Design and control of a magnetic levitation robotic platform for flexible manufacturing

直线电机系统领域的最新发展使人们对制造设施中精确和快速的物料处理/定位重新产生了兴趣。大多数这样的设备仍然局限于单轴（或一个自由度，1-DOF）运动。本研究计划旨在开发一种革命性的磁悬浮地板平台（MLFP），用于柔性制造应用，旨在消除传统的输送机构，最大限度地利用工厂空间。地板采用阵列电磁执行器，可以同时悬浮和移动五个机器人，具有2自由度，用于制造设施的快速工作分配。传统的制造和生产线由几个工位（钻孔、铣削、车床等）组成，将使用电动多路输送机在这些工位之间循环工件进行加工或组装。如果有不同的产品进入生产线，这些固定的生产线应该完全重新安排。重新安排这些固定的生产线既费钱又费时。以拟议的MLFP形式开发一种新的可重构生产线将具有显著的优势。磁悬浮技术将使物理接触、摩擦和噪音降至最低。消除传统的基于接触的刚度传递机构（正时皮带，链轮和齿轮箱）的需求也将提供更长的使用寿命，更少的维护问题。本文的研究将在以下几个步骤进行：1)设计电磁执行器，为机器人的磁悬浮产生足够的磁力；2)利用优化后的能量/热电磁执行器开发磁悬浮平台；3)开发控制系统，实现机器人运动并对其性能进行评估。MLFP在洁净室材料运输、电子工业和制药工业等领域有着非常重要的全球市场。HQP包括一名博士和一名硕士研究生以及两名四年级学生，将在一些关键领域进行培训，包括机电一体化、系统设计、原型设计和制造。

Recent developments in the field of linear-motor systems have led to renewed interest in precise and rapid material handling/positioning in manufacturing facilities. Most of such devices are yet limited to a single-axis (or one degree of freedom, 1-DOF) motion. This research proposal aims at the development of a revolutionary magnetic levitation floor platform (MLFP) for flexible manufacturing applications, aiming to eliminate conventional conveyer mechanism and maximize the factory space usage. The floor uses an array electromagnetic actuators which can levitate and move five robots simultaneously with 2-DOF for rapid work distribution in manufacturing facilities. Conventional manufacturing and production lines consist of several work stations (drilling, milling, lathes, etc.) and motorized multiple conveyers will be used to circulate a workpieces among those workstations to be machined or assembled. These fixed manufacturing/production lines should be totally rearranged if a different product is introduced into the line. Rearrangement of these fixed production lines are costly and time consuming. The development of a novel reconfigurable production line, in the form of the proposed MLFP, will have significant advantages. MagLev technology will allow physical contact, friction and noise to be minimized. Eliminating the need for traditional contact-based stiffness transfer mechanisms (timing belts, sprockets and gearboxes) will also provide for a significantly longer operational lifetime, with fewer maintenance issues. The proposed research will be carried out in the following steps: 1) Design the electromagnetic actuator to generate sufficient magnetic force for robots' magnetic levitation; 2) Develop a magnetic levitation platform using optimized energy/heat electromagnetic actuator; 3) Develop control system to realize the robot motions and evaluate the performance. There is a very significant global market for MLFP such as in cleanroom material transportation, electronic industry, and pharmaceutical industry. HQP including one PhD and one Master's students and two fourth-year students will be trained in a number of key areas, including mechatronics, systems design, prototyping, and manufacturing.