基于疲劳分析的静电粉末喷涂机器人的反求设计
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摘要
本文首先简要介绍了静电喷涂的应用及发展现状,阐述了喷涂机器人的结构、用途和原理,以及其在实际使用中存在的问题,从而提出了本课题的研究重点。然后,详细介绍了静电粉末喷涂的工作原理、生产工艺和生产设备。在实际研究中,本文主要在以下几个方面对静电喷涂机器人进行了研究与改进:
针对传统失效分析中存在的分析周期长、计算工作量大、分析成本高等缺陷,在静电喷涂机器人失效分析中引入了有限元分析方法,通过有限元分析结果和零件失效照片的对比,得出了机械失效的原因。
运用反求工程的理论改进原方案,提出一些新方案,并设计出新的立柱及立柱连接方式,根据理论计算,证实了新方案的可行性。新方案较原方案比较,在抗弯曲强度方面明显改善,解决了其强度不够的问题。在静电喷涂机器人机械部分设计中,不仅仅局限于简单的仿造,通过对其失效的分析,提出了改进方案,并设计出了新的立柱和喷枪支架。
本设计利用ANSYS软件对该喷涂机器人进行实体建模,完成整机结构设计;根据机械装备理论以及对实体模型的参数分析进行结构改进;运用改进模型的参数选择相应的支撑件、加强筋、滚动导轨、滚珠丝杠、交流进给伺服电机,并进行了主要零部件的计算。
由此,在本文中,结合了有限元分析、CAD/CAE结构优化、以及Pro/engineer机械结构设计等多种技术,来对静电喷涂机器人进行失效分析、改进方案选择、结构改进等方面的研究结合以上各种技术的优点,综合提高了静电喷涂机器人的性能。目前,已经投入实际运行,使用寿命提高了3倍以上。
At the beginning of this thesis, the author introduces the application anddevelopment of electrostatic powder coating; introduce the construction, functionand principle of spraying robot. And then some problems to be solved in applicationare present to deduce the focus of this thesis. Describe the principle, work processand equipment of powder coating.
In general, the research is carried out in following aspects: Finite ElementMethod is introduced to the fatigue analysis of electrostatic spraying robot to avoidlong period, huge calculation and high cost of traditional analysis. Then, thecomparison between analysis results and photo of fatigue part is made to get thecause of fatigue.
After analyzing the reason why it loses, we bring forward a new design ofstructure, using the theory in Reverse Engineering. And we design new parts for thenew structure. After theoretical calculation, we know it is a optimization structure.Compared with the original project, new projects have been improved obviously inintensity and the machine’s longevity. During the process of mechanical design,some improvements are presented by fatigue analysis such as the design of standingmast and sprayer frame.
This design uses ANSYS software for the spraying robots complete whole setsof structural design; according to the machinery and equipment theory and thestructural development of the model entities analysis parameters use theimprovement model parameters to choose the corresponding rolling slide away, ballscrew, exchange into the servo motor, and the calculation and the majorcomponents.
In short, this thesis is aimed to improve the performance of electrostaticspraying robot by conducting the research of fatigue analysis, project design choice,and construction improvement and electronic control with the application of finiteelement method, CAD/CAE structure optimizes.
针对传统失效分析中存在的分析周期长、计算工作量大、分析成本高等缺陷,在静电喷涂机器人失效分析中引入了有限元分析方法,通过有限元分析结果和零件失效照片的对比,得出了机械失效的原因。
运用反求工程的理论改进原方案,提出一些新方案,并设计出新的立柱及立柱连接方式,根据理论计算,证实了新方案的可行性。新方案较原方案比较,在抗弯曲强度方面明显改善,解决了其强度不够的问题。在静电喷涂机器人机械部分设计中,不仅仅局限于简单的仿造,通过对其失效的分析,提出了改进方案,并设计出了新的立柱和喷枪支架。
本设计利用ANSYS软件对该喷涂机器人进行实体建模,完成整机结构设计;根据机械装备理论以及对实体模型的参数分析进行结构改进;运用改进模型的参数选择相应的支撑件、加强筋、滚动导轨、滚珠丝杠、交流进给伺服电机,并进行了主要零部件的计算。
由此,在本文中,结合了有限元分析、CAD/CAE结构优化、以及Pro/engineer机械结构设计等多种技术,来对静电喷涂机器人进行失效分析、改进方案选择、结构改进等方面的研究结合以上各种技术的优点,综合提高了静电喷涂机器人的性能。目前,已经投入实际运行,使用寿命提高了3倍以上。
At the beginning of this thesis, the author introduces the application anddevelopment of electrostatic powder coating; introduce the construction, functionand principle of spraying robot. And then some problems to be solved in applicationare present to deduce the focus of this thesis. Describe the principle, work processand equipment of powder coating.
In general, the research is carried out in following aspects: Finite ElementMethod is introduced to the fatigue analysis of electrostatic spraying robot to avoidlong period, huge calculation and high cost of traditional analysis. Then, thecomparison between analysis results and photo of fatigue part is made to get thecause of fatigue.
After analyzing the reason why it loses, we bring forward a new design ofstructure, using the theory in Reverse Engineering. And we design new parts for thenew structure. After theoretical calculation, we know it is a optimization structure.Compared with the original project, new projects have been improved obviously inintensity and the machine’s longevity. During the process of mechanical design,some improvements are presented by fatigue analysis such as the design of standingmast and sprayer frame.
This design uses ANSYS software for the spraying robots complete whole setsof structural design; according to the machinery and equipment theory and thestructural development of the model entities analysis parameters use theimprovement model parameters to choose the corresponding rolling slide away, ballscrew, exchange into the servo motor, and the calculation and the majorcomponents.
In short, this thesis is aimed to improve the performance of electrostaticspraying robot by conducting the research of fatigue analysis, project design choice,and construction improvement and electronic control with the application of finiteelement method, CAD/CAE structure optimizes.
引文
[1]张华东,粉末涂料与涂装发展简史,涂装与电镀,2007,5:15-16
[2]石银文,快速发展的机器人自动喷涂技术,机器人技术与应用,2007,9:11-13
[3]刘影,杭九全,万耀清,反求工程与现代设计,机械设计,1998,15(2):1-4
[4]刘之生,黄纯颖,反求工程技术,北京:机械工业出版社,1992
[5]姚卫星,结构疲劳寿命分析,北京:国防工业出版社,2003
[6]赵少汴,抗疲劳设计,北京:机械工业出版社,1994
[7]张向,杨庆雄,带孔元件裂纹形成及扩展的全寿命计算方法.西北工业大学学报,1984第2 (4):381-392
[8]王彦伟,基于有限元的疲劳分析方法及实践,机械设计与制造,2008,1:22-24
[9]杨国明,静电粉末喷涂技术和设备,1994,8,1994-2007 China AcademicJournal Electronic Publishing House.http://www.cnki.net
[10]秦福建,悬链输送机的性能特点及改造,炭素技术,2006,4(25):40-42
[11]赵先仲,机电系统设计,机械工业出版社,2004
[12]机械工程手册电机工程手册编辑委员会,机械工程手册:机械制造工艺及设备(二)
[13]机械工程手册编辑委员会,机械工程手册:第1篇第7章,机械工业出版社,1996
[14]叶瑞汶,机床大件焊接结构设计,北京:机械工业出版社,1986
[15]朱孝录,中国机械设计大典/机械传动设计,江西:科学技术出版社,2002.1:35-211
[16]张德泉,陈思夫,林彬,机械制造装备及其设计,天津:天津大学出版社,2003
[17]赵丁选,光机电一体化设计实用手册,北京:化学工业出版社,2003
[18]王茁,李颖卓,张波,机电一体化系统设计,北京:化学工业出版社,2005
[19] THK滚珠丝杠产品样本,THK股份有限公司
[20] THK直线运动系列.LM系列产品说明书,THK股份有限公司,1994.10
[21] J.DelamarE,ClassEfzcation and SynthGsis of PermanEnt Magnet BearingConfigurations .IEEE Trans on Magnetics,1995,3(6)
[22]赵松年,张奇鹏,机电一体化机械系统设计,北京:机械工业出版社,1996
[23]涂装机器人控制装置操作说明书,松尾产业株式会社,2001.9
[2]石银文,快速发展的机器人自动喷涂技术,机器人技术与应用,2007,9:11-13
[3]刘影,杭九全,万耀清,反求工程与现代设计,机械设计,1998,15(2):1-4
[4]刘之生,黄纯颖,反求工程技术,北京:机械工业出版社,1992
[5]姚卫星,结构疲劳寿命分析,北京:国防工业出版社,2003
[6]赵少汴,抗疲劳设计,北京:机械工业出版社,1994
[7]张向,杨庆雄,带孔元件裂纹形成及扩展的全寿命计算方法.西北工业大学学报,1984第2 (4):381-392
[8]王彦伟,基于有限元的疲劳分析方法及实践,机械设计与制造,2008,1:22-24
[9]杨国明,静电粉末喷涂技术和设备,1994,8,1994-2007 China AcademicJournal Electronic Publishing House.http://www.cnki.net
[10]秦福建,悬链输送机的性能特点及改造,炭素技术,2006,4(25):40-42
[11]赵先仲,机电系统设计,机械工业出版社,2004
[12]机械工程手册电机工程手册编辑委员会,机械工程手册:机械制造工艺及设备(二)
[13]机械工程手册编辑委员会,机械工程手册:第1篇第7章,机械工业出版社,1996
[14]叶瑞汶,机床大件焊接结构设计,北京:机械工业出版社,1986
[15]朱孝录,中国机械设计大典/机械传动设计,江西:科学技术出版社,2002.1:35-211
[16]张德泉,陈思夫,林彬,机械制造装备及其设计,天津:天津大学出版社,2003
[17]赵丁选,光机电一体化设计实用手册,北京:化学工业出版社,2003
[18]王茁,李颖卓,张波,机电一体化系统设计,北京:化学工业出版社,2005
[19] THK滚珠丝杠产品样本,THK股份有限公司
[20] THK直线运动系列.LM系列产品说明书,THK股份有限公司,1994.10
[21] J.DelamarE,ClassEfzcation and SynthGsis of PermanEnt Magnet BearingConfigurations .IEEE Trans on Magnetics,1995,3(6)
[22]赵松年,张奇鹏,机电一体化机械系统设计,北京:机械工业出版社,1996
[23]涂装机器人控制装置操作说明书,松尾产业株式会社,2001.9