CN110991108B - Mechanical arm joint torque sensor structural design method - Google Patents
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Abstract
The invention discloses a structural design method of a mechanical arm joint torque sensor, and aims to provide a high-efficiency design tool for developing a novel mechanical arm joint torque sensor with high sensitivity and high rigidity. Firstly, starting from design requirements, obtaining an initial configuration of a sensor elastomer; and secondly, selecting a design variable by taking the initial configuration as a reference, taking the stress-strain ratio of the sensor elastomer as a design target, constructing a standard structural optimization design model, and solving the model to output an optimal design scheme. Compared with the conventional method, the method does not need to provide an initial configuration by a designer, thereby greatly reducing the dependence on engineering experience and theoretical knowledge; all steps in the design process do not need a complicated and complicated programming solving process, are easy to understand and implement, and have good engineering practicability.
Description
Technical Field
The invention relates to the technical field of torque sensors, in particular to a structural design method of a mechanical arm joint torque sensor.
Background
Robotic arms have found widespread use in industrial sites such as vehicles, electronics, shipbuilding, and the like. In order to realize effective control of the mechanical arm, a plurality of sensors are arranged to monitor the states of all key positions of the mechanical arm in real time, and the torque sensor is the most widely used sensor. Torque sensors are typically designed at the kinematic joint positions, and effective compensation of motion control errors can be achieved based on signals fed back by the torque sensors. The elastomer is the structural core of the joint torque sensor, and a number of configurations have been developed so far. Among them, more typical ones include: hollow ring type, hub type, cross type, spoke type, etc. The design goals of the above-described joint torque sensor configuration are mainly focused on two aspects: sensitivity and torsional rigidity. The greater sensitivity means that the greater the response stress on the elastomer under an equivalent preload, the stronger the voltage signal that can be output under the piezoresistive effect. And the greater the torsional rigidity, the smaller the angular strain of the elastomer, the smaller the additional deformation error introduced to the joint position of the mechanical arm. Typically, such errors are difficult to compensate. Thus, the designer desires to achieve both high sensitivity and high torsional stiffness, i.e., greater stress and less angular strain. However, existing studies have shown that there is a constraining relationship between the two; in other words, lifting the response stress of the sensor elastomer tends to increase its angular strain. Naturally, the stress-strain ratio is used as a key performance indicator to evaluate the design effect of such sensors.
As previously mentioned, a number of torque sensor designs have been developed. However, as industry demands for sensor cost performance increase, designers need to continually improve sensor performance by proposing new configurations. The basic idea of the traditional design method is to firstly propose a new configuration and then further optimize the design based on the configuration. Presenting a new configuration is challenging for the designer, and the process not only relies on a rich engineering experience, but also requires a deep theoretical foundation. Thus, the design and development of new joint torque sensors face serious obstacles. The joint torque sensor structure design method is independent of engineering experience, easy to understand and implement, and has very important engineering significance for promoting the rapid development of the high-cost-performance mechanical arm.
Disclosure of Invention
The invention overcomes the defects of the prior art, and provides a mechanical arm joint torque sensor structure design method which does not need to provide an initial configuration for a sensor elastomer, thereby greatly reducing the dependence on engineering experience and theoretical knowledge and providing a high-efficiency design tool for developing a novel mechanical arm joint torque sensor with both sensitivity and torsional rigidity.
In order to achieve the above purpose, the invention adopts the following technical scheme: a mechanical arm joint torque sensor structural design method comprises the following steps:
(1) Selecting an elastomer part of the joint torque sensor to be optimized as a design area, defining a design target, wherein the design target is set as follows: S/E R Under the action of preload, S represents the maximum equivalent stress of the sensitive area of the elastomer, E R Representing the maximum angular strain of the elastomeric support region;
(2) Establishing a finite element analysis model A, and simulating stress-strain response of the elastomer under an angular displacement load;
(3) Based on the finite element analysis model A, establishing a topology optimization model and solving to obtain a topology configuration;
(4) Converting the topological configuration into an initial design, selecting design variables, wherein the design variables are required to keep the initial design configuration unchanged, and the design variables can form a design vector X= (X) 1 ,X 2 ,...,X N ) The method comprises the steps of carrying out a first treatment on the surface of the The value range is as follows: x is X i ∈[X i L ,X i R ],i＝1,2,...,N；
(5) Constructing an equivalent stress function and an angular strain function based on the design variables;
(6) Building a structure optimization model, solving and outputting an optimal design scheme;
the structural optimization model is as follows:
optimally designing: x is X * ＝(X 1 * ,X 2 * ,...,X N * )。
Further, in step (1): the elastic body is provided with 8 first moving shaft fixing holes in the outer circumferential area for connecting moving shafts; the central area is provided with 4 first dead axle fixing holes for connecting a dead axle, and 4 first sensitive areas for respectively placing 4 piezoresistors to form a Wheatstone bridge circuit so as to complete the monitoring of input torque.
Further, in the step (2), the process of establishing the finite element analysis model a is as follows:
(2.1) the elastomer builds a shell-feature based structural model;
(2.2) dividing a sensitive area according to design requirements;
(2.3) applying a solid support boundary condition to the dead axle fixing hole;
(2.4) applying an angular displacement boundary condition to the moving shaft fixing hole, setting an angular displacement R Z ；
And (2.5) carrying out general static analysis on the existing finite element analysis software platform to obtain the equivalent stress distribution and the angular strain distribution of the elastomer.
Further, in the step (3), the process of establishing a topological optimization model and solving to obtain a topological configuration is as follows:
(3.1) selecting a region to be designed in the finite element analysis model A;
(3.2) freezing the area where the boundary condition is set;
(3.3) based on the finite element analysis model A, establishing a design response function of the total strain energy E of the sensitive area;
(3.4) establishing a design response function of the volume V based on the area to be designed;
(3.5) with the maximization of E, V.ltoreq.V 0 For constraint, the following topology optimization model is established:
and (3.6) solving on an existing finite element analysis software platform, and outputting the topological configuration of the region to be designed.
Further, in step (3.5), V 0 ∈[15％，40％]。
Further, V 0 ＝20％。
Further, in step 4, according to the technological requirement of single-tool single-station milling, the topological configuration is subjected to standardized treatment, and the initial design is obtained.
Further, the initial design includes a first reference line, a second reference line, and a third reference line, offset by X from the first reference line 1 Obtain a first contour line offset X by a second reference line 2 Obtain a second contour line offset X by a third reference line 3 Obtaining a third profile; this results in a new design, in which 3 offsets X 1 ，X 2 ，X 3 For the selected design variables, a design vector X= (X) can be composed 1 ，X 2 ，X 3 ) The method comprises the steps of carrying out a first treatment on the surface of the The value range is as follows: x is X i ∈[X i L ,X i R ]。
Further, X i L ＝0mm,X i R ＝3mm,i＝1,2,3。
Further, in the step (5), the process of constructing the equivalent stress function and the angular strain function is as follows:
(5.1) building a shell-feature based finite element analysis model B for the design;
(5.2) dividing a sensitive area and a supporting area;
(5.3) applying a solid support boundary condition to the dead axle fixing hole;
(5.4) applying a torque load M to the shaft fixing hole Z ；
(5.5) carrying out general static analysis based on an ABAQUS finite element analysis software platform to obtain the maximum equivalent stress S (X) of the sensitive area and the maximum angular strain E of the supporting area under a certain design scheme X R (X)；
(5.6) for S (X) and E by response surface technique R (X) establishing an explicit approximation function.
Compared with the prior art, the invention has the advantages that:
firstly, the method can directly obtain the initial configuration of the sensor elastomer from the design requirement, thereby greatly reducing the dependence of a designer on engineering experience and theoretical basis. Secondly, the method is used for further optimizing the initial configuration by constructing a standard optimization model, so that the optimal structural design of the joint torque sensor with both sensitivity and torsional rigidity can be realized. In conclusion, the method is easy to understand and implement, and has good engineering practicability.
Drawings
FIG. 1 is a schematic flow chart of the method of the present invention.
Fig. 2 is a schematic diagram of a torque sensor in an embodiment of the present invention.
Fig. 3 is a finite element analysis model under an angular displacement load in an embodiment of the invention.
Fig. 4 is a simulated equivalent stress distribution and angular strain distribution in an example of an application of the invention.
Fig. 5 shows the topology and preliminary design in a specific application example of the present invention.
Fig. 6 is a diagram showing design variables in a specific application example of the present invention.
Fig. 7 is a finite element analysis model under torque load in an example of an application of the present invention.
FIG. 8 is a diagram of two common designs for comparison and the resulting optimal design in a specific application example of the present invention.
Reference numerals: 20. an elastomer; 21. a first moving shaft fixing hole; 22. a first stationary shaft fixing hole; 23. a first sensitive area; 24. a first support region; 30. a first finite element analysis model; 32. a first clamped boundary condition; 321. a second moving shaft fixing hole; 322. a second stationary shaft fixing hole; 323. a second sensitive area; 33. a first control point; 34. a first coupling constraint; 35. angular displacement boundary conditions; 36. a first region; 37. a second region; 38. a third region; 41. equivalent stress distribution; 42. angular stress distribution; 51. topology configuration; 52. initial design; 60. a first design; 601. a first reference line; 602. a second reference line; 603. a third reference line; 611. a first contour line; 612. a second contour line; 613. a third profile; 70. a second finite element analysis model; 72. a second clamped boundary condition; 721. a third moving shaft fixing hole; 722. a third stationary shaft fixing hole; 723. a third sensitive area; 73. a second control point; 74. a second coupling constraint; 75. torque load; 76. a second support region; 80. a second design; 801. a fourth region; 802. a seventh region; 81. hub type design; 811. a fifth region; 812. an eighth region; 82. a spoke type design; 821. a sixth region; 822. and a ninth region.
Detailed Description
The invention is further described below in connection with the examples, which are not to be construed as limiting the invention in any way, but rather as a limited number of modifications which are within the scope of the appended claims.
As shown in fig. 1 to 8, the invention provides a structural design method of a mechanical arm joint torque sensor, which comprises the following processing steps:
step S1: and selecting an elastomer part of the joint torque sensor to be optimized as a design area, and defining a design target. As shown in fig. 2, the elastomer 20 of the joint torque sensor to be optimized in this embodiment is designed and manufactured based on aluminum alloy (AL 7075), and its elastic modulus is set to 71.7GPa and poisson's ratio is 0.33. On the elastic body 20, 8 first moving shaft fixing holes 21 are designed in an outer circumferential area for connecting moving shafts; 4 first dead axle fixing holes 22 are designed in the central area and are used for connecting dead axles; 4 first sensitive areas 23 are provided for placing 4 piezoresistors respectively to form a wheatstone bridge circuit. The torque induced by the relative rotation of the shaft and the stationary shaft will cause a response stress to occur on the elastomer 20; under the effect of the piezoresistive effect, the piezoresistor on the sensitive area 23 generates resistance change; the wheatstone bridge circuit outputs corresponding voltage signals, so that input torque monitoring is completed. On the elastic body 20, the area other than the first movable shaft fixing hole 21, the first stationary shaft fixing hole 22, and the first sensitive area 23 may be referred to as a first support area 24. The maximum equivalent stress meter of the first sensitive area 23 is: s, the maximum angular strain of the first support region 24 is: e (E) R The method comprises the steps of carrying out a first treatment on the surface of the The design targets were set as: S/E R 。
Step S2: a finite element analysis model was built to simulate the stress-strain response of the elastomer 20 under an angular displacement load. As shown in fig. 3, a first finite element analysis model 30 based on shell-characteristics is built on the elastomer 20; partitioning according to design requirements4 second sensitive areas 323 are formed, and the second sensitive areas 323 correspond to the first sensitive areas 23 shown in fig. 2; applying a first clamped boundary condition 32 to the second dead axle fixing hole 322; applying a first coupling constraint 34 based on a first control point 33 to the second moving axis fixing hole 321, and applying an angular displacement boundary condition 35 based on Z-direction rotation on the first control point 33, wherein the angular displacement is R Z =0.001 rad; the second moving shaft fixing hole 321 and the second stationary shaft fixing hole 322 correspond to the first moving shaft fixing hole 21 and the first stationary shaft fixing hole 22 shown in fig. 2, respectively; the general static analysis was performed on an ABAQUS finite element analysis software platform to obtain an equivalent stress profile 41 and an angular strain profile 42 as shown in fig. 4.
Step S3: based on the finite element analysis model 30, a topology optimization model is built and solved to obtain a topology. As shown in fig. 3, a first region 36 is selected as a region to be designed in the finite element analysis model 30; freezing the second region 37 containing the second moving shaft fixing hole 321 and the third region 38 containing the stationary shaft fixing hole 322; based on the finite element analysis model 30, establishing a design response function of the total strain energy E of the second sensitive area 323; establishing a design response function for the volume V based on the first region 36 to be designed; with the maximization E as a design target, and with V less than or equal to V 0 =20% as constraint, build the following topology optimization model:
the topology 51 of the first region 36, which is the design region, is solved for output on an ABAQUS finite element analysis software platform, as shown in fig. 5.
Step S4: the resulting topology 51 is converted to an initial design 52 and design variables are selected. The topological structure 51 is subjected to standardized treatment according to the technological requirements of single-tool single-station milling processing, and an initial design 52 shown in fig. 5 is obtained; the design variables are selected while maintaining the original design 52 configuration unchanged. As shown in fig. 6, a first reference line 601, a second reference line 602, and a third reference line 603 are obtained based on the initial design 52, offset by X by the first reference line 601 1 A first contour line 611 is obtained which,offset X by second reference line 602 2 Second contour line 612 is obtained offset by X with third reference line 603 3 Obtaining a third profile 613; a new design 60 is thus obtained. Wherein 3 offsets (X 1 ，X 2 ，X 3 ) For the selected design variables, a design vector X= (X) can be composed 1 ，X 2 ，X 3 ) The method comprises the steps of carrying out a first treatment on the surface of the The value range is as follows: x is X i ∈[X i L ,X i R ],X i L ＝0mm,X i R ＝3mm,i＝1,2,3。
Step S5: based on the design variables, an equivalent stress function and an angular strain function are constructed. As shown in fig. 7, a second finite element analysis model 70 based on shell-features is built for the first design solution 60; 4 third sensitive areas 723 are divided, the third sensitive areas 723 corresponding to the second sensitive areas 323 shown in fig. 3; applying a second clamped boundary condition 72 to the third dead axle fixing hole 722; applying a second coupling constraint 74 based on a second control point 73 to a third dynamic axis fixation hole 721, applying a Z-direction based torque load 75 on the second control point 73, the torque being set to M Z ＝10N . m; a second supporting region 76 which does not include the third dynamic axis fixing hole 721 and the third static axis fixing hole 722, the third sensitive region 723 is divided; the third moving shaft fixing hole 721 and the third stationary shaft fixing hole 722 correspond to the second moving shaft fixing hole 321 and the second stationary shaft fixing hole 322, respectively, as shown in fig. 3. The maximum equivalent stress S (X) of the third sensitive region 723 and the maximum angular strain E of the second supporting region 76 under a certain design scheme X can be obtained by performing general static analysis on an ABAQUS finite element analysis software platform R (X). By randomly sampling 50 times within the designed variable value range, S (X) and E R (X) establishing a second order response surface function, writable:
S(X)＝8.585-1.852X 1 -0.881X 2 -0.486X 3 +0.721X 1 2 +0.002X 2 2 -0.057X 3 2 -0.128X 1. X 2 -0.220X 1. X 3 +0.141X 2. X 3
E R (X))＝4.062-1.750X 1 -0.611X 2 -1.090X 3 +1.138X 1 2 +0.508X 2 2 +0.647X 3 2 -0.398X 1. X 2 -0.097X 1. X 3 +0.151X 2. X 3
step S6: and establishing a structural optimization model, solving and outputting an optimal design scheme. In S (X)/E R (X) as a design target, building a structural optimization model as follows:
solving the optimization model by adopting a classical two-sequence planning method to obtain an optimal design: x is X * ＝(0.70mm,0.46mm,0.67mm)，S(X)＝6.81MPa，E R (X)＝2.66e-4。
To demonstrate the beneficial effects of the proposed method, the optimal design is compared in performance with the two common designs. As described in the background art, the greater the equivalent stress of the sensitive area, the higher the sensitivity of the torque sensor; the smaller the angular strain of the elastomer is, the better the rigidity of the torque sensor is, and the better the linearity is; therefore, the stress-strain ratio is employed in this embodiment to measure the performance of the torque sensor design. As shown in fig. 8, the hub-type design 81 and the spoke-type design 82 are two designs that are more common for joint torque sensor elastomers, and the second design 80 is the optimal design. The fourth, fifth and sixth regions 801, 811, 821 are sensitive regions of the second, hub and spoke-type designs 80, 81, 82, respectively, and the seventh, eighth and ninth regions 802, 812, 822 are support regions of the second, hub and spoke-type designs 80, 81, 82, respectively. Finite element analysis similar to step S5 was performed for the second design 80, hub-type design 81, and spoke-type design 82, extracting the maximum equivalent stress of the fourth region 801, fifth region 811, and sixth region 821 as sensitive regions and the maximum angular strain of the seventh region 802, eighth region 812, and ninth region 822 as support regions, as listed in table 1. From the results, it can be seen that the resulting second design 80 has a maximum stress to strain ratio (2.56) of 2.5 times that of the hub-type design 81 and 3.4 times that of the spoke-type design 82; thus, it is shown that the proposed method results in a second design 80 that has optimal performance among the three and has significant performance advantages over the hub-type design 81 and spoke-type design 82. On the other hand, from the whole design process of the embodiment, a designer can obtain the initial configuration of the torque sensor elastomer without relying on engineering experience, and the engineering practicability is better than that of the conventional method.
TABLE 1
Claims (9)
1. The mechanical arm joint torque sensor structural design method is characterized by comprising the following processing steps:
(1) Selecting an elastomer part of the joint torque sensor to be optimized as a design area, and defining a design target, wherein the design target is set as follows: S/E R Wherein S represents the maximum equivalent stress of the elastomer sensitive area, E R Representing the maximum angular strain of the elastomeric support region;
(2) Establishing a finite element analysis model A, and simulating stress-strain response of the elastomer under an angular displacement load;
(3) Based on the finite element analysis model A, establishing a topology optimization model and solving to obtain a topology configuration;
(4) Converting the topological configuration into an initial design, selecting design variables, wherein the design variables are required to keep the initial design configuration unchanged, and the design variables can form a design vector X= (X) 1 ,X 2 ,...,X N ) The method comprises the steps of carrying out a first treatment on the surface of the The value range is as follows: x is X i ∈[X i L ,X i R ],i＝1,2,...,N；
(5) Constructing an equivalent stress function and an angular strain function based on the design variables;
(6) Building a structure optimization model, solving and outputting an optimal design scheme;
the structural optimization model is as follows:
in the step (3), the process of establishing a topological optimization model and solving to obtain a topological configuration is as follows:
(3.1) selecting a region to be designed in the finite element analysis model A;
(3.2) freezing the area where the boundary condition is set;
(3.3) based on a finite element analysis model A, establishing a design response function of the total strain energy E of the sensitive area;
(3.4) establishing a design response function of the volume V based on the region to be designed;
(3.5) with the maximization of E, V.ltoreq.V 0 For constraint, the following topology optimization model is established:
and (3.6) solving on an existing finite element analysis software platform, and outputting the topological configuration of the region to be designed.
2. The method for designing a mechanical arm joint torque sensor structure according to claim 1, wherein in step (1): the elastic body is provided with 8 first moving shaft fixing holes in the outer circumferential area for connecting moving shafts; the central area is provided with 4 first dead axle fixing holes for connecting a dead axle, and 4 first sensitive areas for respectively placing 4 piezoresistors to form a Wheatstone bridge circuit so as to complete the monitoring of input torque.
3. The method for designing a mechanical arm joint torque sensor structure according to claim 1, wherein in the step (2), the process of establishing the finite element analysis model a is as follows:
(2.1) building a shell-feature based structural model for the elastomer;
(2.2) dividing a sensitive area according to design requirements;
(2.3) applying a solid support boundary condition to the dead axle fixing hole;
(2.4) applying an angular displacement boundary condition to the moving shaft fixing hole, setting an angular displacement R Z ；
And (2.5) carrying out general static analysis on the existing finite element analysis software platform to obtain the equivalent stress distribution and the angular strain distribution of the elastomer.
4. The method of claim 1, wherein in step (3.5), V 0 ∈[15％，40％]。
5. The method for structural design of a mechanical arm joint torque sensor according to claim 4, wherein V 0 ＝20％。
6. The method for designing the mechanical arm joint torque sensor structure according to claim 1, wherein in step 4, the topology configuration is standardized according to the technological requirements of single-tool single-station milling processing, so as to obtain an initial design.
7. The method of claim 6, wherein the initial design includes a first reference line, a second reference line, and a third reference line, the first reference line being offset by X 1 Obtain a first contour line offset X by a second reference line 2 Obtain a second contour line offset X by a third reference line 3 Obtaining a third profile; this results in a new design, in which 3 offsets X 1 ，X 2 ，X 3 For the selected design variables, a design vector x=can be formed(X 1 ，X 2 ，X 3 ) The method comprises the steps of carrying out a first treatment on the surface of the The value range is as follows: x is X i ∈[X i L ,X i R ]。
8. The method for structural design of a mechanical arm joint torque sensor according to claim 7, wherein X is i L ＝0mm,X i R ＝3mm,i＝1,2,3。
9. The method for designing a mechanical arm joint torque sensor structure according to any one of claims 1 to 8, wherein in the step (5), the process of constructing the equivalent stress function and the angular strain function is as follows:
(5.1) building a shell-feature based finite element analysis model B for the design;
(5.2) dividing a sensitive area and a supporting area;
(5.3) applying a solid support boundary condition to the dead axle fixing hole;
(5.4) applying a torque load M to the shaft fixing hole Z ；
(5.5) carrying out general static analysis based on a finite element analysis software platform to obtain the maximum equivalent stress S (X) of the sensitive area and the maximum angular strain E of the supporting area under a certain design scheme X R (X)；
(5.6) for S (X) and E by response surface technique R (X) establishing an explicit approximation function.
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Application publication date: 20200410 Assignee: Hunan Hongyuyun Technology Co.,Ltd. Assignor: Hunan City University Contract record no.: X2023980052592 Denomination of invention: A Structural Design Method for Robot Arm Joint Torque Sensor Granted publication date: 20230425 License type: Common License Record date: 20231215 |