Optimization, vibration control and condition monitoring of collaborative robotic machining

使用机器人作为切削刀具夹具从金属零件上去除材料被认为是越来越多的工业应用的有效和灵活的方法。基于机器人的加工系统已成功用于水电设备的维修，也是机械和航空航天制造领域各种工艺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、机动性更强、操作成本更低，而且与工业数控加工中心相比，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类操作员。该计划提出了一种新的机器人加工策略，使用两个六足机器人协作加工操作。主要目的是研究拟议的机器人加工过程的动力学，优化的工具路径和切割参数的平面和曲面的特征加工，并提出一个过程监控方法。该研究计划旨在提高机器人加工的制造准备水平。在拟议的研究计划的范围内，我们将研究一种新的协同加工方法/架构使用两个六足机器人的可行性。我们建议建模和研究的协作机器人系统的动力学，材料去除机制，以及与加工过程中的线性和非线性颤振振动问题。振动控制算法将被提出来稳定机器人加工操作，从而提高生产率和质量的过程。此外，一个新的过程监控方法应用到机器人加工过程中将开发和实施使用无线仪表嵌入式力传感器的机器人加工的在线控制。关于硬件配置，我们提出了一个新的建立使用两个六足。这种设置预计将提供一个增加的灵活性，加工复杂的零件和更容易的设计刀具路径的无颤振和无奇异性的配置，同时移动两个末端执行器和合作。这项研究的独创性在于开发一种新型的协同加工系统，使用并联机器人，主动振动控制策略和在线监测系统，使用嵌入式传感器的机器人加工。该研究将为柔性和可重构制造系统的开发提供贡献，并增加机器人在工业自动化中的应用通用性。

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.