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Smoothness-oriented path optimization for robotic milling processes

Science China(Technological Sciences) 2020年第9期63卷 1751-1763页

作者： PENG JingFu ding Ye ZhanG Gang ding han State Key Laboratory of Mechanical System and Vibration Shanghai Jiao Tong UniversityShanghai200240China HUST-Wuxi Research Institute Wuxi214174China

Industrial robots are increasingly used for five-axis machining operations, where the rotation of the end effector along the toolaxis direction is functionally redundant. This functional redundancy should be carefully resolved when planning the robot path according to the tool path generated by a computer-aided manufacturing(CAM) system. Improper planning of the redundancy may cause drastic variations of the joint motions, which could significantly decrease the machining efficiency as well as the machining accuracy. To tackle this problem, this paper presents a new optimization-based methodology to globally resolve the functional redundancy for the robotic milling process. Firstly, a global performance index concerning the smoothness of the robot path at the joint acceleration level is proposed. By minimizing the smoothness performance index while considering the avoidance of joint limits and the singularity and the constraint of the stiffness performance, the resolution of the redundancy is formulated as a constrained optimization problem. To efficiently solve the problem, the sequential linearization programming method is employed to improve the initial solution provided by the conventional graph-based method. Then, simulations for a given tool path are presented. Compared with the graph-based method, the proposed method can generate a smoother robot path in which a significant reduction of the magnitude of the maximum joint acceleration is obtained, resulting in a smoother tool-tip feedrate profile. Finally, the experiment on the robotic milling system is also presented. The results show that the optimized robot path of the proposed method obtains better surface quality and higher machining efficiency, which verifies the effectiveness of the proposed method.

关键词： robot milling functional redundancy path optimization smoothness sequential linear programming

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Parameter estimation for multirate multi-input systems using auxiliary model and multi-innovation

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Journal of Systems Engineering and Electronics 2010年第6期21卷 1079-1083页

作者： Lili han Feng ding School of IoT Engineering Jiangnan University Wuxi 214122 E R. China

The multirate multi-input systems have different updating periods and sampling periods such that the conventional identification algorithms cannot be used to identify such multirate systems. By using the auxiliary model identification idea, the multiinnovation stochastic gradient algorithm is developed to estimate the parameters of multirate systems. Finally, an illustrative example is given to verify the effectiveness of the proposed algorithm.

关键词： parameter estimation multirate systems multiinnovation auxiliary model.

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Response Sensitivity Analysis of the Dynamic Milling Process Based on the Numerical Integration Method

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Chinese Journal of Mechanical Engineering 2012年第5期25卷 940-946页

作者： ding Ye ZHU Limin ZhanG Xiaojian ding han State Key Laboratory of Mechanical System and Vibration Shanghai Jiao Tong University Shanghai 200240 China State Key Laboratory of Digital Manufacturing Equipment and Technology Huazhong University of Science and Technology Wuhan 430074 China

As one of the bases of gradient-based optimization algorithms, sensitivity analysis is usually required to calculate the derivatives of the system response with respect to the machining parameters. The most widely used approaches for sensitivity analysis are based on time-consuming numerical methods, such as finite difference methods. This paper presents a semi-analytical method for calculation of the sensitivity of the stability boundary in milling. After transforming the delay-differential equation with time-periodic coefficients governing the dynamic milling process into the integral form, the Floquet transition matrix is constructed by using the numerical integration method. Then, the analytical expressions of derivatives of the Floquet transition matrix with respect to the machining parameters are obtained. Thereafter, the classical analytical expression of the sensitivity of matrix eigenvalues is employed to calculate the sensitivity of the stability lobe diagram. The two-degree-of-freedom milling example illustrates the accuracy and efficiency of the proposed method. Compared with the existing methods, the unique merit of the proposed method is that it can be used for analytically computing the sensitivity of the stability boundary in milling, without employing any finite difference methods. Therefore, the high accuracy and high efficiency are both achieved. The proposed method can serve as an effective tool for machining parameter optimization and uncertainty analysis in high-speed milling.

关键词： milling stability sensitivity of the stability boundary numerical integration method

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Climbing robots for manufacturing

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National Science Review 2023年第5期10卷 59-81页

作者： Bo Tao Zeyu Gong han ding State Key Laboratory of Digital Manufacturing Equipment and Technology School of Mechanical Science and EngineeringHuazhong University of Science and Technology

Robotized intelligent manufacturing is a growing trend in the manufacturing of large and complex components in aviation,aerospace,marine engineering and other *** their expansive workspaces and flexible deployment,climbing manufacturing robots can create a revolutionary manufacturing paradigm for large and complex *** paper defines the climbing manufacturing robot based on the application status of climbing robots and then analyzes four key technical re quirements:adhesion,locomotion,localization and ***,the current research status of climbing robots in these four areas is classified and reviewed,along with a clarification of the research frontiers and trends in each area,and the applicability of the relevant research to manufacturing-oriented climbing robotic systems is ***,by concluding the development trends of robotized intelligent manufacturing equipment in terms of manufacturing dimension and scale,environmental adaptability and cluster collaboration capability,we clarify the major challenges for climbing manufacturing robots in terms of adhesion principles,motion mechanisms,positioning technology and control methods,and propose future research directions in these fields.

关键词： climbing manufacturing robot climbing robot robotized intelligent manufacturing

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Cross-coupled controller design for triaxial motion systems based on second-order contour error estimation

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Science China(Technological Sciences) 2015年第7期58卷 1209-1217页

作者： ZHAO Huan ZHU LiMin ding han State Key Laboratory of Digital Manufacturing Equipment and Technology Huazhong University of Science and Technology State Key Laboratory of Mechanical System and Vibration Shanghai Jiao Tong University

The cross-coupled control(CCC)is widely applied to reduce contour errors in contour-following *** such situation,the contour error estimation plays an important ***,the linear or second-order estimation approach is adopted for biaxial motion systems,whereas only linear approach is available for triaxial *** this paper,the second-order contour error estimation,which was presented in our previous work,is utilized to determine the variable CCC gains for motion control systems with three *** integrated stable motion control strategy,which combines the feedforward,feedback and CCC controllers,is developed for multiaxis CNC *** results on a triaxial platform indicate that the CCC scheme based on the second-order estimation,compared with that based on the linear one,significantly reduces the contour error even in the conditions of high tracking feedrate and small radius of curvature.

关键词： cross-coupled controller contour error cross-coupled gains triaxial motion system computer numerical control (CNC)

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Real time tool path smoothing of short linear commands for robot manipulator by constructing asymmetrical Pythagoran-hodograph(PH)splines

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Science China(Technological Sciences) 2023年第3期66卷 674-688页

作者： YANG JiXiang ADILI Abulikemu ding han School of Mechanical Science and Engineering State Key Laboratory of Digital Manufacturing Equipment and TechnologyHuazhong University of Science and TechnologyWuhan 430074China

Tool path smoothing of linear commands is important to guarantee the high-order motion continuity of multi-axis motion control *** existing local tool path smoothing methods mainly construct symmetrical splines at transition corners of linear *** the linear segments are short,the symmetrical splines must be shrunk to avoid overlapping,which gives rise to relatively high curvature and low machining *** paper proposes a tool-path smoothing algorithm for serial industrial robots with 6 rotary(6R)joints by constructing asymmetrical Pythagorean-hodograph(PH)***,symmetrical PH splines are initially constructed at transition corners to realize the third-order differential continuity of tool path position and tool *** tip position smoothing errors are constrained by directly evaluating the control polygon length of spline according to the error tolerance in the workpiece coordinate system,while the tool orientation smoothing errors are constrained by adjusting control polygon length after converting tool orientation error to Euler angles using Jacobian *** asymmetrical splines are constructed by dealing with the spline overlapping problem,while guarantying the fully utilization of error tolerance to reduce spline *** position and orientation are synchronized to the arc-length of the tool tip position to ensure the continuity of acceleration and jerk *** control points and arc-length of the constructed asymmetrical splines can all be solved analytically,which makes it suitable for on-line tool path *** demonstrate that the proposed method achieves higher motion efficiency and lower tracking error than the existing symmetrical and asymmetrical tool path smoothing methods,which validates the advantages of the proposed method in high speed machining.

关键词： robot tool path real time interpolation spline

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Mobile-robotic machining for large complex components:A review study

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Science China(Technological Sciences) 2019年第8期62卷 1388-1400页

作者： TAO Bo ZHAO XingWei ding han State Key Laboratory of Digital Manufacturing Equipment and Technology School of Mechanical Science and EngineeringHuazhong University of Science and Technology

Even though the robotic machining has achieved great success in machining of small components, it lacks the competence to machine large complex components, such as wind turbine blade, train carriage, and aircraft wing. In order to cope with this issue,the mobile machining robot system, which consists of a robot arm integrated with a mobile platform, is proposed to achieve the large workspace and high dexterity, and thus has the potential to machine the large complex components. However, due to the limitation of motion accuracy and structural stiffness, the current mobile-robots are hard to satisfy the high precision requirement of machining tasks. In this paper, some historical mobile-robotic machining systems are reviewed firstly, followed by some key techniques related to structure optimization, dynamics of the machining process, localization, and control techniques, which are fundamental for the structural stiffness and motion accuracy of mobile-robots. Finally, the prospect of mobile-robotic machining and the open questions are addressed.

关键词： robotic machining industrial robot mobile-robot accuracy stiffness

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Milling stability analysis using the spectral method

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Science China(Technological Sciences) 2011年第12期54卷 3130-3136页

作者： ding Ye ZHU LiMin ZhanG XiaoJian ding han State Key Laboratory of Mechanical System and Vibration Shanghai Jiao Tong University Shanghai 200240 China State Key Laboratory of Digital Manufacturing Equipment and Technology Huazhong University of Science and Technology Wuhan 430074 China

This paper focuses on the development of an efficient semi-analytical solution of chatter stability in milling based on the spectral method for integral equations. The time-periodic dynamics of the milling process taking the regenerative effect into account is formulated as a delayed differential equation with time-periodic coefficients, and then reformulated as a form of integral equation. On the basis of one tooth period being divided into a series of subintervals, the barycentric Lagrange interpolation polynomials are employed to approximate the state term and the delay term in the integral equation, respectively, while the Gaussian quadrature method is utilized to approximate the integral tenn. Thereafter, the Floquet transition matrix within the tooth period is constructed to predict the chatter stability according to Floquet theory. Experimental-validated one-degree-of-freedom and two-degree-of-freedom milling examples are used to verify the proposed algorithm, and compared with existing algorithms, it has the advantages of high rate of convergence and high computational efficiency.

关键词： milling stability delayed differential equation integral equation spectral method Floquet theory

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Structural parameter design method for a fast-steering mirror based on a closed-loop bandwidth

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Frontiers of Mechanical Engineering 2020年第1期15卷 55-65页

作者： Guozhen CHEN Pinkuan LIU han ding School of Mechanical Engineering Shanghai Jiao Tong UniversityShanghai 200240China

When a fast-steering mirror(FSM)system is designed,satisfying the performance requirements before fabrication and assembly is *** study proposes a structural parameter design approach for an FSM system based on the quantitative analysis of the required closed-loop ***,the open-loop transfer function of the FSM system is *** accordance with the transfer function,the notch filter and proportional-integral(PI)feedback controller are designed as a closed-loop *** gains of the PI controller are determined by maximizing the closed-loop bandwidth while ensuring the robustness of the ***,the two unknown variables of rotational radius and stiffness in the open-loop transfer function are optimized,considering the bandwidth as a constraint ***,the structural parameters of the stage are determined on the basis of the optimized results of rotational radius and *** are conducted to verify the theoretical analysis.A prototype of the FSM system is fabricated,and corresponding experimental tests are *** results indicate that the bandwidth of the proposed FSM system is 117.6 Hz,which satisfies the minimum bandwidth requirement of 100 Hz.

关键词： fast-steering mirror structural parameter PI controller bandwidth notch filter

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Equivalence relation and partial ordering of parallel mechanisms with applications to mechanism synthesis and mobility analysis

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Chinese Science Bulletin 2010年第16期55卷 1679-1687页

作者： WU YuanQing ding han School of Mechanical Engineering Shanghai Jiao Tong University Shanghai 200240 China

Motion type (or motion pattern) of a mechanism is defined as the set of all rigid motions achievable by the mechanism’s end-effector;the motion type of a parallel mechanism equals the intersection set of all subchain motion *** motion type of a non-instantaneous parallel mechanism locally agrees with a regular submanifold (or a Lie subgroup in particular) of the special Euclidean group SE(3).Based on submanifold germs of SE(3), we can define an equivalence relation and a partial order relation for both motion types and parallel mechanisms: two motion types are equivalent if and only if they agree on an open neighbor-hood around the identity element of SE(3);two motion types are comparable if and only if one is a submanifold of the other on an open neighborhood around the identity of SE(3).It is also possible to define equivalence relation and partial ordering on the col-lection of parallel *** this paper, we first study properties of the equivalence and partial order relation of both motion types and parallel mechanisms, then we discuss their application in type synthesis, mobility analysis and non-overconstrained ness realization of parallel mechanisms.

关键词：等价关系并联机构分析应用机构综合运动类型订购移动并行机制

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