WO2022011845A1 - 航空发动机叶片超声滚压强化机器人加工系统及控制方法 - Google Patents

航空发动机叶片超声滚压强化机器人加工系统及控制方法 Download PDF

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Publication number
WO2022011845A1
WO2022011845A1 PCT/CN2020/119152 CN2020119152W WO2022011845A1 WO 2022011845 A1 WO2022011845 A1 WO 2022011845A1 CN 2020119152 W CN2020119152 W CN 2020119152W WO 2022011845 A1 WO2022011845 A1 WO 2022011845A1
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WIPO (PCT)
Prior art keywords
ultrasonic rolling
blade
robot
strengthening
aero
Prior art date
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Ceased
Application number
PCT/CN2020/119152
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English (en)
French (fr)
Inventor
张显程
李志强
刘爽
韩晓宁
姚树磊
龚从扬
朱林
张开明
涂善东
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Avic Manufacturing Technology Institute
East China University of Science and Technology
AVIC Manufacturing Technology Institute
Original Assignee
Avic Manufacturing Technology Institute
East China University of Science and Technology
AVIC Manufacturing Technology Institute
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Publication date
Application filed by Avic Manufacturing Technology Institute, East China University of Science and Technology, AVIC Manufacturing Technology Institute filed Critical Avic Manufacturing Technology Institute
Priority to US18/015,503 priority Critical patent/US12359271B2/en
Publication of WO2022011845A1 publication Critical patent/WO2022011845A1/zh
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
    • C21D7/00—Modifying the physical properties of iron or steel by deformation
    • C21D7/02—Modifying the physical properties of iron or steel by deformation by cold working
    • C21D7/04—Modifying the physical properties of iron or steel by deformation by cold working of the surface
    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
    • C21D7/00—Modifying the physical properties of iron or steel by deformation
    • C21D7/02—Modifying the physical properties of iron or steel by deformation by cold working
    • C21D7/04—Modifying the physical properties of iron or steel by deformation by cold working of the surface
    • C21D7/06—Modifying the physical properties of iron or steel by deformation by cold working of the surface by shot-peening or the like
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B25—HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
    • B25J—MANIPULATORS; CHAMBERS PROVIDED WITH MANIPULATION DEVICES
    • B25J11/00—Manipulators not otherwise provided for
    • B25J11/005—Manipulators for mechanical processing tasks
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22F—CHANGING THE PHYSICAL STRUCTURE OF NON-FERROUS METALS AND NON-FERROUS ALLOYS
    • C22F1/00—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22F—CHANGING THE PHYSICAL STRUCTURE OF NON-FERROUS METALS AND NON-FERROUS ALLOYS
    • C22F3/00—Changing the physical structure of non-ferrous metals or alloys by special physical methods, e.g. treatment with neutrons

Definitions

  • the invention relates to the field of aero-engine processing, and more particularly to a robotic processing system and a control method for ultrasonic rolling strengthening of aero-engine blades.
  • Ultrasonic rolling strengthening processing is a new surface modification technology that combines ultrasonic shot peening and low plasticity polishing. Through ultrasonic-assisted vibration, the ball-shaped tool head hits the metal surface with high frequency and high amplitude, so that the machined surface produces a certain amount of damage. Plastic deformation layer, thereby reducing the roughness of the metal surface, increasing the hardness of the metal surface layer, and introducing beneficial residual compressive stress into the material, ultimately achieving the purpose of improving the service life of the material.
  • the research shows that the ultrasonic rolling strengthening technology has great potential application value for improving the service life of aero-engine blades.
  • most of the research objects of ultrasonic rolling strengthening processing are test pieces such as flat plates or round bars. Aero-engine blades have complex curved surfaces and thin-walled features, and it is difficult to achieve accurate and effective ultrasonic rolling strengthening of aero-engine blades by traditional CNC machining methods.
  • the invention provides a robot processing system and control method for ultrasonic rolling strengthening of aero-engine blades.
  • the ultrasonic rolling strengthening device and the flexible follow-up support head By controlling the ultrasonic rolling strengthening device and the flexible follow-up support head to exert the same force on the surface of the aero-engine blade as possible, the aero-engine blade is restrained The deformation and flutter generated during the ultrasonic rolling strengthening process finally realize the precise ultrasonic rolling strengthening processing of aero-engine blades.
  • an aero-engine blade ultrasonic rolling strengthening robot processing system comprising:
  • a robot on which an ultrasonic rolling and strengthening device is fixed and drives the ultrasonic rolling and strengthening device to move;
  • a base on which a spindle turntable and a three-dimensional mobile lifting device are installed, a rotatable blade clamp is arranged on the spindle turntable, and a flexible follow-up support head is fixed on the three-dimensional mobile lifting device;
  • the control system is electrically or communicatively connected to the robot, the spindle turntable and the three-dimensional mobile lifting device, respectively.
  • the robot is a five-axis or six-axis robot.
  • the spindle turntable includes a servo motor, a reducer, a turntable base, a rotating spindle, a transition disk and a rotary encoder
  • the reducer is fixed on the turntable base
  • the servo motor and the reducer are
  • the input shaft of the motor is connected to the input shaft
  • the rotating main shaft is connected to the output shaft of the reducer
  • the transition disc is connected to the rotating main shaft
  • the blade clamp is arranged on the transition disc
  • the rotary encoder is built into the servo In the motor
  • the control system is electrically connected to the servo motor and the rotary encoder respectively.
  • the three-dimensional moving lifting device includes a lifting support rod, an X-direction moving drive device, a Y-direction lifting drive device, and a Z-direction moving drive device; the Z-direction moving drive device is arranged on the base, and the X-direction moving drive device is The moving drive device is connected with the Z-direction moving drive device, the Y-direction moving drive device is connected with the X-direction moving drive device, and the lifting support rod is connected with the flexible follow-up support head.
  • the Z-direction moving driving device includes a first driving member, a first ball screw, and a first screw nut, the ball screw is arranged on the base along the Z direction, and the first driving member is connected to the base.
  • the ball screw is connected, and the ball screw passes through the first screw nut and is in driving cooperation with the first screw nut.
  • the X-direction movement driving device includes a mounting plate, a second driving member, a second ball screw, and a second screw nut, the mounting plate is fixed on the first screw nut, and the second The ball screw is arranged on the mounting plate along the X direction, the second driving member is connected with the second ball screw, and the second ball screw is connected to the second screw nut and is connected with the second ball screw.
  • the second lead screw nut is matched for transmission.
  • the Y-direction lifting driving device includes a lifting base plate and a third driving member, a turbine, a worm, a third ball screw and a third screw nut arranged on the lifting base plate, the third ball screw Arranged along the Y direction, the third driving member is connected with the worm, the turbine is respectively engaged with the worm and the third ball screw, and the third ball screw passes through the third screw nut and is connected with the worm.
  • the third lead screw nut is in driving fit, and the lifting support rod is connected with the third lead screw nut.
  • the blade clamp includes an upper pressing block, a lower pressing block, a left holding block and a right holding block.
  • control cabinet and the control system is arranged in the control cabinet.
  • Another aspect of the present invention provides an aero-engine blade ultrasonic rolling strengthening robot processing control method, which at least includes:
  • Step S1 Provide an aero-engine blade ultrasonic rolling strengthening robot processing system as described above, so that the blade clamp clamps the tenon part of the blade, and the to-be-processed surface of the blade faces the ultrasonic rolling strengthening device,
  • the flexible follow-up support head supports the opposite surface of the surface to be processed;
  • Step S2 According to the model of the blade, the "zigzag" processing track of the ultrasonic rolling strengthening device is generated according to the equal section method;
  • Step S3 generating the movement trajectory of the lifting support rod according to the processing trajectory of the ultrasonic rolling strengthening device
  • Step S4 The control system controls the movement of the ultrasonic rolling and strengthening device and the lifting support rod according to the processing trajectory of the ultrasonic rolling strengthening device and the moving trajectory of the lifting support rod, so as to complete the strengthening processing of the blade surface to be processed.
  • step S4 also includes:
  • the control system controls the spindle turntable to rotate continuously, so that the cross-sectional contour line of the opposite surface of the blade to be processed is vertical to the axis of the lifting support rod, the ultrasonic rolling strengthening device and the blade to be processed
  • the contact point of the surface is on the axis of the lifting support rod, and the direction of the ultrasonic rolling strengthening device is always along the normal direction of the surface to be processed of the blade.
  • the ultrasonic rolling strengthening robot processing system and control method of the aero-engine blade of the present invention adopts a robot-assisted clamping ultrasonic rolling device, cooperates with a three-dimensional moving lifting device and a flexible follow-up support head, and adjusts the robot, the spindle turntable and the three-dimensional moving lifting and lowering
  • the device performs coordinated control to achieve precise ultrasonic rolling strengthening of aero-engine blades.
  • the advantages of the robot's high degree of freedom, strong accessibility and good precision are used to realize ultrasonic rolling strengthening along the normal direction of the surface of the aero-engine blade; on the other hand, the flexible follow-up support head can effectively solve the The deformation and flutter problems caused by the high-frequency and high-amplitude ultrasonic vibration rolling during the ultrasonic rolling strengthening process; the ultrasonic rolling strengthening can effectively reduce the surface roughness of the aero-engine blade, improve the hardness of the blade surface, and increase the surface of the blade to the inside of the blade.
  • the introduction of beneficial residual compressive stress is ultimately expected to improve the service life of aero-engines.
  • FIG. 1 is a schematic structural diagram of an aero-engine blade ultrasonic rolling strengthening robot processing system provided by an embodiment of the present invention
  • FIG. 2 is a schematic structural diagram of a spindle turntable according to an embodiment of the present invention.
  • FIG. 3 is a schematic structural diagram of a blade clamp provided by an embodiment of the present invention.
  • FIG. 4 is a top view of a three-dimensional mobile lifting device according to an embodiment of the present invention.
  • Fig. 5 is the A-A sectional view of Fig. 4;
  • Fig. 6 is an enlarged view of part I of Fig. 5;
  • FIG. 7 is an enlarged view of part II of FIG. 5;
  • FIG. 8 is an enlarged view of part III of FIG. 5;
  • FIG. 9 is a schematic flowchart of a robot processing control method for ultrasonic rolling strengthening of an aero-engine blade provided by another embodiment of the present invention.
  • FIG. 10 is a schematic diagram of a machining trajectory of an aero-engine blade provided by another embodiment of the present invention.
  • FIG. 11 is a schematic diagram of a machining process of an aero-engine blade according to another embodiment of the present invention.
  • the present invention defines a coordinate system O-XYZ as shown in FIG. 1 , where ⁇ is the direction of rotation around the Z axis.
  • an embodiment of the present invention provides an ultrasonic rolling and strengthening robot processing system for an aero-engine blade, including a robot 1 , a base 10 and a control cabinet 3 .
  • an ultrasonic rolling strengthening device 4 is fixed on the robot 1 and drives the ultrasonic rolling strengthening device 4 to move;
  • a spindle turntable 5 and a three-dimensional moving lifting device 100 are installed on the base 10, and a blade clamp 6 is arranged on the spindle turntable 5 , used to clamp the aero-engine blade 7 to be processed, the fixture 6 can be rotated around the Z direction, thereby driving the blade 7 to rotate around the Z direction;
  • a flexible follow-up support head 13 is fixed on the three-dimensional mobile lifting device 100 and Drive the support head 13 to complete the movement in the three directions of X, Y and Z;
  • a control system is set in the control cabinet 3, and the control system is electrically or communicatively connected with the robot 1, the spindle turntable 5 and the three-dimensional mobile lifting device 100, and the three The
  • the ultrasonic rolling strengthening device 4 is located above the flexible follow-up support head 13, and the two are located on the upper and lower sides of the blade 7 respectively.
  • the flexible follow-up support head 13 supports the blade, and the ultrasonic rolling strengthening device 4 is used to carry out ultrasonic rolling and strengthening processing on the surface of the blade 7;
  • the control system in the control cabinet 3 controls the movement of the robot 1—that is, controls the motion trajectory of the ultrasonic rolling strengthening device 4 and the rotation of the spindle turntable 5—that is The rotation of the blade 7 and the movement of the three-dimensional moving lifting device 100 ie the movement of the flexible follow-up support head 13 , through the cooperation of these three parts, completes the ultrasonic rolling strengthening process on the surface of the blade 7 .
  • the robot 1 may be a multi-degree-of-freedom joint robot, such as a five-axis or six-axis joint robot, so as to meet the processing requirements of the curved surface of the blade 7 .
  • the ultrasonic rolling strengthening device 4 can be connected to the robot 1 through the connecting device 2 and fixed on the end effector of the robot 1, so that the ultrasonic rolling strengthening device 4 can be controlled by the robot 1 along the normal direction of the surface of the blade 7 Strengthen processing.
  • the connecting device 2 may be a conventional tool connecting device in the prior art, such as a flange, a bolt, a clip, etc., which is not limited in the present invention.
  • the ultrasonic rolling strengthening device 4 can be any strengthening device in the prior art, and generally includes an ultrasonic generator, a force sensor, a spring, an ultrasonic transducer, an ultrasonic horn, a rolling ball and necessary components connected in sequence.
  • the fixing device, the ultrasonic transducer converts the high-frequency electrical signal of the ultrasonic generator into a vibration signal, which is transmitted and amplified by the ultrasonic horn, and finally acts on the surface of the workpiece to be processed by rolling the ball to complete the ultrasonic rolling strengthening. processing.
  • the spindle turntable 5 may include a rotary encoder 17, a servo motor 18, a reducer 19, a reducer mounting plate 20, a coupling 21, a rotating spindle 22, a turntable base 23, a lock nut 24, a bearing Spacer ring 25, tapered roller bearing 26, bearing end cover 27, transition plate 28, wherein, the servo motor 18 is connected with the input shaft of the reducer 19, and the reducer 19 is fixed on the turntable base 23 through the reducer mounting plate 20,
  • the rotating main shaft 22 is connected with the output shaft of the reducer 19 through the coupling 21, two pairs of tapered roller bearings 26 are placed in the turntable base 23 to support the rotating main shaft 22, and the bearing spacer 25 connects the two pairs of tapered roller bearings 26 Spaced apart, the lock nut 24 and the bearing end cover 27 are used to fix the two pairs of tapered roller bearings 26 , and the transition plate 28 is connected to the output end of the rotating main shaft 22 .
  • the blade clamp 6 is arranged on the transition plate 28, so that the blade clamp 6 can be rotated by the drive of the servo motor; the servo motor 18 has a built-in rotary encoder 17, which is used to measure the speed and realize rapid speed regulation; the control system is respectively connected with the servo motor The motor and the rotary encoder are electrically connected, and by controlling the servo motor and the rotary encoder, the blade 7 can be controlled to rotate at a precise angle.
  • the blade jig 6 is designed and manufactured according to the installation method of the blade 7 of the aero-engine on the aviation turbine disk, and according to the blade tenon part 29 using a "reverse mold” method.
  • the blade clamp 6 includes an upper pressing block 31 , a lower pressing block 33 , a left holding block 30 and a right holding block 32 , and the tenon part of the blade 6 is clamped by these four parts.
  • the three-dimensional moving lifting device includes an X-direction moving drive device 8, a Y-direction lifting drive device 11, a Z-direction moving drive device 9 and a lifting support rod 12, the X-direction moving drive device 8, the Y-direction lifting device
  • the driving device 11 and the Z-direction moving driving device 9 jointly realize the three-dimensional movement of the lifting support rod 12 .
  • the Z-direction moving drive device 9 is arranged on the base 10, the X-direction moving drive device 8 is connected with the Z-direction moving drive device 9, the Y-direction lifting drive device 11 is connected with the X-direction moving drive device 8, and the lifting support rod 12 is connected with the Y-direction moving drive device 8.
  • the elevating drive device 11 is connected, the Z-direction moving drive device 8 can drive the X-direction moving drive device 8 to move in the Z-direction, and the X-direction moving drive device 8 can drive the Y-direction elevating drive device 11 to move in the X-direction, and the Y-direction elevating drive device 11 can drive the lifting support rod 12 to move in the Y direction. In this way, with the cooperation of the three, the lifting support rod 12 can realize three-dimensional movement.
  • the Z-direction moving drive device 9 is a ball screw drive structure, including a servo motor 34 (ie, a first drive member), a reducer 35, a flat key 36, The first ball screw 37, the reducer mounting seat 38, the bearing end cover 39, the lock nut 40, the bearing seat 41, the radial ball bearing 42, the sleeve 43, the laser displacement sensor 44, the grating ruler 45, the screw nut pair 46.
  • a servo motor 34 ie, a first drive member
  • reducer 35 ie, a flat key 36
  • the lead screw nut seat 47, the lead screw nut pair 46 and the lead screw nut seat 47 are the first lead screw nut
  • the reducer mounting seat 38 and the bearing seat 41 are respectively fixed on both ends of the base 10
  • the servo motor 34 is fixed on the
  • the two ends of the first ball screw 37 are respectively installed in the bearing seat 41 through double radial ball bearings 42, wherein the double radial ball bearings 42 pass through the bearing end cover 39, the locking nut 40, the sleeve
  • the cylinder 43 is fixed, the lock nut 40 and the sleeve 43 are used to fix the inner ring of the radial ball bearing 42, the bearing end cover 39 is used to fix the outer ring of the radial ball bearing 42, and the bearing end cover 39 passes through the ball screw 37 is fixed on the bearing seat 41, one end of the first ball screw 37 is connected with the output shaft of the reducer 50 through the flat key 36, and the other end is fixed on the bearing seat 41, the ball screw 37 passes through the screw
  • the grating ruler 45 is composed of two parts: a scale grating 45-1 and a grating reading head 45-2, wherein the scale grating 45-1 is fixed on the base 10, and the grating reading head 45 -2 is installed at the bottom of the mounting plate 64, and the scale grating 45-1 cooperates with the grating reading head 45-2 to provide real-time feedback of the Z-direction moving position.
  • the X-direction moving drive device 8 has the same structure as the Z-direction moving drive device 9, both of which are ball screw drive structures. Compared with the Z-direction moving drive device 9, the X-direction moving drive device has an additional mounting plate 64, wherein the mounting plate 64 It is fixed on the screw nut seat 47 of the Z-direction moving drive device 9, while the servo motor (ie the second drive member), the second ball screw, the screw nut seat and the screw nut pair (ie, the X-direction moving drive device) The second screw nut), reducer and other components are arranged on the mounting plate 64, so that the X-direction moving drive device 8 can move freely in the Z-direction.
  • the installation method is the same as the Z-direction moving drive device 9. Repeat.
  • the guide rail 48 may also be provided on the base 10 along the Z direction, and the mounting plate 64 may be provided with a chute matching the guide rail 48 , so that the X-direction moving driving device 8 can slide on the guide rail 48 .
  • the Y-direction lift driving device 11 includes a servo motor 49 (ie, a third driving member), a reducer 50 , a reducer mounting seat 51 , a worm bearing seat 52 , a lifting base plate 53 , a lock Tight nut 54, screw bearing seat 55, radial ball bearing 56, bearing spacer 57, thrust bearing 58, turbine 59, worm 60, ball screw 61 (ie the third ball screw), screw nut pair 62 (ie the third screw nut), the lifting device housing 63, wherein the lifting base plate 53 is fixed on the screw nut seat 47 (ie the second screw nut) of the X-direction moving drive device 8, so that the lifting base plate 53 can be Free movement in the Z direction; the reducer mounting seat 51, the worm bearing seat 52, and the screw bearing seat 55 are all fixed on the lifting base plate 53, the reducer 50 is installed on the reducer mounting seat 51, and the input of the servo motor 49
  • a servo motor 49 ie,
  • the ball screw 61 is arranged along the Y direction, and one end is fixed on the screw bearing seat 55.
  • the ball screw The rod 61 passes through the screw nut pair 62 and is driven with it.
  • the lifting support rod 12 is connected with the screw nut pair 62 and slides in the lifting device housing 63; the turbine 59 is installed on the lifting base plate 53 and is respectively connected with the worm 60 and the ball.
  • the screw 61 is meshed, so that under the action of the servo motor 49, the worm 60 is driven to rotate, the worm 60 drives the turbine 59 to rotate, and the turbine 59 drives the ball screw 61 to rotate, so that the screw nut pair 62 moves along the Y direction , so as to realize the Y-direction movement of the lifting support rod 12, the thrust bearing 58, the bearing spacer 57, the radial ball bearing 56, and the locking nut 54 are sequentially installed on the lower end of the ball screw 61, and the radial ball bearing 56 and the thrust Half of the bearing 58 is fixed in the screw bearing seat 55, the radial ball bearing 56 is used to ensure the normal rotation of the ball screw 61, the thrust bearing 58 is used to ensure the normal rotation of the turbine 59, and the bearing spacer 57 is used to The radial ball bearing layer 56 is separated from the thrust bearing 58 .
  • the lock nut 54 is screwed with the ball screw 61 for fixing the inner ring of the radial ball
  • the flexible follow-up support head 13 Since the flexible follow-up support head 13 is connected with the lift support rod 12, the flexible follow-up support head 13 can also realize three-dimensional movement.
  • the flexible follow-up support head 13 can use any flexible follow-up support device in the prior art, generally including a plurality of balls, ball support rods, force sensors, springs and other components, the ball support rod and the spring are connected to form a flexible support , used to support the ball, the ball is connected with the ball support rod, the force sensor is connected with the spring, and is used to monitor the size of the support force in real time.
  • a flexible support used to support the ball
  • the ball is connected with the ball support rod
  • the force sensor is connected with the spring, and is used to monitor the size of the support force in real time.
  • multiple balls are in contact with the blade 7 to play a role of flexible support.
  • control cabinet 3 of the aero-engine blade ultrasonic rolling strengthening robot processing system of the present invention can also be replaced by a console, and a control device such as a computer or a PLC is placed on it to control the robot 1, the spindle turntable 5 ,
  • the coordinated control of the three-dimensional moving lifting device 100 realizes the precise ultrasonic rolling and strengthening processing of the blade 7 .
  • the ultrasonic rolling strengthening robot processing system for aero-engine blades provided by the embodiment of the present invention adopts a robot-assisted clamping ultrasonic rolling device, cooperates with a three-dimensional mobile lifting device and a flexible follow-up support head, and adjusts the robot, the spindle turntable and the three-dimensional mobile lifting and lowering
  • the device performs coordinated control to achieve precise ultrasonic rolling strengthening of aero-engine blades.
  • the advantages of the robot's high degree of freedom, strong accessibility and good precision are used to realize ultrasonic rolling strengthening along the normal direction of the surface of the aero-engine blade; on the other hand, the flexible follow-up support head can effectively solve the The deformation and flutter problems caused by the high-frequency and high-amplitude ultrasonic vibration rolling during the ultrasonic rolling strengthening process; the ultrasonic rolling strengthening can effectively reduce the surface roughness of the aero-engine blade, improve the hardness of the blade surface, and increase the surface of the blade to the inside of the blade.
  • the introduction of beneficial residual compressive stress is ultimately expected to improve the service life of aero-engines.
  • the present embodiment provides an ultrasonic rolling strengthening robot processing control method for an aero-engine blade, which at least includes:
  • Step S1 Provide an aero-engine blade ultrasonic rolling strengthening robot processing system as described in the first embodiment, so that the blade clamp 6 clamps the tenon part of the blade 7, so that the to-be-processed surface of the blade 7 faces the ultrasonic rolling strengthening
  • the device 4, the flexible follower support head 13 supports the opposite surface of the surface to be processed.
  • Step S2 According to the model of the blade, the "zigzag" processing trajectory of the ultrasonic rolling strengthening device is generated according to the equal section method.
  • the machining trajectory of the ultrasonic rolling strengthening device 4 is generated according to the equal-section method.
  • the equal-section method is a kind of machining trajectory planning method, that is, when generating the trajectory, a plurality of equidistant parallel planes are used. The intersection line with the blade is used as the machining trajectory.
  • the direction of the arrow in the figure is the processing trajectory of the ultrasonic strengthening device 4, which is "zigzag". The processing efficiency of the zigzag processing trajectory is higher.
  • the generated processing trajectory is input into the control system, and the control system controls the robot. 1.
  • the robot 1 drives the ultrasonic rolling strengthening device 4 to process the blade 7 along the generated processing track.
  • Step S3 generating a movement trajectory of the lifting support rod according to the processing trajectory of the ultrasonic rolling strengthening device.
  • the flexible follow-up support head 13 needs to support the blade 7 during processing, the flexible follow-up support head 13 needs to move along with the processing track of the ultrasonic rolling strengthening device 4, while the flexible follow-up support
  • the movement trajectory of the head 13 is determined by the movement of the lifting support rod 12. After the processing trajectory of the ultrasonic rolling strengthening device 4 is generated, the movement trajectory of the lifting support rod 12 can be calculated, and the movement trajectory is also input into the control system.
  • the control system controls the three-dimensional mobile lifting device, and then the three-dimensional mobile lifting device drives the lifting support rod 12 and the flexible follow-up support head 13 to move according to the generated movement trajectory.
  • Step S4 The control system controls the movement of the ultrasonic rolling and strengthening device and the lifting support rod according to the processing trajectory of the ultrasonic rolling strengthening device and the moving trajectory of the lifting support rod, so as to complete the strengthening processing of the blade surface to be processed.
  • control system controls the movement of the ultrasonic rolling strengthening device 4 and the lifting support rod 12 at the same time, and simultaneously controls the spindle rotary table 5 to rotate continuously, so that the cross-sectional contour line of the opposite surface of the blade 7 to the surface to be processed is the same as that of the lifting support rod 12.
  • the axis is kept vertical, the contact point between the ultrasonic rolling and strengthening device 4 and the surface to be processed of the blade 7 is on the axis of the lifting support rod, and the direction of the ultrasonic rolling and strengthening device 4 is always along the normal direction of the surface to be processed of the blade 7 .
  • the ultrasonic rolling strengthening processing control method of the aero-engine blade is introduced in detail.
  • the contour of the processed section 14 is divided into The pressure surface 15 of the cross-sectional contour and the suction surface 16 of the cross-sectional contour. If the pressure surface 15 of the processed section 14 of the blade 7 is subjected to ultrasonic rolling and strengthening processing, the flexible follower support head is supported on the suction surface 16 of the section outline.
  • the "zigzag" machining trajectory of the ultrasonic rolling strengthening device 4 is generated according to the equal section method according to the CAD model of the blade, as shown in Fig. 10;
  • the control system controls the ultrasonic rolling strengthening device 4 and the flexible follow-up support head 13 to move according to the processing trajectory and the moving trajectory respectively, so as to complete the strengthening processing of the to-be-processed surface of the blade 7 .
  • the arrow direction in the figure is the machining direction of the machining surface 14.
  • the blade 7 keeps the suction surface 16 perpendicular to the axis of the lifting support rod by continuously rotating, and the ultrasonic rolling strengthening device 4.
  • the contact point with the pressure surface 15 is on the axis of the lifting support rod 12, and the direction of the ultrasonic rolling strengthening device 4 is always along the normal direction of the blade surface where the contact point is located to ensure that the ultrasonic rolling strengthening device and the blade surface are always vertical.
  • the ultrasonic rolling energy is introduced into the blade 7 of the aero-engine to the maximum extent.
  • the ultrasonic rolling strengthening robot processing control method for aero-engine blades realizes precise ultrasonic rolling strengthening of aero-engine blades by coordinating the control of the robot, the spindle turntable and the three-dimensional mobile lifting device.

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  • Crystallography & Structural Chemistry (AREA)
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Abstract

本发明涉及一种航空发动机叶片超声滚压强化机器人加工系统及控制方法，该超声滚压强化机器人加工系统包括：机器人，其上固定有一超声滚压强化装置并带动该超声滚压强化装置移动；底座，其上安装有主轴转台和三维移动升降装置，所述主轴转台上设置有可旋转的叶片夹具，三维移动升降装置上则固定一柔性随动支撑头；控制系统，分别与所述机器人、主轴转台和三维移动升降装置电连接或通讯连接。本发明的航空发动机叶片超声滚压强化机器人加工系统及控制方法，采用机器人辅助夹持超声滚压装置，配合三维移动升降装置以及柔性随动支撑头，并通过对三者进行协同控制，实现航空发动机叶片的精确超声滚压强化。

Description

航空发动机叶片超声滚压强化机器人加工系统及控制方法 技术领域
本发明涉及航空发动机加工领域，更具体地涉及一种航空发动机叶片超声滚压强化机器人加工系统及控制方法。
背景技术
叶片作为航空发动机中最核心的部件之一，长期服役于高温高压高速等极端环境下，是典型的限寿命部件。超声滚压强化加工是一种将超声喷丸与低塑性抛光相结合的新型表面改性技术，通过超声辅助振动使球型工具头高频高幅撞击金属表面，从而使被加工表面产生一定的塑性变形层，进而降低金属表面粗糙度、提高金属表层硬度以及对材料内部引入有益残余压应力，最终达到提高材料使用寿命的目的。研究表明，超声滚压强化技术对于提升航空发动机叶片的服役寿命具有较大的潜在应用价值。目前，超声滚压强化加工的研究对象大多是平板或圆棒等试验件，强化加工设备大多是根据数控车床或铣床通过更换刀具的方式进行改装而成。航空发动机叶片具有复杂曲面、薄壁特征，传统的数控加工方式难以实现航空发动机叶片精确有效的超声滚压强化。
随着工业机器人技术的发展，关节机器人以其较高的自由度和可达性、良好的精度，在加工复杂曲面工件方面的应用具有较大的优势。机器人通过夹持强化工具，可以实现沿叶片表面法向进行强化加工。然而，在对航空发动机叶片的表面强化研究中发现，一方面，具有高幅高频超声振动的强化工具作用于叶片上会引起叶片的颤振，另一方面，强化工具对叶片施加的冲击力会造成叶片较大的形变，这将严重影响叶片超声滚压强化的表面改性效果和强化加工的几何精度。
因此，在对航空发动机叶片进行超声滚压强化加工时，如何设置相应的辅助支撑系统，以使施加于叶片上的力尽可能相同，来抵消叶片因单侧受力过大而造成形变，同时减小叶片在超声滚压强化加工过程中产生的颤振是本领域技术人员亟待解决的技术问题。
发明内容
本发明提供一种航空发动机叶片超声滚压强化机器人加工系统及控制方法，通过控制超声滚压强化装置和柔性随动支撑头施加在航空发动机叶片表面的力尽可能相同，以抑制航空发动机叶片在超声滚压强化过程中产生的形变和颤振，最终实现对航空发动机叶片精确的超声滚压强化加工。
本发明一方面提供一种航空发动机叶片超声滚压强化机器人加工系统，包括：
机器人，其上固定有一超声滚压强化装置并带动该超声滚压强化装置移动；
底座，其上安装有主轴转台和三维移动升降装置，所述主轴转台上设置有可旋转的叶片夹具，三维移动升降装置上则固定一柔性随动支撑头；
控制系统，分别与所述机器人、主轴转台和三维移动升降装置电连接或通讯连接。
进一步地，所述机器人为五轴或六轴机器人。
进一步地，所述主轴转台包括伺服电机、减速器、转台基座、旋转主轴、过渡盘和旋转编码器，所述减速器固定在所述转台基座上，所述伺服电机与所述减速器的输入轴相连，所述旋转主轴与所述减速器的输出轴相连，所述过渡盘与旋转主轴相连，所述叶片夹具设于所述过渡盘上，所述旋转编码器内置于所述伺服电机中，所述控制系统分别与所述伺服电机、旋转编码器电连接。
进一步地，所述三维移动升降装置包括升降支撑杆、X向移动驱动装置、Y向升降驱动装置、Z向移动驱动装置；所述Z向移动驱动装置设于所述底座上，所述X向移动驱动装置与所述Z向移动驱动装置相连，所述Y向移动驱动装置与所述X向移动驱动装置相连，所述升降支撑杆与所述柔性随动支撑头相连。
进一步地，所述Z向移动驱动装置包括第一驱动件、第一滚珠丝杠、第一丝杠螺母，所述滚珠丝杠沿Z向设置在所述底座上，所述第一驱动件与所述滚珠丝杠相连，所述滚珠丝杠与穿过所述第一丝杠螺母且与所述第一丝杠螺母传动配合。
进一步地，所述X向移动驱动装置包括安装板、第二驱动件、第二滚珠丝杠、第二丝杠螺母，所述安装板固定在所述第一丝杠螺母上，所述第二滚珠丝杠沿X向设置在所述安装板上，所述第二驱动件与所述第二滚珠丝杠相连，所述第二滚珠丝杠与穿过所述第二丝杠螺母且与所述第二丝杠螺母传动配合。
进一步地，所述Y向升降驱动装置包括升降底板以及设置在所述升降底板上的第三驱动件、涡轮、蜗杆、第三滚珠丝杠和第三丝杠螺母，所述第三滚珠丝杠沿Y向设置，所述第三驱动件与所述蜗杆相连，所述涡轮分别与所述蜗杆和第三滚珠丝杠相啮合，第三滚珠丝杠穿过所述第三丝杠螺母且与所述第三丝杠螺母传动配合，所述升降支撑杆与所述第三丝杠螺母相连。
进一步地，所述叶片夹具包括上压块、下压块、左抱块和右抱块。
进一步地，还包括控制柜，所述控制系统设于所述控制柜中。
本发明另一方面提供一种航空发动机叶片超声滚压强化机器人加工控制方法，至少包括：
步骤S1：提供一种如上所述的航空发动机叶片超声滚压强化机器人加工系统，使所述叶片夹具夹住叶片的榫根部位，并使叶片的待加工面朝向所述超声滚压强化装置，所述柔性随动支撑头则支撑所述待加工面的对立面；
步骤S2：根据叶片的模型按照等截面法生成超声滚压强化装置的“之”字形加工轨迹；
步骤S3：根据所述超声滚压强化装置的加工轨迹生成升降支撑杆的移动轨迹；
步骤S4：控制系统根据所述超声滚压强化装置的加工轨迹和所述升降支撑杆的移动轨迹控制超声滚压强化装置和升降支撑杆的移动，以完成叶片待加工面的强化加工。
进一步地，所述步骤S4还包括：
控制系统控制所述主轴转台不断旋转，以使所述叶片的待加工面的对立面的截面轮廓线与所述升降支撑杆的轴线保持垂直、所述超声滚压强化装置与所述叶片的待加工面的接触点在所述升降支撑杆的轴线上、所述超声滚压强化装置的方向始终沿所述叶片的待加工面的法线方向。
本发明的航空发动机叶片超声滚压强化机器人加工系统及控制方法，采用机器人辅助夹持超声滚压装置，配合三维移动升降装置以及柔性随动支撑头，并通过对机器人、主轴转台和三维移动升降装置进行协同控制，实现航空发动机叶片的精确超声滚压强化。一方面，利用机器人自由度高、可达性强、精度好的优点，实现沿航空发动机叶片表面法线方向进行超声滚压强化；另一方面，通过柔性随动支撑头有效解决航空发动机叶片在超声滚压强化过程中由于高频高幅超声振动滚压强化产生的形变和颤振问题；经过超声滚压强化能够有效降低航空发动机叶片表面的粗糙度、提高叶片表层的硬度，并向叶片内部引入有益的残余压应力，最终有望提高航空发动机服役寿命。
附图说明
图1为本发明一实施例提供的航空发动机叶片超声滚压强化机器人加工系统的结构示意图；
图2为本发明一实施例提供的主轴转台的结构示意图；
图3为本发明一实施例提供的叶片夹具的结构示意图；
图4为本发明一实施例提供的三维移动升降装置的俯视图；
图5为图4的A-A剖视图；
图6为图5的I部放大图；
图7为图5的II部放大图；
图8为图5的III部放大图；
图9为本发明另一实施例提供的航空发动机叶片超声滚压强化机器人加工控制方法的流程示意图；
图10为本发明另一实施例提供的航空发动机叶片的加工轨迹示意图；
图11为本发明另一实施例提供的航空发动机叶片的加工过程示意图。
具体实施方式
下面结合附图，给出本发明的较佳实施例，并予以详细描述。
应当注意的是，为了便于描述，本发明定义了如图1所示的坐标系O-XYZ，ω为绕Z轴旋转的方向。
实施例一
如图1所示，本发明实施例提供一种航空发动机叶片超声滚压强化机器人加工系统，包括机器人1、底座10和控制柜3。其中，机器人1上固定有一超声滚压强化装置4并带动该超声滚压强化装置4移动；底座10上安装有主轴转台5和三维移动升降装置100，所述主轴转台5上设置有叶片夹具6，用于夹持待加工的航空发动机叶片7，该夹具6可以绕着Z方向进行旋转，从而带动叶片7绕着Z方向旋转；三维移动升降装置100上则固定一柔性随动支撑头13并带动该支撑头13完成X、Y、Z三个方向的移动；控制柜3中设置控制系统，所述控制系统分别与机器人1、主轴转台5和三维移动升降装置100电连接或通讯连接，三者协同运动，图1中的虚线表示电连接或通讯连接。
在加工过程中，超声滚压强化装置4位于柔性随动支撑头13的上方，且两者分别位于叶片7的上下两侧，柔性随动支撑头13对叶片起支撑作用，超声滚压强化装置4则用于对叶片7表面进行超声滚压强化加工；控制柜3中的控制系统则控制机器人1的运动——即控制超声滚压强化装置4的运动轨迹、主轴转台5的旋转——即叶片7的旋转和三维移动升降装置100的移动——即柔性随动支撑头13的移动，通过这三部分的配合，完成对叶片7表面的超声滚压强化加工。
所述机器人1可以为多自由度的关节机器人，例如为五轴或六轴的关节机器人，以满足对叶片7的曲面表面的加工要求。
超声滚压强化装置4可以通过连接装置2与机器人1相连，并固定在机器人1的末端执行器上，这样超声滚压强化装置4即可在机器人1的控制下沿叶片7表面的法线方向进行强化加工。
具体地，连接装置2可以为现有技术中的常规工具连接装置，例如法兰，螺栓、卡扣等等，本发明对此不做限定。
超声滚压强化装置4可以采用现有技术中的任意一种强化装置，一般包括依次相连的超声发生器、力传感器、弹簧、超声换能器、超声变幅杆、滚压小球以及必要的固定装置，超声换能器将超声发生器的高频电信号转换为振动信号，经过超声变幅杆的传递和放大，最终通过滚压小球作用到被加工工件表面，从而完成超声滚压强化加工。
如图2所示，主轴转台5可以包括旋转编码器17、伺服电机18、减速器19、减速器安装板20、联轴器21、旋转主轴22、转台基座23、锁紧螺母24、轴承隔环25、圆锥滚子轴承26、轴承端盖27、过渡盘28，其中，伺服电机18与减速器19的输入轴相连，减速器19通过减速器安装板20固定于转台基座23上，旋转主轴22通过联轴器21与减速器19的输出轴相连，两对圆锥滚子轴承26置于转台基座23内用以支撑旋转主轴22，轴承隔环25将两对圆锥滚子轴承26隔开，锁紧螺母24与轴承端盖27用于固定两对圆锥滚子轴承26，过渡盘28与旋转主轴22输出端相连。叶片夹具6设置于过渡盘28上，这样，通过伺服电机的驱动，可以使叶片夹具6发生旋转；伺服电机18内置旋转编码器17，用于测量转速并实现快速调速；控制系统分别与伺服电机和旋转编码器电连接，通过对伺服电机和旋转编码器进行控制，从而控制叶片7实现精确角度的旋转。
如图3所示，叶片夹具6是按照航空发动机的叶片7在航空涡轮盘上的安装方式，根据叶片榫根部位29采用“倒模”的方式进行设计并制造。具体地，叶片夹具6包括上压块31、下压块33、左抱块30和右抱块32，通过这四部分对叶片6榫根部位进行夹持。
如图1和图4所示，三维移动升降装置包括X向移动驱动装置8、Y向升降驱动装置11、Z向移动驱动装置9和升降支撑杆12，X向移动驱动装置8、Y向升降驱动装置11和Z向移动驱动装置9共同实现升降支撑杆12的三维运动。Z向移动驱动装置9设于底座10上，X向移动驱动装置8与Z向移动驱动装置9相连，Y向升降驱动装置11则与X向移动驱动装置8相连，升降支撑杆12与Y向升降驱动装置11相连，Z向移动驱动装置8可以带动X向移动驱动装置8进行Z向移动，而X向移动驱动装置8可以带动Y向升降驱动装置11进行X向移动，Y向升降驱动装置11则可以带动升降支撑杆12进行Y向移动，这样，在三者的配合下，升降支撑杆12可以实现三维移动。
具体地，如图4-图7所示，Z向移动驱动装置9为滚珠丝杠传动结构，包括沿Z向设置的伺服电机34(即第一驱动件)、减速器35、平键36、第一滚珠丝杠37、减速器安装座38、轴承端盖39、锁紧螺母40、轴承座41、径向滚珠轴承42、套筒43、激光位移传感器44、光栅尺45、丝杠螺母副46、丝杠螺母座47，丝杠螺母副46和丝杠螺母座47即为第一丝杠螺母，减速器 安装座38和轴承座41分别固定在底座10的两端，伺服电机34固定在减速器50的输出端，第一滚珠丝杠37的两端分别通过双径向滚珠轴承42安装于轴承座41中，其中双径向滚珠轴承42通过轴承端盖39、锁紧螺母40、套筒43进行固定，锁紧螺母40和套筒43用于固定径向滚珠轴承42的内圈，轴承端盖39用于固定径向滚珠轴承42的外圈，轴承端盖39穿过滚珠丝杠37固定在轴承座41上，第一滚珠丝杠37的一端通过平键36与减速器50的输出轴相连，另一端则固定在轴承座41上，滚珠丝杠37穿过丝杠螺母座47，两者形成丝杠螺母副36，这样可以将滚珠丝杠37的转动转化为丝杠螺母座47的移动，从而使丝杠螺母座47可以在Z向自由运动，激光位移传感器44固定在底座10上用于检测Z向移动驱动装置的直线位移，光栅尺45由标尺光栅45-1和光栅读数头45-2两部分组成，其中标尺光栅45-1固定于底座10上，光栅读数头45-2安装于安装板64的底部，标尺光栅45-1与光栅读数头45-2配合实时反馈Z向移动位置。
X向移动驱动装置8与Z向移动驱动装置9结构相同，均为滚珠丝杠传动结构，与Z向移动驱动装置9相比，X向移动驱动装置多了安装板64，其中，安装板64固定在Z向移动驱动装置9的丝杠螺母座47上，而X向移动驱动装置的伺服电机(即第二驱动件)、第二滚珠丝杠、丝杠螺母座和丝杠螺母副(即第二丝杠螺母)、减速器等其他部件则设置在安装板64上，从而使X向移动驱动装置8能够在Z向自由移动，安装方式与Z向移动驱动装置9相同，此处不再赘述。
具体地，还可以在底座10上沿Z向设置导轨48，安装板64上则设置与导轨48相配合的滑槽，从而使X向移动驱动装置8可以在导轨48上滑动。
如图4、图5和图8所示，Y向升降驱动装置11包括伺服电机49(即第三驱动件)、减速器50、减速器安装座51、蜗杆轴承座52、升降底板53、锁紧螺母54、丝杠轴承座55、径向滚珠轴承56、轴承隔环57、止推轴承58、涡轮59、蜗杆60、滚珠丝杠61(即第三滚珠丝杠)、丝杠螺母副62(即第三丝杠螺母)、升降装置外壳63，其中，升降底板53固定在X向移动驱动装置8的丝杆螺母座47(即第二丝杠螺母)上，从而使升降底板53可以在Z向自由移动；减速器安装座51、蜗杆轴承座52、丝杠轴承座55均固定在升降底板53上，减速器50安装在减速器安装座51上，伺服电机49与减速器50的 输入轴相连，蜗杆60的两端均安装在轴承座52上，且其中一端与减速器50的输出轴相连，滚珠丝杠61沿Y向设置，且一端固定在丝杠轴承座55上，滚珠丝杠61穿过丝杠螺母副62且与其传动配合，升降支撑杆12与丝杠螺母副62相连并且在升降装置外壳63内滑动；涡轮59则安装在升降底板53上且分别与蜗杆60和滚珠丝杆61相啮合，这样，在伺服电机49的作用下，带动蜗杆60转动，蜗杆60再带动涡轮59转动，涡轮59再带动滚珠丝杠61转动，从而使丝杠螺母副62沿Y向运动，从而实现升降支撑杆12的Y向移动，止推轴承58、轴承隔环57、径向滚珠轴承56、锁紧螺母54依次安装在滚珠丝杠61的下端，径向滚珠轴承56和止推轴承58的半部分固定在丝杠轴承座55内，径向滚珠轴承56用于保证滚珠丝杠61的正常转动，止推轴承58用于保证涡轮59的正常转动，轴承隔环57用于将径向滚珠轴承层56和止推轴承58隔开，锁紧螺母54与滚珠丝杠61螺纹连接用于固定径向滚珠轴承61的内圈，在升降装置外壳63固定在升降底板53上。
由于柔性随动支撑头13与升降支撑杆12相连，因此，柔性随动支撑头13也可以实现三维移动。
柔性随动支撑头13可以采用现有技术中的任意一种柔性随动支撑装置，一般包括多个滚珠、滚珠支撑杆、力传感器、弹簧等零部件，滚珠支撑杆和弹簧相连形成柔性支撑件，用于支撑滚珠，滚珠与滚珠支撑杆相连，力传感器与弹簧相连，用于实时监控支撑力的大小，在使用时，多个滚珠与叶片7接触，从而起到柔性支撑的作用。
在一个可行的实施方式中，本发明的航空发动机叶片超声滚压强化机器人加工系统的控制柜3还可由控制台替换，计算机或PLC等控制装置置于其上，以对机器人1、主轴转台5、三维移动升降装置100的协调控制，实现对叶片7的精确超声滚压强化加工。
本发明实施例提供的航空发动机叶片超声滚压强化机器人加工系统，采用机器人辅助夹持超声滚压装置，配合三维移动升降装置以及柔性随动支撑头，并通过对机器人、主轴转台和三维移动升降装置进行协同控制，实现航空发动机叶片的精确超声滚压强化。一方面，利用机器人自由度高、可达性强、精度好的优点，实现沿航空发动机叶片表面法线方向进行超声滚压强化；另一方面，通过柔性随动支撑头有效解决航空发动机叶片在超声滚压强 化过程中由于高频高幅超声振动滚压强化产生的形变和颤振问题；经过超声滚压强化能够有效降低航空发动机叶片表面的粗糙度、提高叶片表层的硬度，并向叶片内部引入有益的残余压应力，最终有望提高航空发动机服役寿命。
实施例二
如图9所示，本实施例提供一种航空发动机叶片超声滚压强化机器人加工控制方法，其至少包括：
步骤S1：提供一种如实施例一中所述的航空发动机叶片超声滚压强化机器人加工系统，使叶片夹具6夹住叶片7的榫根部位，使叶片7的待加工面朝向超声滚压强化装置4，柔性随动支撑头13则支撑所述待加工面的对立面。
步骤S2：根据叶片的模型按照等截面法生成超声滚压强化装置的“之”字形加工轨迹。
具体地，根据叶片7的CAD模型按照等截面法生成超声滚压强化装置4的加工轨迹，等截面法是加工轨迹规划方法的一种，即在生成轨迹的时候用多个等距的平行平面与叶片的交线作为加工轨迹。如图10所示，图中箭头方向即为超声强化装置4的加工轨迹，呈“之字形”，之字形加工轨迹的加工效率更高，生成的加工轨迹输入控制系统中，由控制系统控制机器人1，再由机器人1带动超声滚压强化装置4沿着生成的加工轨迹对叶片7进行加工。
步骤S3：根据所述超声滚压强化装置的加工轨迹生成升降支撑杆的移动轨迹。
具体地，由于柔性随动支撑头13在加工过程中需要对叶片7起到支撑作用，因此，柔性随动支撑头13需要跟随超声滚压强化装置4的加工轨迹一起移动，而柔性随动支撑头13的移动轨迹是由升降支撑杆12的移动确定的，超声滚压强化装置4的加工轨迹生成后，即可计算出升降支撑杆12的移动轨迹，该移动轨迹也输入控制系统中，由控制系统控制三维移动升降装置，再由三维移动升降装置带动升降支撑杆12和柔性随动支撑头13按照生成的移动轨迹移动。
步骤S4：控制系统根据所述超声滚压强化装置的加工轨迹和所述升降支撑杆的移动轨迹控制超声滚压强化装置和升降支撑杆的移动，以完成叶片待加工面的强化加工。
具体地，控制系统同时控制超声滚压强化装置4和升降支撑杆12的移动，同时控制主轴旋转台5不断旋转，以使叶片7的待加工面的对立面的截面轮廓线与升降支撑杆12的轴线保持垂直、超声滚压强化装置4与叶片7的待加工面的接触点在升降支撑杆的轴线上、超声滚压强化装置4的方向始终沿叶片7的待加工面的法线方向。
如图11所示，以叶片7某一被加工截面14为例具体介绍该航空发动机叶片超声滚压强化加工控制方法，将该被加工截面14的轮廓线按照叶片型面的命名方式，分为截面轮廓线的压力面15和截面轮廓线的吸力面16。若对叶片7的被加工截面14的压力面15进行超声滚压强化加工，则柔性随动支撑头支撑在截面轮廓线的吸力面16。首先，根据叶片CAD模型按照等截面法生成超声滚压强化装置4的“之”字形加工轨迹，如图10所示；然后根据该加工轨迹生成柔性随动支撑头13和升降支撑杆12的移动轨迹；控制系统控制超声滚压强化装置4和柔性随动支撑头13分别按照加工轨迹和移动轨迹移动，从而完成对叶片7待加工面的强化加工。
如图11所示，图中箭头方向为对被加工面14进行加工的加工方向，在加工过程中，叶片7通过不断旋转使吸力面16与升降支撑杆的轴线保持垂直，超声滚压强化装置4与压力面15的接触点在升降支撑杆12的轴线上，超声滚压强化装置4的方向始终沿接触点所在叶片表面的法线方向，确保超声滚压强化装置与叶片表面始终保持垂直，使得超声滚压能量最大限度引入到航空发动机的叶片7中。
本实施例提供的航空发动机叶片超声滚压强化机器人加工控制方法通过对机器人、主轴转台和三维移动升降装置进行协同控制，实现了航空发动机叶片的精确超声滚压强化。
以上所述的，仅为本发明的较佳实施例，并非用以限定本发明的范围，本发明的上述实施例还可以做出各种变化。即凡是依据本发明申请的权利要求书及说明书内容所作的简单、等效变化与修饰，皆落入本发明专利的权利要求保护范围。本发明未详尽描述的均为常规技术内容。

Claims (11)

  1. 一种航空发动机叶片超声滚压强化机器人加工系统，其特征在于，包括：
    机器人，其上固定有一超声滚压强化装置并带动该超声滚压强化装置移动；
    底座，其上安装有主轴转台和三维移动升降装置，所述主轴转台上设置有可旋转的叶片夹具，三维移动升降装置上则固定一柔性随动支撑头；
    控制系统，分别与所述机器人、主轴转台和三维移动升降装置电连接或通讯连接。
  2. 根据权利要求1所述的航空发动机叶片超声滚压强化机器人加工系统，其特征在于，所述机器人为五轴或六轴机器人。
  3. 根据权利要求1所述的航空发动机叶片超声滚压强化机器人加工系统，其特征在于，所述主轴转台包括伺服电机、减速器、转台基座、旋转主轴、过渡盘和旋转编码器，所述减速器固定在所述转台基座上，所述伺服电机与所述减速器的输入轴相连，所述旋转主轴与所述减速器的输出轴相连，所述过渡盘与旋转主轴相连，所述叶片夹具设于所述过渡盘上，所述旋转编码器内置于所述伺服电机中，所述控制系统分别与所述伺服电机、旋转编码器电连接。
  4. 根据权利要求1所述的航空发动机叶片超声滚压强化机器人加工系统，其特征在于，所述三维移动升降装置包括升降支撑杆、X向移动驱动装置、Y向升降驱动装置、Z向移动驱动装置；所述Z向移动驱动装置设于所述底座上，所述X向移动驱动装置与所述Z向移动驱动装置相连，所述Y向移动驱动装置与所述X向移动驱动装置相连，所述升降支撑杆与所述柔性随动支撑头相连。
  5. 根据权利要求4所述的航空发动机叶片超声滚压强化机器人加工系统，其特征在于，所述Z向移动驱动装置包括第一驱动件、第一滚珠丝杠、第一丝杠螺母，所述第一滚珠丝杠沿Z向设置在所述底座上，所述第一驱动件与所述第一滚珠丝杠相连，所述第一滚珠丝杠与穿过所述第一丝杠螺母且与所述第一丝杠螺母传动配合。
  6. 根据权利要求5所述的航空发动机叶片超声滚压强化机器人加工系统，其特征在于，所述X向移动驱动装置包括安装板、第二驱动件、第二滚珠丝杠、第二丝杠螺母，所述安装板固定在所述第一丝杠螺母上，所述第二滚珠丝杠沿X向设置在所述安装板上，所述第二驱动件与所述第二滚珠丝杠相连，所述第二滚珠丝杠与穿过所述第二丝杠螺母且与所述第二丝杠螺母传动配合。
  7. 根据权利要求6所述的航空发动机叶片超声滚压强化机器人加工系统， 其特征在于，所述Y向升降驱动装置包括升降底板以及设置在所述升降底板上的第三驱动件、涡轮、蜗杆、第三滚珠丝杠和第三丝杠螺母，所述第三滚珠丝杠沿Y向设置，所述第三驱动件与所述蜗杆相连，所述涡轮分别与所述蜗杆和第三滚珠丝杠相啮合，第三滚珠丝杠穿过所述第三丝杠螺母且与所述第三丝杠螺母传动配合，所述升降支撑杆与所述第三丝杠螺母相连。
  8. 根据权利要求1所述的航空发动机叶片超声滚压强化机器人加工系统，其特征在于，所述叶片夹具包括上压块、下压块、左抱块和右抱块。
  9. 根据权利要求1所述的航空发动机叶片超声滚压强化机器人加工系统，其特征在于，还包括控制柜，所述控制系统设于所述控制柜中。
  10. 一种航空发动机叶片超声滚压强化机器人加工控制方法，其特征在于，至少包括：
    步骤S1：提供一种如权利要求1-9任一项所述的航空发动机叶片超声滚压强化机器人加工系统，使所述叶片夹具夹住叶片的榫根部位，并使叶片的待加工面朝向所述超声滚压强化装置，所述柔性随动支撑头则支撑所述待加工面的对立面；
    步骤S2：根据叶片的模型按照等截面法生成超声滚压强化装置的“之”字形加工轨迹；
    步骤S3：根据所述超声滚压强化装置的加工轨迹生成升降支撑杆的移动轨迹；
    步骤S4：控制系统根据所述超声滚压强化装置的加工轨迹和所述升降支撑杆的移动轨迹控制超声滚压强化装置和升降支撑杆的移动，以完成叶片待加工面的强化加工。
  11. 根据权利要求10所述的航空发动机叶片超声滚压强化机器人加工控制方法，其特征在于，所述步骤S4还包括：
    控制系统控制所述主轴转台不断旋转，以使所述叶片的待加工面的对立面的截面轮廓线与所述升降支撑杆的轴线保持垂直、所述超声滚压强化装置与所述叶片的待加工面的接触点在所述升降支撑杆的轴线上、所述超声滚压强化装置的方向始终沿所述叶片的待加工面的法线方向。
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