巨型重载锻造操作机系统性能研究
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摘要
大锻件制备是重型装备制造业的基础，而锻造自动化是提高大锻件生产率和质量并降低制造成本的必要条件。本文结合大锻件锻造自动化的需要，针对巨型重载锻造操作机系统的性能建模与分析展开研究，包括操作机的运动学建模以及运动和承载性能分析、动态抗倾覆稳定性指标、结合锻造工艺的压机与操作机联动整体运动学建模、联动锻造中用于操作机柔顺控制的复合刚度模型、以及程序化自由锻造工艺仿真模型，讨论了联动锻造系统整体可视化仿真软件的设计与实现。主要内容如下：
1)给出了一种新的串并联混合结构的锻造操作机，建立了具有封闭解的运动学正反解和解析形式的运动雅克比计算算法，在此基础上进行了该操作机的运动特性以及承载性能的分析，由此建立起重载操作机数学模型。
2)基于操作机使用过程中安全性的需要，提出了一种新的移动操作手动态抗倾覆稳定性指标，该指标具有明确的物理意义，考虑了移动操作手工作状态下各种动静态因素的影响。
3)利用自由锻造工艺分析中的展宽系数理论，建立了操作机与压机联动锻造时操作机的夹持端的顺应速度模型，在此基础上建立了整体协调运动模型。该模型是进行操作机轨迹规划以及进行虚拟锻造系统运动仿真的基础。
4)建立了联动锻造时锻件变形与操作机柔顺控制之间的力学模型。首先考虑了轴类锻件变形时的弹塑性形变效应，建立了锻件非变形区的弹性刚度模型；然后利用保守同余刚度变换方法，建立了操作机的完备操作空间刚度模型；锻件的弹塑性变形与操作机的柔顺控制响应之间互相影响，形成耦合的力学和变形关系。在锻件弹性刚度模型和操作机完备操作空间刚度模型基础上建立了整体的复合刚度模型。
5)利用展宽系数理论，结合空间几何变换方法，建立了程序化锻造时锻件的变形模型。并形成了多工步自由锻造工艺的快速规划和仿真算法。
6)提出了虚拟锻造工厂的软件建模体系结构，对虚拟锻造系统进行了软件分析和设计，并对其中的一些关键技术如多工步锻造工艺自动FEA软件的实现、复杂塑性有限元变形模型在虚拟现实系统中的可视化等问题进行了研究，给出了虚拟锻造软件的机械——工艺协同仿真解决方案。
本文的研究成果是巨型重载操作机系统、程序化锻造工艺以及数字化虚拟锻造系统的设计基础。
The manufacturing of heavy forgings is the foundation of heavy equipment industry,and the automation of forging process is the necessary condition for the production ofhigh-productivity, high-quality and low-cost heavy forgings. This work focuses on theneed of automation in heavy forging production, and discussed some key technologies onthe modeling and performance analysis of heavy-duty forging manipulator system, whichcan be integrated with forging press to realize programmed open-die forging process.These key technologies include kinematic modeling and analysis of forging manipulator,dynamic tip-over stability of mobile manipulator, the overall model of the coordinatedforging system that includes press, manipulator and the forging process, the compoundstiffness model for the compliant control of manipulator, pass schedule of programmedopen-die forging process, and the software realization of virtual open-die forging plants.This dissertation’s main work can be concluded as:
1) A new-type serial-parallel forging manipulator is presented, the closed formdirect and inverse kinematic solutions are derived, and the analytic algorithm for thecomputation of Jacobian matrix is also presented. Based on which the kinematicperformance and the load capacity are analyzed. All those lead to the establishment of themathematic model of the forging manipulator.
2) A new tip-over stability measure for mobile manipulators is proposed, whichhelps to improve the operational safety of the forging manipulator. This measure has aconcrete physical meaning, considering all static and dynamic factors under different working state of mobile manipulators.
3) The compliance velocity of the manipulator gripper during forging is derived onthe basis of Spread Coefficient theory of open-die forging process, based on which theoverall coordinated model of the integrated forging manipulator system is established.This model can be used for trajectory plan or kinematic simulation of virtual forgingsystem.
4) The mechanical interaction of the deformed workpiece and the compliantcontrolled manipulator is built. Firstly the elastic and plastic deformation model of theshaft-shaped workpieces are investigated and the elastic stiffness matrix of thenon-deformation portion of the workpiece is derived; Then the conservativeoperational-space stiffness matrix of the manipulator is computed by using the method ofConservative Congruence Transformation (CCT); The compound stiffness model of thewhole system is established base the elastic stiffness matrix and the conservativeoperational-space stiffness matrix.
5) The simulation algorithm for square bar drawing process between simple dies isproposed based on Spread Coefficient theory and geometric transformation. The real-timesimulation algorithm of programmed forging process is then formed.
6) The software architecture of the virtual forging system is proposed, and thedesign and analysis processes of the software are conducted. Some key technologies forthe software development, such as automatic simulation of multi-step open-die forgingprocess and the visualization of the simulated complex forging process in virtual realityenvironment, are investigated.
This work provides a relatively complete theoretic base for the analysis and design ofheavy-duty forging manipulators, programmed forging process conducted by coordinatedpress and manipulators, and the realization of virtual forging system.
1)给出了一种新的串并联混合结构的锻造操作机，建立了具有封闭解的运动学正反解和解析形式的运动雅克比计算算法，在此基础上进行了该操作机的运动特性以及承载性能的分析，由此建立起重载操作机数学模型。
2)基于操作机使用过程中安全性的需要，提出了一种新的移动操作手动态抗倾覆稳定性指标，该指标具有明确的物理意义，考虑了移动操作手工作状态下各种动静态因素的影响。
3)利用自由锻造工艺分析中的展宽系数理论，建立了操作机与压机联动锻造时操作机的夹持端的顺应速度模型，在此基础上建立了整体协调运动模型。该模型是进行操作机轨迹规划以及进行虚拟锻造系统运动仿真的基础。
4)建立了联动锻造时锻件变形与操作机柔顺控制之间的力学模型。首先考虑了轴类锻件变形时的弹塑性形变效应，建立了锻件非变形区的弹性刚度模型；然后利用保守同余刚度变换方法，建立了操作机的完备操作空间刚度模型；锻件的弹塑性变形与操作机的柔顺控制响应之间互相影响，形成耦合的力学和变形关系。在锻件弹性刚度模型和操作机完备操作空间刚度模型基础上建立了整体的复合刚度模型。
5)利用展宽系数理论，结合空间几何变换方法，建立了程序化锻造时锻件的变形模型。并形成了多工步自由锻造工艺的快速规划和仿真算法。
6)提出了虚拟锻造工厂的软件建模体系结构，对虚拟锻造系统进行了软件分析和设计，并对其中的一些关键技术如多工步锻造工艺自动FEA软件的实现、复杂塑性有限元变形模型在虚拟现实系统中的可视化等问题进行了研究，给出了虚拟锻造软件的机械——工艺协同仿真解决方案。
本文的研究成果是巨型重载操作机系统、程序化锻造工艺以及数字化虚拟锻造系统的设计基础。
The manufacturing of heavy forgings is the foundation of heavy equipment industry,and the automation of forging process is the necessary condition for the production ofhigh-productivity, high-quality and low-cost heavy forgings. This work focuses on theneed of automation in heavy forging production, and discussed some key technologies onthe modeling and performance analysis of heavy-duty forging manipulator system, whichcan be integrated with forging press to realize programmed open-die forging process.These key technologies include kinematic modeling and analysis of forging manipulator,dynamic tip-over stability of mobile manipulator, the overall model of the coordinatedforging system that includes press, manipulator and the forging process, the compoundstiffness model for the compliant control of manipulator, pass schedule of programmedopen-die forging process, and the software realization of virtual open-die forging plants.This dissertation’s main work can be concluded as:
1) A new-type serial-parallel forging manipulator is presented, the closed formdirect and inverse kinematic solutions are derived, and the analytic algorithm for thecomputation of Jacobian matrix is also presented. Based on which the kinematicperformance and the load capacity are analyzed. All those lead to the establishment of themathematic model of the forging manipulator.
2) A new tip-over stability measure for mobile manipulators is proposed, whichhelps to improve the operational safety of the forging manipulator. This measure has aconcrete physical meaning, considering all static and dynamic factors under different working state of mobile manipulators.
3) The compliance velocity of the manipulator gripper during forging is derived onthe basis of Spread Coefficient theory of open-die forging process, based on which theoverall coordinated model of the integrated forging manipulator system is established.This model can be used for trajectory plan or kinematic simulation of virtual forgingsystem.
4) The mechanical interaction of the deformed workpiece and the compliantcontrolled manipulator is built. Firstly the elastic and plastic deformation model of theshaft-shaped workpieces are investigated and the elastic stiffness matrix of thenon-deformation portion of the workpiece is derived; Then the conservativeoperational-space stiffness matrix of the manipulator is computed by using the method ofConservative Congruence Transformation (CCT); The compound stiffness model of thewhole system is established base the elastic stiffness matrix and the conservativeoperational-space stiffness matrix.
5) The simulation algorithm for square bar drawing process between simple dies isproposed based on Spread Coefficient theory and geometric transformation. The real-timesimulation algorithm of programmed forging process is then formed.
6) The software architecture of the virtual forging system is proposed, and thedesign and analysis processes of the software are conducted. Some key technologies forthe software development, such as automatic simulation of multi-step open-die forgingprocess and the visualization of the simulated complex forging process in virtual realityenvironment, are investigated.
This work provides a relatively complete theoretic base for the analysis and design ofheavy-duty forging manipulators, programmed forging process conducted by coordinatedpress and manipulators, and the realization of virtual forging system.
引文
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