冲裁上料机器人设计与视觉伺服系统的研究
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摘要
冲压生产是当代机械加工和制造过程中一种重要的成型制造技术,具有速度快、效率高、材料利用率高、节约能源、污染少等优点,广泛应用于工业生产诸多领域中。随着先进制造技术的发展,冲压生产技术正在向精密化、高速化、自动化、柔性化的方向发展,采用自动化技术、机器人技术、伺服技术等先进制造技术手段,构成自动化冲压生产技术的重要发展方向。
视觉伺服系统一般由摄像机、图像预处理、图像理解、伺服控制器等部分组成,将视觉伺服系统同机器人相结合,使机器人具有同外部环境进行智能交互的能力,是当今机器人发展的一个主要方向。
本文以三自由度RRR关节型冲裁上料机器人(简称SR09)为原型,就其概念设计、运动学、动力学及视觉伺服系统和伺服控制器的设计进行了深入地研究,主要内容及成果如下：
第一章首先就冲压机器人对冲压生产自动化的影响、作用及意义进行了说明；对冲压机器人的种类与结构形式、与压力机的同步与协调方式及冲压自动化生产线全线的同步与协调方式等一系列问题进行分析和归纳。该章还讨论了机器人概念设计的方法对机器人这样的现代复杂的机电一体化系统的重要意义,分析了视觉伺服系统及其相关的图象处理、神经网络、模糊控制、机器人多传感器信息融合等技术的发展现状；论述了研究与开发冲压机器人及新一代的具有自治能力的智能冲压机器人对冲压生产自动化,提高企业的制造水平与能力,提高企业快速响应市场的能力的重要意义。
第二章介绍了UML建模语言的基本构成及作用,总结了使用UML建模语言进行系统概念设计的优越性。基于信息系统的建模理论,应用面向对象的软件工程方法,建立了基于UML的现代机械系统用例驱动的设计过程模型。总结分析了用例驱动方法进行机电系统概念设计的步骤及目标,并用这种方法进行了冲裁上料机器人SR09的概念设计,对设计的结果进行了运动学动力学的仿真。
第三章以串联关节式机器人(简称操作臂)为基础,构成操作臂的杆件被看作刚体,建立了SR09的连杆坐标系统和Denavit-Hartenbcrg描述体系及运动转换矩阵,给出了视觉系统坐标系,机器人本体坐标系及端拾器坐标系三者之间的关系,推导了SR09操作臂的运动学与动力学方程,并给出了方程的封闭正反解,开发了一种简洁实用基于牛顿欧拉方程的动力学算法,进行了动力学分析与仿真。
第四章是关于机器人轨迹生成与最佳工作位置计算,这里轨迹是指位置、速度,加速度在关节空间或笛卡尔空间的时间历程。内容包括了常用的轨迹生成方法,对SR09的直线、弧线组成的综合轨迹进行了有圆滑过渡与无圆滑过渡的对比仿真试验研究,提出了一种基于SR09的最佳工作位置的优化算法。
第五章讨论了视觉系统的构成与线性摄像机的模型及摄像机标定主要方法,给山了SR09的视觉系统的标定方式及相应的内、外参数矩阵。机器人的视觉系统主要由图像获取、图像处理两大部分构成。图像获取主要通过数码扫描仪、相机等数字化设备获取目标图像,图像处理主要经过数字滤波消除噪声,通过二值化算法,使彩色及各种灰度图像成为便于处理的黑白图像,经过边缘检测得到物体轮廓构造,通过图像分割得到所需的目标的图像坐标。该章提出了基于BP神经网络的工件识别算法,试验表明该算法能较好地解决SR09视觉系统进行工件识别的技术问题。
第六章研究eye-in-hand方式下单目、双目机械手视觉伺服控制及基于位置的模糊PID控制,给出了单目Eye-in-Hand配置和双目立体配置下的视觉伺服控制模块的基本原理。主要内容包括：分析研究了单目Eye-in-Hand配置下的图像雅可比矩阵和基于PD(比例微分)的机械手控制算法,以及基于双目立体视觉的机械手视觉伺服控制,分别给出了SR09针对5个与8个工件特征点及直线与圆弧轨迹跟踪在Eye-in-Hand配置下的仿真实验。为提高机器人的自主性与适应性,从改善其工作性能,该章采用分段控制的模糊PID控制器,使得模糊控制参数和规则在控制过程中根据误差及变化率自动地调整、修改,从而使系统的控制性能不断改善,达到最佳的控制效果。SR09对斜平面内圆弧轨迹追踪仿真试验结果表明模糊PID控制效果较好。
第七章是关于机器人多信息融合技术及控制。目前信息融合的方式主要有加权平均法,D-S证据法,产生式规则法,模糊理论与神经网络法。SR09机器人工作在物料抓取、搬运、物料放置的工作循环中,频繁与周围环境发生接触,保证机器人端拾器能够按规定的轨迹运动同时使其与环境的接触力在可接受的范围内十分重要。在没有力传感器的情况下,通过检测关节电机电流的变化了解关节力矩的变化,从而了解作用于操作臂末端的环境作用力的变化情况,产生接近觉,是控制机械臂精确安全定位,节省制造成本的一个好办法。该章讨论了视觉信息、力信息融合时,在无力传感器情况下基于关节电机电流反馈的力/位混合控制策略,实现了无力传感器情况下的机器人的接近觉反应,利用P.I.Corke博士的机器人工具箱构成了基于SR09的位置力矩控制仿真平台,进行了仿真试验。
第八章对全文作出总结,计划将进一步考虑SR09的弹性动力学及参数辩识问题,以使SR09向高速化与轻量化发展；同时,对SR09端拾器轨迹转折处的关节角轨迹的圆滑过渡曲线进行优化设计,以及视觉系统及物料识别的实时性问题将作进一步研究。
Press manufacturing is an important metal forming technique in modern machining and fabrication process. Being of the advantages of rapid, efficient, material and energy economy and less pollution, press manufacturing technique is widely used in many industry fields and is developing towards precision, high-speed, automation and flexibility with the progress of Advanced Manufacturing Technology. It has been a significant trend for modern press manufacturing pro-cess to be automatic and flexible in forms of automatic press manufacturing unit or automatic production line employing automation, robot and servo technology.
It is an important developing direction that the robot is accompanied by vi-sion so that it can interact intelligently with its working environment. Generally, the system of visual servoing can be divided into following subsystems:camera, image preprocessing, image understanding, visual servoing controller of robot. To improve the accuracy and range of application, camera calibration, feature detection and designing of visual servoing controller are deeply researched.
Based on a visual servoing of stamping material feeding robot SR09, this dissertation researched a series of issues of robot including conceptual design of robot, kinematics, dynamics, visual servoing system as well as design of controller. The main points and fruits are following:
The first chapter mainly dealt with the current trend in stamping robot and the technique of visual servoing. This chapter began with the trend in press process, then discuss of the impact of robot on press process. Also the category and configuration, coordination with press, and its synchronization and coordi-nation with whole automatic press production line are explored, analyzed and summarized. In addition, a survey of visual servoing and its related technologies are presented. It is concluded that it is highly significant to research and de-velop new generation of intelligently autonomous robot for automation of press process, enhancement of capability and level of manufacturing, enhancement of rapid response to market.
In chapter two, after the components and advantages of the uniform mod-eling language (UML) being researched and analyzed, a model of modern design process based on UML (uniform modeling language) is proposed, subsequently the procedure and object of conceptual design of mechatronic system were ex-pounded. In the ending of chapter two, the conceptual design of SR09 was carried based on uniform modeling language (UML) by means of case driven methodol-ogy, and the results of simulation of kinematics and dynamics of robot SR09 was given.
Chapter three based on the articulate robot (manipulator for short), view-ing the links which composes the manipulator as rigid body, applying principle of rigid body mechanics, expatiates the basic motion description and computa-tion of kinematics and dynamics of robot SR09. In this chapter, motion frame of links and Denavit-Hartenbcrg notation as well as motion transform matrix of SR09 are established; the transformation among vision frame, base frame of robot SR09 and workpiece frame also discussed. Moreover, equation of kinematics and dynamics of manipulator of SR09 are deduced and closed form solution to these equations is given; a simple and specific dynamical algorithm based on Newton Euler equation using MapleTM is proposed too.
In chapter four, article concerns with methods of computing a trajectory in multidimensional space which describes the desired motion of a manipulator. Here, trajectory refers to a time history of position, velocity, and acceleration in joint space or Cartesian space. The contents includes several typical method of trajectory generation in joint angles such as Cubic polynomials, Cubic polyno-mials for a path with via points, higher order polynomials, linear function with parabolic blends, B-spline. In Cartesian space scheme. Chapter four also relates the mostly used trajectory in stamping robot, and a optimal algorithm comput-ing the work position of robot with minimum joint angles in non-singularity work space. A comparative Simulation is presented to verify a integrated trajectory that is composed several straight line and a circle in ADAMSTM at the end of chapter, and the simulation results shows that robot SR09 works well with the trajectory.
Chapter five discusses the structure of vison system, pin-hole camera prin-ciple, camera calibration. Machine vision system mainly consists of acquisition of image, and process of image. Image process aim at canceling noise by digital filtering, converting color or grey image into binary image, getting the contours of workpieces through edge detecting, computing the pixel coordinates by seg-menting image. The camera calibration of SR09 is given and an algorithm of object workpiece recognizing based on BP neural network is advanced, and the algorithm verified by test.
Chapter six discusses the monocular and binocular visual servoing systems and position based fuzzy PID controller. In this chapter, the principle, configura-tion of monocular and binocular with eye-in-hand are researched; including image Jacobian matrix, combination of multi-feature points Jacobian matrix, control al-gorithm of manipulator based on PD (Proportional derivative) control, binocular stereo visual servoing control system and related simulations.
Because the visual servoing robot takes the vision system as the motion sens-ing unit, undergone all kinds of disturbance, characterized with hyper non-linear and time varying, the precision of robot controller is deadly affected by the en-vironment. In order to improve the autonomy and adaptability of robot and to enhance its performance, in this chapter, a fuzzy PID controller is designed for SR09. making the control parameters be modified with error and derivative of the error and the control performance be improved continuously. The tracking simulation of a circle on a slant plane verified the controller working well.
Chapter seven is related to information fusion of robot. Information fusion is a process to use a numbers of synergistic sensors and combine these sensors effectively to form sensing system of high performance to acquire a consistent description of the sensed system. For the time being, the main methods to fu-sion information are weighted mean, Shafer-Dempster evidence inference, product ruler, fuzzy theory and neural network.
Stamping robot contacts the environment frequently when they works in a loop of grabbing objet, transporting the object and laying down the object. It is imperative that the normal force between the end-effector and environment be maintained in a certain controlled range. When the force sensor is absence, it is possible to know the force exerting on environment by measuring the current that flow through coil of the joint motor. Therefore, a sense of access is obtained. This is a good method to control the robot to position precisely with low cost. In this chapter the principle of hybird control of force and position was analyzed with no force sensor just by measuring the current of joint motor. By means of Robotics TOOLBOX for MATLAB developed by Doctor P. I. coke,a simulation system is build up and the simulation carried out.
Chapter eight is the conclusion. In this chapter some conclusions are made and a plan is advanced for future works.
视觉伺服系统一般由摄像机、图像预处理、图像理解、伺服控制器等部分组成,将视觉伺服系统同机器人相结合,使机器人具有同外部环境进行智能交互的能力,是当今机器人发展的一个主要方向。
本文以三自由度RRR关节型冲裁上料机器人(简称SR09)为原型,就其概念设计、运动学、动力学及视觉伺服系统和伺服控制器的设计进行了深入地研究,主要内容及成果如下：
第一章首先就冲压机器人对冲压生产自动化的影响、作用及意义进行了说明；对冲压机器人的种类与结构形式、与压力机的同步与协调方式及冲压自动化生产线全线的同步与协调方式等一系列问题进行分析和归纳。该章还讨论了机器人概念设计的方法对机器人这样的现代复杂的机电一体化系统的重要意义,分析了视觉伺服系统及其相关的图象处理、神经网络、模糊控制、机器人多传感器信息融合等技术的发展现状；论述了研究与开发冲压机器人及新一代的具有自治能力的智能冲压机器人对冲压生产自动化,提高企业的制造水平与能力,提高企业快速响应市场的能力的重要意义。
第二章介绍了UML建模语言的基本构成及作用,总结了使用UML建模语言进行系统概念设计的优越性。基于信息系统的建模理论,应用面向对象的软件工程方法,建立了基于UML的现代机械系统用例驱动的设计过程模型。总结分析了用例驱动方法进行机电系统概念设计的步骤及目标,并用这种方法进行了冲裁上料机器人SR09的概念设计,对设计的结果进行了运动学动力学的仿真。
第三章以串联关节式机器人(简称操作臂)为基础,构成操作臂的杆件被看作刚体,建立了SR09的连杆坐标系统和Denavit-Hartenbcrg描述体系及运动转换矩阵,给出了视觉系统坐标系,机器人本体坐标系及端拾器坐标系三者之间的关系,推导了SR09操作臂的运动学与动力学方程,并给出了方程的封闭正反解,开发了一种简洁实用基于牛顿欧拉方程的动力学算法,进行了动力学分析与仿真。
第四章是关于机器人轨迹生成与最佳工作位置计算,这里轨迹是指位置、速度,加速度在关节空间或笛卡尔空间的时间历程。内容包括了常用的轨迹生成方法,对SR09的直线、弧线组成的综合轨迹进行了有圆滑过渡与无圆滑过渡的对比仿真试验研究,提出了一种基于SR09的最佳工作位置的优化算法。
第五章讨论了视觉系统的构成与线性摄像机的模型及摄像机标定主要方法,给山了SR09的视觉系统的标定方式及相应的内、外参数矩阵。机器人的视觉系统主要由图像获取、图像处理两大部分构成。图像获取主要通过数码扫描仪、相机等数字化设备获取目标图像,图像处理主要经过数字滤波消除噪声,通过二值化算法,使彩色及各种灰度图像成为便于处理的黑白图像,经过边缘检测得到物体轮廓构造,通过图像分割得到所需的目标的图像坐标。该章提出了基于BP神经网络的工件识别算法,试验表明该算法能较好地解决SR09视觉系统进行工件识别的技术问题。
第六章研究eye-in-hand方式下单目、双目机械手视觉伺服控制及基于位置的模糊PID控制,给出了单目Eye-in-Hand配置和双目立体配置下的视觉伺服控制模块的基本原理。主要内容包括：分析研究了单目Eye-in-Hand配置下的图像雅可比矩阵和基于PD(比例微分)的机械手控制算法,以及基于双目立体视觉的机械手视觉伺服控制,分别给出了SR09针对5个与8个工件特征点及直线与圆弧轨迹跟踪在Eye-in-Hand配置下的仿真实验。为提高机器人的自主性与适应性,从改善其工作性能,该章采用分段控制的模糊PID控制器,使得模糊控制参数和规则在控制过程中根据误差及变化率自动地调整、修改,从而使系统的控制性能不断改善,达到最佳的控制效果。SR09对斜平面内圆弧轨迹追踪仿真试验结果表明模糊PID控制效果较好。
第七章是关于机器人多信息融合技术及控制。目前信息融合的方式主要有加权平均法,D-S证据法,产生式规则法,模糊理论与神经网络法。SR09机器人工作在物料抓取、搬运、物料放置的工作循环中,频繁与周围环境发生接触,保证机器人端拾器能够按规定的轨迹运动同时使其与环境的接触力在可接受的范围内十分重要。在没有力传感器的情况下,通过检测关节电机电流的变化了解关节力矩的变化,从而了解作用于操作臂末端的环境作用力的变化情况,产生接近觉,是控制机械臂精确安全定位,节省制造成本的一个好办法。该章讨论了视觉信息、力信息融合时,在无力传感器情况下基于关节电机电流反馈的力/位混合控制策略,实现了无力传感器情况下的机器人的接近觉反应,利用P.I.Corke博士的机器人工具箱构成了基于SR09的位置力矩控制仿真平台,进行了仿真试验。
第八章对全文作出总结,计划将进一步考虑SR09的弹性动力学及参数辩识问题,以使SR09向高速化与轻量化发展；同时,对SR09端拾器轨迹转折处的关节角轨迹的圆滑过渡曲线进行优化设计,以及视觉系统及物料识别的实时性问题将作进一步研究。
Press manufacturing is an important metal forming technique in modern machining and fabrication process. Being of the advantages of rapid, efficient, material and energy economy and less pollution, press manufacturing technique is widely used in many industry fields and is developing towards precision, high-speed, automation and flexibility with the progress of Advanced Manufacturing Technology. It has been a significant trend for modern press manufacturing pro-cess to be automatic and flexible in forms of automatic press manufacturing unit or automatic production line employing automation, robot and servo technology.
It is an important developing direction that the robot is accompanied by vi-sion so that it can interact intelligently with its working environment. Generally, the system of visual servoing can be divided into following subsystems:camera, image preprocessing, image understanding, visual servoing controller of robot. To improve the accuracy and range of application, camera calibration, feature detection and designing of visual servoing controller are deeply researched.
Based on a visual servoing of stamping material feeding robot SR09, this dissertation researched a series of issues of robot including conceptual design of robot, kinematics, dynamics, visual servoing system as well as design of controller. The main points and fruits are following:
The first chapter mainly dealt with the current trend in stamping robot and the technique of visual servoing. This chapter began with the trend in press process, then discuss of the impact of robot on press process. Also the category and configuration, coordination with press, and its synchronization and coordi-nation with whole automatic press production line are explored, analyzed and summarized. In addition, a survey of visual servoing and its related technologies are presented. It is concluded that it is highly significant to research and de-velop new generation of intelligently autonomous robot for automation of press process, enhancement of capability and level of manufacturing, enhancement of rapid response to market.
In chapter two, after the components and advantages of the uniform mod-eling language (UML) being researched and analyzed, a model of modern design process based on UML (uniform modeling language) is proposed, subsequently the procedure and object of conceptual design of mechatronic system were ex-pounded. In the ending of chapter two, the conceptual design of SR09 was carried based on uniform modeling language (UML) by means of case driven methodol-ogy, and the results of simulation of kinematics and dynamics of robot SR09 was given.
Chapter three based on the articulate robot (manipulator for short), view-ing the links which composes the manipulator as rigid body, applying principle of rigid body mechanics, expatiates the basic motion description and computa-tion of kinematics and dynamics of robot SR09. In this chapter, motion frame of links and Denavit-Hartenbcrg notation as well as motion transform matrix of SR09 are established; the transformation among vision frame, base frame of robot SR09 and workpiece frame also discussed. Moreover, equation of kinematics and dynamics of manipulator of SR09 are deduced and closed form solution to these equations is given; a simple and specific dynamical algorithm based on Newton Euler equation using MapleTM is proposed too.
In chapter four, article concerns with methods of computing a trajectory in multidimensional space which describes the desired motion of a manipulator. Here, trajectory refers to a time history of position, velocity, and acceleration in joint space or Cartesian space. The contents includes several typical method of trajectory generation in joint angles such as Cubic polynomials, Cubic polyno-mials for a path with via points, higher order polynomials, linear function with parabolic blends, B-spline. In Cartesian space scheme. Chapter four also relates the mostly used trajectory in stamping robot, and a optimal algorithm comput-ing the work position of robot with minimum joint angles in non-singularity work space. A comparative Simulation is presented to verify a integrated trajectory that is composed several straight line and a circle in ADAMSTM at the end of chapter, and the simulation results shows that robot SR09 works well with the trajectory.
Chapter five discusses the structure of vison system, pin-hole camera prin-ciple, camera calibration. Machine vision system mainly consists of acquisition of image, and process of image. Image process aim at canceling noise by digital filtering, converting color or grey image into binary image, getting the contours of workpieces through edge detecting, computing the pixel coordinates by seg-menting image. The camera calibration of SR09 is given and an algorithm of object workpiece recognizing based on BP neural network is advanced, and the algorithm verified by test.
Chapter six discusses the monocular and binocular visual servoing systems and position based fuzzy PID controller. In this chapter, the principle, configura-tion of monocular and binocular with eye-in-hand are researched; including image Jacobian matrix, combination of multi-feature points Jacobian matrix, control al-gorithm of manipulator based on PD (Proportional derivative) control, binocular stereo visual servoing control system and related simulations.
Because the visual servoing robot takes the vision system as the motion sens-ing unit, undergone all kinds of disturbance, characterized with hyper non-linear and time varying, the precision of robot controller is deadly affected by the en-vironment. In order to improve the autonomy and adaptability of robot and to enhance its performance, in this chapter, a fuzzy PID controller is designed for SR09. making the control parameters be modified with error and derivative of the error and the control performance be improved continuously. The tracking simulation of a circle on a slant plane verified the controller working well.
Chapter seven is related to information fusion of robot. Information fusion is a process to use a numbers of synergistic sensors and combine these sensors effectively to form sensing system of high performance to acquire a consistent description of the sensed system. For the time being, the main methods to fu-sion information are weighted mean, Shafer-Dempster evidence inference, product ruler, fuzzy theory and neural network.
Stamping robot contacts the environment frequently when they works in a loop of grabbing objet, transporting the object and laying down the object. It is imperative that the normal force between the end-effector and environment be maintained in a certain controlled range. When the force sensor is absence, it is possible to know the force exerting on environment by measuring the current that flow through coil of the joint motor. Therefore, a sense of access is obtained. This is a good method to control the robot to position precisely with low cost. In this chapter the principle of hybird control of force and position was analyzed with no force sensor just by measuring the current of joint motor. By means of Robotics TOOLBOX for MATLAB developed by Doctor P. I. coke,a simulation system is build up and the simulation carried out.
Chapter eight is the conclusion. In this chapter some conclusions are made and a plan is advanced for future works.
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