O of the tool location point is expressed as O ═ a + (R-W) v, and the generated tool location trajectory vector includes the tool position vector O and the arbor vector a, which is expressed as Co ═ Oa;
wherein a is the cutter shaft vector direction of the grinding and polishing cutter, n is the curved surface normal vector direction, u is the cutter feeding direction, theta is the reverse direction deflection angle value of the cutter shaft vector direction a of the grinding and polishing cutter relative to the curved surface normal vector direction n in the feeding direction u, and a, n and u are unit vectors.
9. The method as claimed in claim 5, wherein the step of driving the robot to move according to the processing path planning program file inputted by the controller to drive the polishing tool mounted on the end effector to contact the processing surface for processing includes:
when the grinding and polishing tool and the processed curved surface are in mutual contact processing, strain signals are acquired and measured through a force/torque sensor, and digital signals which can be identified are output and transmitted to a computer after signal conversion, amplification and filtering processing;
the computer processes the collected digital signals, performs weight compensation calculation according to a weight compensation algorithm, and converts the measurement result into actual polishing force Fc；
The computer will measure the actual polishing force FcAnd a set polishing force FdPerforming comparative calculation to obtain a force compensation value delta F; converting the force compensation value delta F into a position compensation value delta X, and adjusting the compensation value delta X and the polishing track planning value XpPerforming compensation conversion to obtain the actual polishing position XdThe same process gives Yd、ZdValue of (A), Xd、Yd、ZdAre each in the base coordinate system OBPosition values of the lower X, Y, Z three coordinate directions.
The computer feeds back the adjusted Xd，Yd、ZdAnd transmitting the attitude angle data of the three grinding and polishing workpieces to a robot controller, controlling the robot to perform feedback adjustment by the robot controller, and performing corresponding position and attitude adjustment on the grinding and polishing workpieces in a robot motion belt to realize constant and controllable grinding and polishing force in the machining process.
10. The method as claimed in claim 9, wherein the calculating of the weight compensation according to the weight compensation algorithm comprises:
in-system robot base coordinate system OBIn the following, the polishing tool gravity is expressed as:BFg＝[00-G]the expression of the gravity of the grinding and polishing tool measured by the force/moment sensor isSFg＝[FgXFgYFgZ]The conversion relationship between the two isIn the formula,for end effector coordinate system OETo base coordinate system OBOf the transformation matrix, the machineDetermining a robot body;as sensor coordinate system OSTo end effector coordinate system OEThe transformation matrix of (2) is determined by the installation mode of the sensor and the end effector of the robot,as sensor coordinate system OSTo base coordinate system OBTransformation moment of (F)gXIs the gravity magnitude of the tool in the X direction under the sensor coordinate system, FgYIs the gravity magnitude of the tool in the Y direction under the sensor coordinate system, FgZThe gravity value of the tool in the Z direction under the sensor coordinate system is obtained.
Obtaining a system robot base coordinate system O through coordinate matrix transformationBDownward grinding and polishing force
Converting the measured value in the force sensor coordinate system to the base coordinate system to eliminate the interference of gravity on the grinding and polishing force and obtain the base coordinate OBActual polishing forceBFc＝BFm-BFg；
Wherein,BFmin order to provide a system robot with a base coordinate system for lower polishing force,SFmis the polishing force under the sensor coordinate system,BFgthe base coordinate is the gravity of the lower polishing tool itself,BFithe inertial force generated for the feed movement.
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