弱刚度构件工业机器人铣削偏转误差建模

Modeling of milling deflection errors in industrial robots and low-stiffness component system

  • 摘要: 弱刚度构件机器人铣削过程中,机器人与悬臂工件均具有柔性特征,在铣削力作用下二者极易产生较大弹性变形,进而导致刀具轴线与铣削端面发生偏移,严重影响加工精度与表面质量。针对该问题,提出了一种综合考虑机器人末端定位误差与机器人-弱刚度构件偏转误差的建模与补偿方法。首先,利用线激光传感器对工业机器人进行定位误差辨识与偏转刚度标定,并采用有限元方法求解弱刚度构件的偏转误差。然后,建立综合考虑机器人定位误差、偏转误差与工件偏转误差的误差模型。最后,基于该模型得到误差补偿值,开展了机器人铣削偏转误差补偿试验。试验结果表明,经偏转误差补偿的样件表面粗糙度降低了13.42%,平面度降低了27.27%,有效提升了表面加工质量。

     

    Abstract: During the robotic milling process of low-stiffness components, both the robot and workpiece exhibit flexible characteristics that can induce significant elastic deformations under milling forces, resulting in axial misalignment between the cutting tool and workpiece. This phenomenon severely compromises machining accuracy and surface quality. To address this issue, a modeling and compensation method that comprehensively considers the positioning error at the end of the robot and the deflection error of the robot-weak stiffness component is proposed. Firstly, a laser displacement sensor is employed for robot positioning error identification and deflection stiffness calibration, while finite element analysis is implemented to calculate the component deflection errors. Secondly, an integrated error model is subsequently established incorporating robot positioning errors, robot deflection errors, and workpiece deflection errors. Finally, based on this model, compensation for robotic end-face milling deflection errors is implemented. Experimental results demonstrate that compared with uncompensated machining, the proposed compensation method achieves 13.42% and 27.27% reductions in surface roughness and flatness error respectively, effectively enhancing surface machining quality.

     

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