Modal analysis and mid-spatial-frequency errors suppression of 6-DOF bonnet polishing robot
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摘要: 针对六自由度串联式关节机器人气囊抛光系统因刚度不足引起的加工振动以及引入中频误差的问题，以IRB 6700机器人作为研究对象，基于Ansys Workbench建立模态分析模型，并结合实验分析机器人气囊抛光系统工况频带内动态特性，实验与仿真结果共同表明，机器人气囊抛光系统在工况频带至少存在5阶模态，且共振时机器人末端抖动幅值为mm级，机器人加工严重受限。同时针对机器人气囊抛光系统先进光学元件抛光工艺应用，设计一种阻尼抑振气囊工具头，与普通气囊工具头进行定点抛光与整面抛光对比实验。结果表明：抑振气囊头定点抛光斑粗糙度与频谱幅值普遍低于普通气囊工具头，引入的中频误差较一般气囊工具头低40%，抛光优化效果显著。Abstract: Aiming at the insufficient stiffness of the bonnet polishing system of the six-degree-of-freedom tandem joint robot, which may cause vibration and further mid-spatial-frequency errors, used we the IRB 6700 robot as the research object, established the modal analysis model based on Ansys Workbench and combined experiment to analyze the dynamic characteristics of the robot bonnet polishing system in the working condition frequency range. The experimental and simulation results together show that the robot bonnet polishing system has at least 5 modes in the working condition frequency range, and the jitter amplitude at the end of the robot is millimeter-level when the resonance occurs. Robot processing is severely restricted. In addition, for the application of advanced optical component polishing technology in the robotic bonnet polishing system, a vibration suppression bonnet tool was designed, and the fixed-point polishing and whole-surface polishing comparison experiments were carried out with the ordinary bonnet tool. The results show that the RMS and spectral amplitude of the fixed-point polishing spot of the vibration suppression bonnet are generally lower than that of the ordinary bonnet, and the introduced mid-spatial-frequency errors PSD is 40% lower than that of general bonnet polishing.
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图 3 脉冲激励法模态实验传感器布点
Figure 3. Sensor placement in pulse excitation method modal experiment
图 4 机器人双姿态各测点加速度响应频谱
Figure 4. Acceleration response spectrum of each measuring point of the robot in dual postures
图 6 工业机器人变转速空转各关节点位移响应
Figure 6. Displacement response of each joint point of an industrial robot at variable speed idling
图 8 不同规格弹性元件仿真耗能值
Figure 8. Simulated energy consumption values of elastic components of different specifications
图 11 普通气囊与抑振气囊定点抛光RMS对比
Figure 11. Comparison of fixed-point polishing RMS between ordinary bonnet tool and vibration suppression bonnet tool
图 12 普通气囊与抑振气囊定点抛光斑频谱对比
Figure 12. Comparison of spectra of fixed-point polishing spots between ordinary bonnet tool and vibration suppression bonnet tool
图 13 原始气囊工具头与抑振气囊工具头抛光效果对比
Figure 13. Comparison of the polishing effect of the original bonnet tool and the vibration suppression bonnet tool
图 14 原始气囊整面抛光与抑振气囊整面抛光Y向中频误差对比
Figure 14. Comparison of the Y-direction mid-frequency error between the whole surface polishing of the original bonnet tool and the whole surface polishing of the vibration suppression bonnet tool
表 1 气囊抛光系统参数
Table 1. Bonnet polishing system parameters
scope of work/m carrying capacity/kg repeatability/mm repeat path accuracy/mm total mass/kg 2.6 200 0.05 0.10 1170 
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表 2 仿真材料参数
Table 2. Simulation material parameters
material density/(kg/m3) Young’s modulus/MPa Poisson’s ratio gray cast iron 7200 1.1×1011 0.28 aluminum alloy 2770 7.1×1010 0.33 concrete 2300 3×1010 0.18 sand 2000 1×108 0.25 60Si2MnA 7740 2.06×1011 0.29
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表 3 IRB 6700关节刚度
Table 3. IRB 6700 joint stiffness
joint1 joint2 joint3 joint4 joint5 joint6 joint stiffness/(mm∙N/rad) 2.53×109 9.31×108 6.52×108 9.12×107 4.36×107 2.34×107
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表 5 Mooney-Rivilin超弹性本构模型
Table 5. Mooney-Rivilin hyperelastic constitutive model
material constant/Pa C10 C01 2.45×106 −9.58×105
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表 6 3阶广义麦克斯韦粘弹性本构模型
Table 6. The third-order generalized Maxwell viscoelastic constitutive model
dimensionless material constant relaxation time/s g1 g2 g3 τ1 τ2 τ3 0.10293 0.57067 0.05479 0.02905 0.00082 0.78611
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表 7 原始气囊工具头与抑振气囊工具头抛光效果对比
Table 7. Comparison of the polishing effect of the original bonnet tool and the vibration suppression bonnet tool
comparison parameters originary bonnet vibration suppression bonnet relative reduction rate PV/μm before polishing 2.866 2.000 — after polishing 2.809 1.948 PSD/(mm·nm2) before polishing — — 40% after polishing 316.9 187.5 RMS/nm before polishing 540.773 395.562 — after polishing 534.043 382.256
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