【作者】 徐峰；

【导师】 姚恩涛；

【作者基本信息】 南京航空航天大学 ， 测试计量技术及仪器， 2022， 硕士

【摘要】 地铁车厢使用的不锈钢管材具有不同直径、不同长度、不同形状,这些管材都是由细长管材加工而成。目前,管材从拣选到下料通常由人工完成。大长细比管材弯曲刚度小、变形较大,人工拣选时容易发生弯曲,且重复的拣选作业会增加操作人员的劳动强度。管材的下料涉及多段管材的切割工序,操作不慎极易引发安全问题,此外,市场上现有的自动化拣选或下料设备往往难以进行多种规格或规模较大的作业,改造成本较高。本文设计一种柔性化自动拣选和下料设备,并对其中的关键性问题进行研究。具体研究内容如下:1)根据某制造企业的大长细比管材的拣选和下料功能需求,确定了拣选和下料设备的性能指标。采用可配置柔性化体系结构,并在此基础上设计了数据通信网络,实现设备的互联互通与控制管理。基于Modbus总线技术与无线通信技术设计主从分布式控制系统网络结构,根据管材搬运和夹取的工作特点,确定采用电气混合的驱动方式。2)使用Solid Works对拣选机械手进行模块化结构设计,使用Ansys-workbench对拣选机械手取料和放料工况进行静力学分析,验证拣选机械手的刚度和强度满足要求。进行模态分析,确认拣选机械手振动稳定性情况,并未产生共振。为保证在拣选过程中管材不会产生塑性形变,采用多机械手协同工作的拣选模式,并设计同步控制策略。最后搭建拣选机械手样机,对带轮直线驱动结构和柔性气动夹爪等结构进行设计。编写现场调度器、通用控制器的软件程序,通过实验验证了拣选系统的可行性,同步控制响应时间差为4.59ms,拣选周期为28.19s,符合技术指标。3)设计下料设备各个功能模块机械结构,确定驱动方式和传动方式。针对送料模块中大位移的精确定位问题,研究送料模块位置控制系统,设计了位置、速度双闭环反馈的PID控制方法,使用MATLAB/Simulink软件进行仿真并分析。针对不同管径管材的切割问题,设计柔性钳口调节辅助机构。最后搭建下料设备样机,并与拣选机械手进行联动作业实验,下料精度达到±1mm内,进一步验证了可配置柔性化体系结构的合理性。4)对送料模块中应用的拉线位移传感器进行研究,分析其误差来源,针对非线性误差的补偿,设计一种基于PSO-BP的拉线位移传感器误差补偿方法,搭建拉线位移传感器测量实验平台,建立数据集进行网络训练,将训练后的网络进行误差的预测及补偿,将补偿前后的误差情况对比,平均绝对值误差由2.809mm降低为0.167mm,标准偏差由2.102mm降低为0.102mm,精度由0.136%FS提高到0.007%FS,补偿效果显著。更多还原

【Abstract】 The stainless steel pipes used in subway cars have different diameters,lengths and shapes,and are made from slender pipes.At present,pipe from picking to blanking is usually completed manually.Large slenderness ratio of pipe bending stiffness is small,large deformation,manual picking is prone to bending,and repeated picking operation will increase the labor intensity of operators.The blanking of pipe involves the cutting process of multiple sections of pipe,and the careless operation is easy to cause safety problems.In addition,the existing automatic picking or blanking equipment in the market is often difficult to carry out a variety of specifications or large-scale operations,and the transformation cost is high.In this paper,a flexible automatic picking and blanking equipment is designed and its key problems are studied.The specific research contents are as follows:1)The performance indexes of the picking and blanking equipment are determined according to the functional requirements of the large slenderness ratio pipe and blanking of a manufacturing enterprise.The data communication network is designed based on the configurable flexible architecture to realize the interconnection and control management of equipment.Based on Modbus technology and wireless communication technology,the master-slave distributed control system network structure is designed.According to the working characteristics of pipe handling and clamping,the electric hybrid driving mode is determined.2)Use Solid Works to design the modular structure of the picking manipulator,use ANSYS-Workbench to carry out statics analysis of the picking manipulator’s picking and discharging conditions,and verify that the stiffness and strength of the picking manipulator meet the requirements.Modal analysis was conducted to confirm the vibration stability of the picking manipulator and no resonance was generated.In order to ensure no plastic deformation in the process of picking,the picking mode of multi-manipulator working together is adopted and the synchronous control strategy is designed.Finally,a picking manipulator prototype is built,and the linear drive structure with wheels and flexible pneumatic gripper are designed.The software program of field scheduler and general controller was written,and the feasibility of picking system was verified through experiments.The response time difference of synchronous control was 4.59 ms,and the picking cycle was 28.19 s,which met the technical specifications.3)Design the mechanical structure of each functional module of blanking equipment,and determine the driving mode and transmission mode.Aiming at the precise positioning problem of large displacement in the feeding module,the position control system of the feeding module was studied,and the PID control method with double closed-loop feedback of position and speed was designed,which was simulated and analyzed by MATLAB/Simulink software.In view of the cutting problem of pipes with different diameters,the auxiliary adjusting mechanism of flexible jaws is designed.Finally,the prototype of the blanking device was built,and the linkage operation experiment was carried out with the picking manipulator.The blanking accuracy reached ±1mm,which further verified the rationality of the configurable flexible system structure.4)of the module of feeding the application thread displacement sensor is studied,the analysis of the error sources,in view of the nonlinear error compensation,design a kind of based on PSO and BP drawing displacement sensor error compensation method,set up drawing displacement sensor measurement experiment platform,establishing network training data set,the training after the network error prediction and compensation,The average absolute error decreases from 2.809 mm to0.167 mm,the standard deviation decreases from 2.102 mm to 0.102 mm,and the accuracy increases from 0.136%FS to 0.007%FS.The compensation effect is significant.更多还原