风机叶片打磨机器人的控制研究
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摘要
风能作为一种清洁可再生能源，逐渐受到人们的青睐和重视。叶片是风力发电机的重要部件之一，常因受到砂害、盐雾侵蚀以及空气中昆虫和脏物的吸附而破坏其表面质量，从而影响风机的运行成本和安全。对叶片进行打磨再加工是恢复其表面质量的常用方法，而叶片尺寸巨大，且打磨过程中会产生大量的短纤维和有害粉尘，所以维修成本较高。随着风电装机容量的爆发式增长，相当一部分叶片已经进入了维修期，且陆续进入维修期的叶片将越来越多，如何及时有效地对风机叶片进行打磨维修，将成为该领域急需解决的一项关键技术。应用机器人进行风机叶片的修复打磨具有加工质量高、加工成本低、有效降低作业强度和粉尘危害的特点，是把作业人员从高污染、大劳动强度的作业环境中解放出来的有效方法。
由于风机叶片尺寸巨大，风机叶片打磨机器人需采用移动机械手结构。移动机械手由移动平台和机械手组成，是集行走和操作功能于一体的复杂机器人系统，有较好的操作灵活性和工作空间的广阔性。本研究提出：在移动机械手的末端安装上打磨工具，构成用于风机叶片修复的移动式打磨机器人。移动机械手结构复杂，存在非完整约束，机械手和平台之间存在动力学耦合等，这些因素的存在给移动机械手的控制带来了挑战。此外，打磨机器人在作业过程中，与外界环境存在着力的交互，打磨操作力的有效控制也是机器人控制系统的核心问题之一。
针对风机叶片修复打磨的特点和要求，提出了将装有打磨工具的移动机械手作为风机叶片修复的移动式打磨机器人，在以下方面开展了研究工作。
分析和确定了移动式风机叶片打磨机器人的结构方案，建立了打磨机器人的分层递阶控制结构，确定机器人自由运动状态和末端接触作业状态下的控制策略。
对移动平台、机械手和打磨机器人系统进行了运动学建模，并分析了打磨机器人系统的可控性和冗余特性。建立了机械手的SimMechanics机构模型，通过仿真分析，获得了机器人的工作空间。分析了典型叶片的截面尺寸数据，获得了叶片的尺寸范围，通过对比分析，验证了所设计的机器人机构的合理性。进行了打磨机器人末端执行器的轨迹规划。
利用拉格朗日功能平衡法建立了打磨机器人的动力学方程，并将该方程分解为移动平台和机械手两个子系统的动力学方程，同时推导出了子系统间动力学耦合项的表达式；建立了机器人系统的SimMechanics模型，通过仿真分析，获得了动力学耦合对各子系统的影响规律，为控制系统的研究奠定了基础。
研究了打磨机器人的控制策略。建立了基于反步控制的移动平台速度控制器，在此基础上设计了实现移动平台动力学稳定收敛的控制器。设计了机械手系统的比例微分加前馈补偿的控制器。针对移动平台和机械手之间存在的动力学耦合，各控制器中均对此进行了补偿，以提高控制效果。
分析比较了主动柔顺控制中的力/位混合控制和阻抗控制两种策略，确定了阻抗控制作为打磨机器人操作力的控制策略。建立了打磨机器人的阻抗控制器，并进行了仿真分析，为叶片打磨过程中操作力的控制奠定了理论基础。
建立了叶片打磨作业系统坐标系，推导了叶片相对机器人基坐标系的位姿描述和机械手关节速度描述；分析了磨削力大小的影响因素；建立了叶片打磨过程的控制模型。基于Solidworks、ADAMS和Matlab/Simulink，建立了打磨机器人作业过程的协同仿真平台，进行了打磨作业的仿真实验，结果验证了所设计的打磨机器人及其控制系统的可行性。
As clean reproducible energy, wind energy has winned more and more good graces. As one of the important parts of wind turbine, blade is always damaged by the sand disaster and the erosion of salt spray, besides, the adsorption of insects and dirt in the air always destroy the surface finish, and the operation cost and safety are affected. The common method of recover the surface finish is grinding and reprocessing. The blade is so huge that its maintenance cost is very high, much short fiber and harmful dust is produced during the grinding process. With the outbreak increase of wind energy installed capacity recent years, quite a few blades has entered maintenance period. As more and more blades require the maintenance, how to provide the timely and effective grinding maintenance has been a key technique. The application of robot in blade repairing has many advantages, such as high quality and low cost, reduce the harm of dust and the work intensity, so it is an effective method of liberating worker from the high pollution and intense work.
As we know that the blade is always very huge, so mobile manipulator should be adopted as the grinding robot. The mobile manipulator composed of mobile platform and manipulator, is a complex robotic system with the function of movement and operation. It has the advantages of operation flexibility and space broadness. A mobile grinding robot is presented here, with a grinding tool fixed on the end of mobile manipulator. The complex structure and non-holonomic constrain of the mobile manipulator, and the existing dynamic coupling between the platform and manipulator, all these factors bring a great challenge to the control of the robotic system. Besides, there exists interactive force between the manipulator and external environment during the working process, so the effective control of operation force is one of the core problems.
A mobile manipulator equipped with grinding tool is used for wind turbine blade maintain mobile robot, as recoording to the characteristic and requirement of blade grinding. The following research work has been carried out.
The structure scheme of the mobile wind turbine blade grinding robot is analyzed and determined. The hierarchical control structure of grinding robot is built. And the control strategy of free movement and end-point contact manipulation is determined.
Kinematics modeling of mobile platform, manipulator and grinding robot has been finished. The controllability of the robot system has been analyzed, and the motion constraint equation has been derived. The workspace has been gained by building the mechanism model of the manipulator with SimMechanics. The dimension data of typical section has been analyzed to learn the size range of the blade, the rationality of robot mechanism has been verified by comparative analysis.
The kinetic equation of the grinding robot is built by Lagrange energy balance method, and the kinetic equations of platform and manipulator are derived from the robot's, based on which the dynamic coupling is derived. The rule of how the dynamic coupling affects the subsystems is derived by the simulation based on the built SimMechanics model. The finished work affords the base for control system research.
The control strategy has been studied. A backstepping velocity controller has been built for the mobile platform, and a dynamic controller with stable convergence is built with considering the velocity controller. A proportion differential plus feedforward compensation controller is built for the manipulator. Compensation is considered for the dynamic coupling between the platform and manipulator, so as to improve the control effect.
Force/position hybrid control and impedance control have been compared, and impedance control is accepted as the operation force control strategy. An impedance controller has been built, and simulation is carried out, the finished work establishs foundation for the operation force control of blade grinding process.
Coordinate system of blade grinding system is built. Pose and joint velocity description relativing to base coordinate have been derived. The influencing factors of grinding force have been analysised. The control model of the the blade grinding process has been built. The simulation platform based on Solidworks, ADAMS and Matlab/Simulink has been established, and the simulation experiment has been carried out, the feasibility of the grinding robot and its control system has been verified by the experimental results.
由于风机叶片尺寸巨大，风机叶片打磨机器人需采用移动机械手结构。移动机械手由移动平台和机械手组成，是集行走和操作功能于一体的复杂机器人系统，有较好的操作灵活性和工作空间的广阔性。本研究提出：在移动机械手的末端安装上打磨工具，构成用于风机叶片修复的移动式打磨机器人。移动机械手结构复杂，存在非完整约束，机械手和平台之间存在动力学耦合等，这些因素的存在给移动机械手的控制带来了挑战。此外，打磨机器人在作业过程中，与外界环境存在着力的交互，打磨操作力的有效控制也是机器人控制系统的核心问题之一。
针对风机叶片修复打磨的特点和要求，提出了将装有打磨工具的移动机械手作为风机叶片修复的移动式打磨机器人，在以下方面开展了研究工作。
分析和确定了移动式风机叶片打磨机器人的结构方案，建立了打磨机器人的分层递阶控制结构，确定机器人自由运动状态和末端接触作业状态下的控制策略。
对移动平台、机械手和打磨机器人系统进行了运动学建模，并分析了打磨机器人系统的可控性和冗余特性。建立了机械手的SimMechanics机构模型，通过仿真分析，获得了机器人的工作空间。分析了典型叶片的截面尺寸数据，获得了叶片的尺寸范围，通过对比分析，验证了所设计的机器人机构的合理性。进行了打磨机器人末端执行器的轨迹规划。
利用拉格朗日功能平衡法建立了打磨机器人的动力学方程，并将该方程分解为移动平台和机械手两个子系统的动力学方程，同时推导出了子系统间动力学耦合项的表达式；建立了机器人系统的SimMechanics模型，通过仿真分析，获得了动力学耦合对各子系统的影响规律，为控制系统的研究奠定了基础。
研究了打磨机器人的控制策略。建立了基于反步控制的移动平台速度控制器，在此基础上设计了实现移动平台动力学稳定收敛的控制器。设计了机械手系统的比例微分加前馈补偿的控制器。针对移动平台和机械手之间存在的动力学耦合，各控制器中均对此进行了补偿，以提高控制效果。
分析比较了主动柔顺控制中的力/位混合控制和阻抗控制两种策略，确定了阻抗控制作为打磨机器人操作力的控制策略。建立了打磨机器人的阻抗控制器，并进行了仿真分析，为叶片打磨过程中操作力的控制奠定了理论基础。
建立了叶片打磨作业系统坐标系，推导了叶片相对机器人基坐标系的位姿描述和机械手关节速度描述；分析了磨削力大小的影响因素；建立了叶片打磨过程的控制模型。基于Solidworks、ADAMS和Matlab/Simulink，建立了打磨机器人作业过程的协同仿真平台，进行了打磨作业的仿真实验，结果验证了所设计的打磨机器人及其控制系统的可行性。
As clean reproducible energy, wind energy has winned more and more good graces. As one of the important parts of wind turbine, blade is always damaged by the sand disaster and the erosion of salt spray, besides, the adsorption of insects and dirt in the air always destroy the surface finish, and the operation cost and safety are affected. The common method of recover the surface finish is grinding and reprocessing. The blade is so huge that its maintenance cost is very high, much short fiber and harmful dust is produced during the grinding process. With the outbreak increase of wind energy installed capacity recent years, quite a few blades has entered maintenance period. As more and more blades require the maintenance, how to provide the timely and effective grinding maintenance has been a key technique. The application of robot in blade repairing has many advantages, such as high quality and low cost, reduce the harm of dust and the work intensity, so it is an effective method of liberating worker from the high pollution and intense work.
As we know that the blade is always very huge, so mobile manipulator should be adopted as the grinding robot. The mobile manipulator composed of mobile platform and manipulator, is a complex robotic system with the function of movement and operation. It has the advantages of operation flexibility and space broadness. A mobile grinding robot is presented here, with a grinding tool fixed on the end of mobile manipulator. The complex structure and non-holonomic constrain of the mobile manipulator, and the existing dynamic coupling between the platform and manipulator, all these factors bring a great challenge to the control of the robotic system. Besides, there exists interactive force between the manipulator and external environment during the working process, so the effective control of operation force is one of the core problems.
A mobile manipulator equipped with grinding tool is used for wind turbine blade maintain mobile robot, as recoording to the characteristic and requirement of blade grinding. The following research work has been carried out.
The structure scheme of the mobile wind turbine blade grinding robot is analyzed and determined. The hierarchical control structure of grinding robot is built. And the control strategy of free movement and end-point contact manipulation is determined.
Kinematics modeling of mobile platform, manipulator and grinding robot has been finished. The controllability of the robot system has been analyzed, and the motion constraint equation has been derived. The workspace has been gained by building the mechanism model of the manipulator with SimMechanics. The dimension data of typical section has been analyzed to learn the size range of the blade, the rationality of robot mechanism has been verified by comparative analysis.
The kinetic equation of the grinding robot is built by Lagrange energy balance method, and the kinetic equations of platform and manipulator are derived from the robot's, based on which the dynamic coupling is derived. The rule of how the dynamic coupling affects the subsystems is derived by the simulation based on the built SimMechanics model. The finished work affords the base for control system research.
The control strategy has been studied. A backstepping velocity controller has been built for the mobile platform, and a dynamic controller with stable convergence is built with considering the velocity controller. A proportion differential plus feedforward compensation controller is built for the manipulator. Compensation is considered for the dynamic coupling between the platform and manipulator, so as to improve the control effect.
Force/position hybrid control and impedance control have been compared, and impedance control is accepted as the operation force control strategy. An impedance controller has been built, and simulation is carried out, the finished work establishs foundation for the operation force control of blade grinding process.
Coordinate system of blade grinding system is built. Pose and joint velocity description relativing to base coordinate have been derived. The influencing factors of grinding force have been analysised. The control model of the the blade grinding process has been built. The simulation platform based on Solidworks, ADAMS and Matlab/Simulink has been established, and the simulation experiment has been carried out, the feasibility of the grinding robot and its control system has been verified by the experimental results.
引文
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