機器人化復合材料自動(dòng)鋪層技術(shù)綜述
doi: 10.16383/j.aas.c230149
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1.
華南理工大學(xué)自動(dòng)化科學(xué)與工程學(xué)院 廣州 510000
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武漢大學(xué)工業(yè)科學(xué)研究院 武漢 430000
A Review on Robotized Automated Lay-up Technology for Composite Material Manufacturing
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1.
School of Automation Science and Engineering, South China University of Technology, Guangzhou 510000
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The Institute of Technological Sciences, Wuhan University, Wuhan 430000
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摘要: 碳纖維增強復合材料(Carbon fiber-reinforced composite, CFRC)因具有輕質(zhì)高強、耐腐蝕、耐沖擊等優(yōu)越性能, 在生產(chǎn)生活中的應用已越來(lái)越廣泛, 然而復材產(chǎn)品的生產(chǎn)制造仍是勞動(dòng)密集性產(chǎn)業(yè), 主要依靠人工. 機械臂自上世紀50年代進(jìn)入工業(yè)生產(chǎn)中以來(lái), 極大提高了生產(chǎn)效率和質(zhì)量, 然而目前機械臂在復材產(chǎn)品制造中的應用是少見(jiàn)的, 主要集中在機械臂形式的自動(dòng)鋪絲(Automated fiber placement, AFP)中. 復材產(chǎn)品制造工藝繁瑣, 將復合材料鋪放在模具上是復材產(chǎn)品制造過(guò)程中的一個(gè)重要環(huán)節, 本文稱(chēng)之為“鋪層”, 使用機械臂完成復合材料自動(dòng)鋪層將是未來(lái)復材產(chǎn)品制造自動(dòng)化、智能化發(fā)展的一個(gè)關(guān)鍵方向. 本文將機械臂進(jìn)行復合材料自動(dòng)鋪層操作分為兩種主要形式: 鋪片和鋪帶(絲), 通過(guò)案例調研和分析, 歸納總結現有的設計理念和技術(shù)方法, 提出未來(lái)發(fā)展趨勢, 以期對機械臂的應用和研究、復材產(chǎn)品的智能化制造和工業(yè)4.0的發(fā)展形成參考.
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關(guān)鍵詞:
- 碳纖維增強復合材料 /
- 機械臂控制 /
- 末端設計 /
- 自動(dòng)鋪層
Abstract: Carbon fiber-reinforced composite (CFRC) has been widely used in production and life because of its superior properties such as light weight and high strength, corrosion resistance and impact resistance. However, the manufacturing of composite products is still a labor-intensive industry, mainly relying on manual labor. Since the robot arm entered the industrial production in the 1950s, it has greatly improved the production efficiency and quality, however, the current application of robot arm in the manufacturing of composite products is rare, mainly focusing on the robot arm form of automated fiber placement (AFP). The manufacturing process of composite products is tedious, and laying the composite material on the mold is an important part of the manufacturing process of composite products, which we call “l(fā)ay-up”, and the use of robot arm to complete the automated lay-up operation will be a key direction for the future automation and intelligent development of the manufacturing of composite products. This paper offers a thorough examination of automated lay-up operation for robot arm, and categorizes them into two primary types: Lay-up sheets and lay-up tapes (fibers). Through case study and analysis of existing design concepts and technical methods, this paper identifies trend and suggests future development direction. The insights are of significant value for application and research related to robot arm, intelligent manufacturing of composite products, and the progression of Industry 4.0. -
圖 1 復材產(chǎn)品制造工藝的生產(chǎn)流程圖
Fig. 1 Production flow chart of the manufacturing process of composite products
圖 6 面向工業(yè)生產(chǎn)的多機械臂協(xié)同鋪層研究案例
Fig. 6 Multi-robot arms collaborative lay-up study cases for industrial production
表 1 機械臂在傳統工業(yè)場(chǎng)景和復材產(chǎn)品制造場(chǎng)景應用特點(diǎn)對比
Table 1 Comparison of the application characteristics of robot arm in traditional industrial scenario and composite products manufacturing scenario
對比 特點(diǎn) 傳統工業(yè)場(chǎng)景 復材產(chǎn)品制造場(chǎng)景 噴涂 點(diǎn)焊 搬運 裝配 鋪片 鋪帶(絲) 相同之處 重復定位精度 高 位置跟蹤要求 高 不同之處 操作是否接觸 否 是 是 是 是 是 操作材料特性 氣體 高溫 硬質(zhì) 硬質(zhì) 柔軟粘性 柔軟粘性 是否需要加熱 否 是 否 否 是 是 是否有接觸力 否 否 是 是 是 是 末端構造 噴嘴 焊鉗 夾持 各類(lèi)工具 夾持懸垂拾取 專(zhuān)有鋪放頭 
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表 2 不同拾取原理的優(yōu)劣對比
Table 2 Comparison of the advantages and disadvantages of different pick-up principles
拾取原理 對材料的損壞程度 成本 實(shí)現難度 易操作性 針刺 高 低 低 高 低溫 中 中 中 中 真空吸取 無(wú) 高 中 中
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表 3 單機械臂鋪層研究案例對比
Table 3 Comparison of single robot arm lay-up study cases
研究機構 研究重點(diǎn) 路徑規劃 運動(dòng)規劃 工藝參數 系統軟件 使用的機械臂 相關(guān)文獻 德國宇航中心 全過(guò)程自動(dòng)化 基于視覺(jué)生成 系統生成 未知 獨立開(kāi)發(fā) KUKA [45?46, 71?72] 漢堡科技大學(xué) 工藝流程優(yōu)化 未知 未知 未知 未知 ABB [73?76] 慕尼黑工業(yè)大學(xué) 全過(guò)程自動(dòng)化 人類(lèi)專(zhuān)家設計 控制器生成 人類(lèi)專(zhuān)家設計 CFK-Tex.Office KUKA KR-500 [32?34, 77] 布里斯托大學(xué) 鋪放自動(dòng)化 未知 未知 人類(lèi)專(zhuān)家設計 未知 ABB [62] 德國宇航中心 全過(guò)程自動(dòng)化 系統生成 系統生成 未知 獨立開(kāi)發(fā) KUKA [78?79] 南丹麥大學(xué) 鋪放自動(dòng)化 基于模擬方法 系統生成 未知 獨立開(kāi)發(fā) KUKA KR-360 [60, 80?84]
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表 4 多機械臂協(xié)同鋪層研究案例對比
Table 4 Comparison of multi-robot arms collaborative lay-up study cases
研究機構 機械臂數量 研究?jì)热?/td> 路徑規劃 運動(dòng)規劃 系統軟件 使用的機械臂 相關(guān)文獻 南卡羅萊納大學(xué) 3 路徑規劃 運動(dòng)規劃 算法生成 控制器生成 獨立開(kāi)發(fā) KUKA-iiwa [85?87, 89?91] 斯圖加特大學(xué) 3 系統搭建 路徑規劃 人類(lèi)專(zhuān)家設計 系統生成 獨立開(kāi)發(fā) ABB [64, 92] 德國宇航中心 2 系統搭建 路徑規劃 算法生成 系統生成 獨立開(kāi)發(fā) KUKA-KR270 [93?101] 空客集團 2 系統搭建 末端開(kāi)發(fā) 人類(lèi)專(zhuān)家設計 系統生成 獨立開(kāi)發(fā) KUKA [41?42, 106] 林雪平大學(xué) 2 技術(shù)驗證 末端開(kāi)發(fā) 未知 未知 未知 KUKA-KR10, ABB [107?108] 慕尼黑工業(yè)大學(xué) 2 系統搭建 路徑規劃 算法生成 系統生成 獨立開(kāi)發(fā) Staubli, KUKA [24] 思克萊德大學(xué) 1 技術(shù)驗證 人類(lèi)專(zhuān)家設計 系統生成 獨立開(kāi)發(fā) KUKA-KR6 [110] 維也納技術(shù)大學(xué) 2 技術(shù)驗證 人類(lèi)專(zhuān)家設計 系統生成 未知 自制 [111?112]
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表 5 鋪帶(絲)頭中采用的切割方式對比
Table 5 Comparison of cutting methods used in tape (fiber) lay-up heads
切割方式 成本 優(yōu)點(diǎn) 缺點(diǎn) 機械道具切割 低 結構簡(jiǎn)單, 切割效率高, 適用于多種復雜環(huán)境,
維修更換比較方便難以控制切割深度且切口毛糙, 損傷預浸料,
無(wú)法保證切口質(zhì)量激光切割 較高 切割效率高, 非接觸式切割, 產(chǎn)品邊緣光滑平整,
激光對位精準, 切割精度高溫度較高, 使復合材料發(fā)生變質(zhì)且
切割深度不易控制水噴射切割 低 設備結構簡(jiǎn)單, 操作容易, 工作機構具有噴頭體積小、
后坐力小、移動(dòng)方便、生產(chǎn)效率高等特點(diǎn)給整個(gè)鋪帶環(huán)境帶來(lái)大量污染液體,
影響復合材料成型, 鋪帶工作不便超聲波切割 較高 切割效率高, 切口平整; 合適的切割速度、
切割深度滿(mǎn)足不同工況下的切割易受負載、溫度等因素影響, 引起諧振頻率、
等效阻抗等參數漂移變化
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表 6 鋪帶(絲)頭中采用的加熱方式對比
Table 6 Comparison of heating methods used in tape (fiber) lay-up heads
加熱方式 成本 優(yōu)點(diǎn) 缺點(diǎn) 電阻絲加熱 低 加熱均勻, 實(shí)現簡(jiǎn)單 熱損失大, 功率密度低, 使用壽命短 激光加熱 高 激光加熱效率高, 響應快 溫度難以控制, 容易產(chǎn)生局部過(guò)熱 熱風(fēng)加熱 低 溫度場(chǎng)均勻, 調節范圍廣 加熱升溫時(shí)間長(cháng), 熱效率較低 紅外加熱 高 熱效率高, 加熱均勻, 響應速度快 輻射面存在一定限制, 溫度場(chǎng)不均勻
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表 7 路徑規劃方法對比
Table 7 Comparison of path planning methods
分類(lèi) 方法 優(yōu)點(diǎn) 缺點(diǎn) 參考路徑生成 自然路徑法 可以避免纖維起皺, 軌跡可鋪放性良好 計算量大, 僅適用于低曲率表面 定角度路徑法 原理及計算過(guò)程簡(jiǎn)單 僅適用于整體曲率波動(dòng)較小的曲面 變角度路徑法 能夠自適應芯模曲面不規則情況 算法計算量大 路徑密化 等距偏置算法 算法簡(jiǎn)單, 能夠覆蓋整個(gè)芯模表面 在復雜表面上可能存在間隙和重疊 等角度算法 算法實(shí)現簡(jiǎn)單, 適應各種復雜構件 易存在間隙和重疊
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關(guān)鍵技術(shù) 研究?jì)热?/td> 研究目標 軌跡規劃 根據構件3D表面設計相應路徑規劃算法, 自適應生成鋪放軌跡 滿(mǎn)足構件結構的方向性、鋪放順序和鋪疊層數要求 鋪放路徑覆蓋 根據曲面上相鄰路徑的間距, 對鋪絲路徑的覆蓋性進(jìn)行檢驗與優(yōu)化 實(shí)現對模具的滿(mǎn)覆蓋、不重疊, 滿(mǎn)足空隙容差 邊界處理 根據構件的邊界輪廓信息, 設計邊界處理算法, 控制邊緣和角部的鋪放方式與形態(tài) 確保鋪放邊界質(zhì)量和表面光潔度 后置處理 數控代碼生成、代碼優(yōu)化與合成、加工仿真技術(shù)等 機器人能夠識別執行的指令
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表 9 現有自動(dòng)化缺陷檢測技術(shù)優(yōu)劣對比
Table 9 Comparison of the advantages and disadvantages of existing automated defect detection technologies
檢測技術(shù) 使用設備 安裝方式 優(yōu)點(diǎn) 缺點(diǎn) 相關(guān)文獻 激光輔助檢測 激光投影儀 固定支架安裝 實(shí)時(shí)性好、精度高、分辨率高 投影儀與模具間的相對位置精度要求高,
對效率提升不明顯[189?191] 紅外熱成像檢測 熱成像儀 集成在鋪放頭 檢測成本低 對環(huán)境溫度要求嚴格, 精度難以保證 [192?195] 基于輪廓數據檢測 激光輪廓儀 集成在鋪放頭或安裝在
機械臂末端檢測結果準確, 不易受環(huán)境影響 計算量大, 需要極高性能計算平臺,
僅能檢測外部缺陷[196?200] 機器視覺(jué)檢測 工業(yè)相機 集成在鋪放頭 檢測效果好, 自動(dòng)化程度高 檢測系統適應性不高 [201?212]
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