Optimization, vibration control and condition monitoring of collaborative robotic machining

使用机器人作为切削刀架从金属零件上去除材料被认为是一种有效和灵活的方法，用于越来越多的工业应用。基于机器人的加工系统已经成功地用于水电设备的维修，也是机械和航空航天制造领域各种过程自动化的有趣替代解决方案。与传统的计算机数控（CNC）加工相比，机器人加工具有几个优点。机器人加工系统不仅更灵活、可操作、操作成本更低，而且与工业CNC加工中心相比，它们还可以节省高达40%的生产工作空间。机器人加工也更适合在危险的工作条件下取代人工操作。******该程序提出了一种新的机器人加工策略，使用两个六足机器人进行协作机器人加工操作。主要目的是研究所提出的机器人加工过程的动力学特性，优化平面和曲面特征加工的刀具轨迹和切削参数，并提出一种过程监控方法。本研究计划旨在提高机器人加工的制造准备水平。在提出的研究计划范围内，我们将研究使用两个六足机器人的新型协同加工方法/体系结构的可行性。我们建议建模和研究协作机器人系统的动力学、材料去除机制以及与加工过程相关的线性和非线性颤振问题。振动控制算法将提出稳定机器人加工操作，从而提高生产率和质量的过程。此外，还将开发一种应用于机器人加工过程的新型过程监控方法，并利用无线嵌入式力传感器对机器人加工过程进行在线控制。关于硬件配置，我们建议使用两个六足架的新构建。该装置有望通过同时和协作移动两个末端执行器，为复杂零件的加工提供更高的灵活性，并更容易设计无颤振和无奇点配置的刀具路径。******这项研究计划的独创性在于开发一种新型的协同加工系统，该系统使用并联机器人，主动振动控制策略和使用嵌入式传感器的机器人加工在线监测系统。该研究将为柔性和可重构制造系统的发展和提高机器人在工业自动化中的应用多功能性提供贡献

The use of robots as cutting tool holders to remove material from metal parts is recognized as an effective and flexible approach for an increasing number of industrial applications. Robot-based machining systems have been successfully used for the repair of hydroelectric equipment and are also an interesting alternative solution for automating various processes in the field of mechanical and aerospace manufacturing. Robotic machining offers several advantages compared to conventional computer numerical control (CNC) machining. Robotic machining systems are not only more flexible, manoeuvrable and less expensive to operate, they can also save up to 40% in production workspace compared to industrial CNC machining centers. Robotic machining is also more suitable in hazardous working conditions to replace human operators.******This program proposes a new robotic machining strategy using two hexapods for collaborative robotic machining operations. The main objective is to investigate the dynamics of the proposed robotic machining processes, to optimize the tool path and cutting parameters for feature machining of planar and curved surfaces and to propose a process monitoring approach. This research program is intended to increase the level of manufacturing readiness of the robotic machining. Within the scope of the proposed research program, we will study the feasibility of a new collaborative machining approach/architecture using two hexapods. We propose to model and study the dynamics of the collaborative robotic system, the material removal mechanism, and the linear and nonlinear chatter vibration problems associated with the machining process. Vibration control algorithms will be proposed to stabilize robotic machining operations and thereby increase the productivity and quality of the process. Moreover, a new process monitoring approach applied to the robotic machining process will be developed and implemented using wireless instrumented embedded force sensors for online control of the robotic machining. Regarding the hardware configuration, we propose a new build up using two hexapods. This set-up is expected to offer an increased dexterity for the machining of complex parts and easier design of tool path for chatter-free and singularity-free configurations by moving both end-effectors simultaneously and cooperatively.******The originality of this research proposal lies in the development of a novel collaborative machining system using parallel robots, an active vibration control strategy and an online monitoring system using embedded sensors for robotic machining. This research will provide contributions for the development of flexible and reconfigurable manufacturing systems and increase the application versatility of robots in industrial automation.**