大型航空结构件高效加工并联机器人设计理论与方法

大型航空结构件高效加工是飞机机体制造的关键技术之一。我国目前主要依靠串联五轴龙门铣床完成，其加工效率和精度严重制约我国先进机型量产和新机研发进度。目前波音、空客等大量使用基于并联机器人的航空结构件高效加工装备，但我国在面向高效加工的并联机器人设计中存在机构设计与加工工艺、测量控制相互割裂脱节这一瓶颈难题，与国际先进水平相比差距显著。本项目面向国家重大需求和国际机构学前沿，研究具有最少铰链数和确定输出转轴的并联机器人构型综合、并联机器人-铣削过程交互动力学建模与参数优化、误差建模、标定优化与补偿控制等，揭示过约束强耦合下并联机构输出转轴构造与迁移原理，阐明并联机构动态响应与铣削过程动态特性交互机理，建立并联机器人高维多源误差空间与输出精度空间非线性映射规律，形成并联机器人“构型-加工-测量-控制”一体化设计理论与方法体系，为我国航空结构件高效加工并联机器人装备自主开发提供理论基础与技术支撑。

High-performance machining of large aircraft structures is one of the key technologies in airframe’s manufacture. In China, most of those works are finished on five-axis planer milling machines with serial structures, whose low efficiency and accuracy have seriously limited the quantity production and development of advanced aircraft. Foreign companies such as Boeing and Airbus have widely applied high-performance machining tools based on parallel robots to manufacture aircraft structures. While the design of parallel robots for high-performance machining has a bottleneck problem in our country that is mechanism design, machining process, measurement, and control are isolated from each other. There are obvious gaps between China and foreign countries in this field. To satisfy nation’s significant demands and promote the development of mechanisms, this project proposes to investigate type synthesis of parallel manipulators with less kinematic joints and real rotational axes, interaction dynamic modeling of parallel robots machining process, dimensional optimization, error modeling, calibration and compensation control. This project aims to reveal the construction and transformation principle of rotational axes in strong-coupling overconstrained parallel manipulators. Besides, the dynamic interaction mechanism of parallel manipulator’s dynamic response and milling process will be disclosed. Furthermore, nonlinear mapping rules between the high-dimensional multisource error space and output accuracy of parallel robots will be established. These form an integrated system of design theory and method for parallel robots in terms of mechanism, machining, measurement, and control, providing a theoretical foundation and technical support for independent development of parallel robot equipment used in high-performance machining of large aircraft structures.