Robot-based incremental sheet forming - compensating for disturbances caused by a local heating and the inaccuracy of the metal forming device

基于机器人的增量板材成形 - 补偿由局部加热和金属成形设备的不准确性引起的干扰

基本信息

批准号：
389056414
负责人：
Professor Dr.-Ing. Bernd Kuhlenkötter
金额：
--
依托单位：
Lehrstuhl für Produktionssysteme
依托单位国家：
德国
项目类别：
Research Grants
财政年份：
2017
资助国家：
德国
起止时间：
2016-12-31 至 2020-12-31
项目状态：
已结题

来源：
https://gepris.dfg.de/gepris/projekt/389056414?language=en
关键词：
Robot based incremental sheet forming

项目摘要

Incremental sheet forming (ISF) is a flexible, workpiece-independent procedure to manufacture sheet metal parts in small lot sizes. One of the major drawbacks of ISF processes is their low geometrical accuracy, which limits a widespread industrial application of these especially when it comes to forming asymmetric parts. The research Projects, which have been successfully advanced at the Chair of Production Systems (LPS), prove that robot-based ISF has high industrial potentials especially for prototyping. It has been possible to considerably reduce the geometrical deviations especially as a result of performing the forming processes at elevated temperatures. Therefore, the aim of this project is to use the positive results of hot forming achieved so far and react on the current causes of deviations resulting from inaccuracies of the forming device and from forming at elevated temperatures. To achieve this, the research focus shall be placed on the following:(1) compensating for the compliance of the forming device,(2) increasing the positioning accuracy of the forming device,(3) compensating for the shrinkage behavior as a result of local heating.To implement the compensation strategies, the first objective is to develop a process control system which makes it possible to centrally monitor the state information of the forming device and to influence the real-time forming process. Afterwards, the project integrates the stiffness model, which has successfully been implemented on the forming robot at the LPS, into the implemented real-time environment. This stiffness model is enhanced to include a combined operation of the forming and supporting robot to increase the stiffness of the entire forming device. In addition, the project is designed to develop a coordinated force control of both forming tools and to integrate it into the control system to increase the positioning accuracy of the forming device.Moreover, the project has the aim to analyze the geometric inaccuracies caused by local heating. A statistical experimental planning serves to thoroughly investigate the shrinking behavior of a hot formed sheet. To identify the characteristic of the shrinking behavior, it is necessary to determine the cause-effect relationships of varying process and geometry parameters and the resulting component shrinkage. Based on this, our project develops a model to calculate an optimized tool path in dependence of the actual process and geometry parameters in order to work against the shrinkage of the sheet. The developed compensation strategies are finally brought together in the process control.Our project lays the necessary basis for a successful realization of a procedure to manufacture sheet prototypes and small batch series; it aims at increasing the accuracy, at centrally monitoring and controlling the forming process as well as investigating the shrinking behavior of hot incrementally formed sheets.

增量板形成（ISF）是一种灵活的，无独立的工程，以制造小尺寸的钣金零件。 ISF过程的主要缺点之一是它们的低几何准确性，这限制了这些精度的广泛工业应用，尤其是在形成不对称零件时。该研究项目已成功地在生产系统主席（LP）（LPS）中推进，证明基于机器人的ISF具有很高的工业潜力，尤其是针对原型制作。可能会大大减少几何偏差，尤其是由于在升高温度下进行形成过程的结果。因此，该项目的目的是利用到目前为止取得的热形成的积极结果，并对成型设备不准确的当前偏差原因以及在温度升高时形成。为了实现这一目标，研究重点应放在以下内容上：（1）补偿成型设备的依从性，（2）提高成型设备的定位准确性，（3）补偿因当地供暖而导致的收缩行为。要实施薪酬策略，第一个目标是开发一个可以在状态进行中心的工艺控制系统的过程，并影响了形式的设备，并能够实现该设备的实时信息。之后，该项目集成了刚度模型，该模型已成功地在LPS的成型机器人上实施，并将其纳入实现的实时环境。增强了这种刚度模型，包括形成和支撑机器人的组合操作，以增加整个成型设备的刚度。此外，该项目旨在开发两种形成工具的协调力控制，并将其集成到控制系统中以提高成型设备的定位准确性。此外，该项目的目的是分析由局部暖气引起的几何不准确性。统计实验计划旨在彻底研究热纸的缩水行为。为了确定收缩行为的特征，有必要确定变化过程和几何参数的原因效应关系以及所得组件收缩。基于此，我们的项目开发了一个模型，以计算实际过程和几何参数的依赖性，以对抗纸张的收缩。最终将开发的薪酬策略汇集在流程控制中。它旨在提高准确性，以中央监测和控制形成过程，并研究热逐渐形成板的收缩行为。