基于并联机构理论大型锻造操作机设计与分析
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摘要
锻造操作机是现代锻造系统的重要设备之一，它的使用能大大地提高大锻件锻造的生产效率和质量。但是国内大型锻造操作机的设计与分析还几乎处于空白，所以本文将基于并联机构相关理论对大型锻造操作机进行系统地设计与分析，主要研究内容如下：
采用基于螺旋理论的约束综合法对大型锻造操作机的构型设计进行了系统地研究，得到了多种并联机构和串并联形式的混联机构锻造操作机新构型；提出了两种判别过约束并联机构自由度瞬时性的简便方法，并对构造得到的过约束并联机构锻造操作机构型进行了自由度瞬时性判别。
从解耦性、侧向缓冲缸安装位置和夹持能力三个运动特性方面对一种典型DDS锻造操作机机构、一种典型SMS锻造操作机机构和四种新型锻造操作机机构进行了比较分析；分析了其中五种锻造操作机的主运动机构的位置正解和静力学，对其综合受力性能进行了比较分析，发现了操作机机构受力性能多个有规律的特征。
提出了两种求解过约束并联机构变形协调方程的新方法，考虑系统弹性变形推导了冗余驱动并联机构驱动力/力矩解的一般解析表达式，同时证明了采用伪逆法求解冗余驱动并联机构的驱动力/力矩时不存在内力，并将理论分析结果应用到冗余驱动锻造操作机机构2SPS+R的驱动力求解；将被动过约束并联机构动平台受到的约束力螺旋中的线性相关部分定义为过约束力螺旋系，并将其转化成线性无关的等效约束力螺旋系，考虑连杆的弯曲、拉伸和扭转变形推导得到了分支过约束力螺旋刚度矩阵，建立了被动过约束并联机构受力分析比较完整的具有普适性的研究方法，并采用该方法对一种被动过约束锻造操作机悬挂机构4-SS进行了受力分析。
考虑钳杆的所有锻造操作动作，以两种新型平行连杆式锻造操作机为例，采用修正的Grübler-Kutzbach公式计算了锻造操作机整体机构的自由度，并以机构重力势能最低为约束条件对机构的运动规律进行了优化分析，得到了符合实际情况的运动规律，对锻造操作机的整体机构进行了全面的运动学分析，并采用Adams软件对理论分析结果进行了仿真验证。
提出了一种改进的比例系数法用于求解平面并联机构能承受的最大外力与最大力矩，与传统的比例系数法相比，该方法计算量小而且得到的结果更加精确，并采用改进的比例系数法分析了一种新型锻造操作机机构能夹持的最大锻件重力以及由于锻件重力引起的最大力矩。
基于Adams仿真软件提出了一种建立并联机构仿真模型的新方法，这种方法建模简单、快捷，通用性强，能够快速地实现并联机构的运动学仿真与尺度优化分析，并采用该建模方法建立了一种新型锻造操作机主运动机构的参数化模型，对其进行了尺度优化。
研制了一种新型锻造操作机机构的1/20比例实验模型，并开展了该操作机比例实验模型完成各种锻造操作动作和受力性能测试的实验研究，实验结果表明该操作机能实现构型理论分析的所有锻造操作动作，并验证了这样的结论：平行连杆式锻造操作机机构升降缸驱动力与锻件偏心距大小几乎无关。
Forging manipulator is one of the important equipments for the modern forgingsystem. By using the forging manipulator, production efficiency and quality of the heavyforged piece can be greatly improved. However, design and analysis of the large-scaleforging manipulator is still almost blank home, so design and analysis of the large-scaleforging manipulator will be carried out systematically based on parallel mechanism theoryin this paper. The main research contents are as follows:
Type synthesis of the forging manipulator is studied systematically by using theconstraint-synthesis method based on screw theory, many new configurations of parallelmechanism and hybrid serial-parallel mechanism for the forging manipulator are obtained.Two simple methods for distinguishing the mobility’s instantaneity of the overconstrainedparallel mechanism are put forward, and the mobility’s instantaneity of theoverconstrained parallel mechanisms for the forging manipulator configurated above isdistinguished by using the proposed methods.
Based on three motion characteristics, which are decoupling, installation position ofthe lateral buffering cylinder and clamping ability, respectively, a typical mechanism ofDDS forging manipulator, a typical mechanism of SMS forging manipulator, and four newmechanisms of forging manipulator are compared. Forward positon and static analysis ofthe main motion mechanism of five mechanisms among them are conducted, thencomparative analysis on comprehensive force performance of these five mechanisms iscarried out, and several regular features of force performance of the forging manipulatorare also discovered.
Two novel methods for establishing deformation compatibility equations of theoverconstrained parallel mechanism are proposed, and the general analytical expression ofthe actuated force/moment solution to the redundantly actuated parallel manipulators isderived in the condition that system elastic deformation is taken into account. Besides, it isproved that no internal forces exist within the pseudo-inverse solution to the actuated force/moment of the redundantly actuated parallel manipulators. And then, theoreticalanalysis results are applied to solving the actuated forces of the redundantly actuatedforging manipulator2SPS+R. The linearly dependant constraint wrenches imposed on themoving platform of the passive overconstrained parallel mechanism are defined asoverconstraint wrenches, and they are transformed into equivalent linearly independantconstraint wrenches. Then considering the link’s bending, tensile and torsionaldeformation, Stiffness matrix of the branch’s overconstraint wrenches is deduced, a morecomplete and universal method for force analysis of the passive overconstrained parallelmechanism is built up, and force analysis of a passive overconstrained suspensionmechanism4-SS of forging manipulator is performed by using this method.
Considering the gripper carrier’s all forging operation action, two new parallel linkmechanisms of forging manipulator are taken as examples, the degree of freedom of thewhole mechanism of forging manipulator is calculated by using the modifiedGrübler-Kutzbach criterion. Taking minimum gravitational potential energy of themechanism as the constraint condition, optimization analysis of the mechanism isperformed, and the actual motion law is obtained. Kinematic analysis of the wholemechanism of forging manipulator is carried out, and the mechanism is simulated byAdams software to testify the correctness of the theoretical analysis results.
A modified scaling factor method for force capabilities analysis of the planar parallelmanipulators is presented, by which the solution of the largest force and the largestmoment can be derived. For this modified method, the process is computationally smalland the results obtained are more exact. The largest weight of the forged piece and thelargest moment generated by the eccentricity of the forged piece that a new mechanism offorging manipulator is analyzed by using this modified scaling factor method.
A new approach for establishing simulation model of the parallel mechanism basedon Adams software is proposed.This modeling method is simple, fast and versatile, whichcan realize kinematic simulation and dimensional optimization analysis of the parallelmechanism quickly. And then, parametric model of the main motion mechanism of a newforging manipulator is established by using the new approach, dimensional optimization ofthe mechanism is carried out.
Experimental model with ratio1/20of a new forging manipulator is developed, andexperimental study on completing various forging operation action and force performancetesting is performed. The experimental results show that the new forging manipulator canachieve all the forging operation action as the configuration theory analyzed, and verifythe conclusion that the lifting cylinder’s driving force of paralle link mechanism of forgingmanipulator is independent of the eccentricity of the forged piece.
采用基于螺旋理论的约束综合法对大型锻造操作机的构型设计进行了系统地研究，得到了多种并联机构和串并联形式的混联机构锻造操作机新构型；提出了两种判别过约束并联机构自由度瞬时性的简便方法，并对构造得到的过约束并联机构锻造操作机构型进行了自由度瞬时性判别。
从解耦性、侧向缓冲缸安装位置和夹持能力三个运动特性方面对一种典型DDS锻造操作机机构、一种典型SMS锻造操作机机构和四种新型锻造操作机机构进行了比较分析；分析了其中五种锻造操作机的主运动机构的位置正解和静力学，对其综合受力性能进行了比较分析，发现了操作机机构受力性能多个有规律的特征。
提出了两种求解过约束并联机构变形协调方程的新方法，考虑系统弹性变形推导了冗余驱动并联机构驱动力/力矩解的一般解析表达式，同时证明了采用伪逆法求解冗余驱动并联机构的驱动力/力矩时不存在内力，并将理论分析结果应用到冗余驱动锻造操作机机构2SPS+R的驱动力求解；将被动过约束并联机构动平台受到的约束力螺旋中的线性相关部分定义为过约束力螺旋系，并将其转化成线性无关的等效约束力螺旋系，考虑连杆的弯曲、拉伸和扭转变形推导得到了分支过约束力螺旋刚度矩阵，建立了被动过约束并联机构受力分析比较完整的具有普适性的研究方法，并采用该方法对一种被动过约束锻造操作机悬挂机构4-SS进行了受力分析。
考虑钳杆的所有锻造操作动作，以两种新型平行连杆式锻造操作机为例，采用修正的Grübler-Kutzbach公式计算了锻造操作机整体机构的自由度，并以机构重力势能最低为约束条件对机构的运动规律进行了优化分析，得到了符合实际情况的运动规律，对锻造操作机的整体机构进行了全面的运动学分析，并采用Adams软件对理论分析结果进行了仿真验证。
提出了一种改进的比例系数法用于求解平面并联机构能承受的最大外力与最大力矩，与传统的比例系数法相比，该方法计算量小而且得到的结果更加精确，并采用改进的比例系数法分析了一种新型锻造操作机机构能夹持的最大锻件重力以及由于锻件重力引起的最大力矩。
基于Adams仿真软件提出了一种建立并联机构仿真模型的新方法，这种方法建模简单、快捷，通用性强，能够快速地实现并联机构的运动学仿真与尺度优化分析，并采用该建模方法建立了一种新型锻造操作机主运动机构的参数化模型，对其进行了尺度优化。
研制了一种新型锻造操作机机构的1/20比例实验模型，并开展了该操作机比例实验模型完成各种锻造操作动作和受力性能测试的实验研究，实验结果表明该操作机能实现构型理论分析的所有锻造操作动作，并验证了这样的结论：平行连杆式锻造操作机机构升降缸驱动力与锻件偏心距大小几乎无关。
Forging manipulator is one of the important equipments for the modern forgingsystem. By using the forging manipulator, production efficiency and quality of the heavyforged piece can be greatly improved. However, design and analysis of the large-scaleforging manipulator is still almost blank home, so design and analysis of the large-scaleforging manipulator will be carried out systematically based on parallel mechanism theoryin this paper. The main research contents are as follows:
Type synthesis of the forging manipulator is studied systematically by using theconstraint-synthesis method based on screw theory, many new configurations of parallelmechanism and hybrid serial-parallel mechanism for the forging manipulator are obtained.Two simple methods for distinguishing the mobility’s instantaneity of the overconstrainedparallel mechanism are put forward, and the mobility’s instantaneity of theoverconstrained parallel mechanisms for the forging manipulator configurated above isdistinguished by using the proposed methods.
Based on three motion characteristics, which are decoupling, installation position ofthe lateral buffering cylinder and clamping ability, respectively, a typical mechanism ofDDS forging manipulator, a typical mechanism of SMS forging manipulator, and four newmechanisms of forging manipulator are compared. Forward positon and static analysis ofthe main motion mechanism of five mechanisms among them are conducted, thencomparative analysis on comprehensive force performance of these five mechanisms iscarried out, and several regular features of force performance of the forging manipulatorare also discovered.
Two novel methods for establishing deformation compatibility equations of theoverconstrained parallel mechanism are proposed, and the general analytical expression ofthe actuated force/moment solution to the redundantly actuated parallel manipulators isderived in the condition that system elastic deformation is taken into account. Besides, it isproved that no internal forces exist within the pseudo-inverse solution to the actuated force/moment of the redundantly actuated parallel manipulators. And then, theoreticalanalysis results are applied to solving the actuated forces of the redundantly actuatedforging manipulator2SPS+R. The linearly dependant constraint wrenches imposed on themoving platform of the passive overconstrained parallel mechanism are defined asoverconstraint wrenches, and they are transformed into equivalent linearly independantconstraint wrenches. Then considering the link’s bending, tensile and torsionaldeformation, Stiffness matrix of the branch’s overconstraint wrenches is deduced, a morecomplete and universal method for force analysis of the passive overconstrained parallelmechanism is built up, and force analysis of a passive overconstrained suspensionmechanism4-SS of forging manipulator is performed by using this method.
Considering the gripper carrier’s all forging operation action, two new parallel linkmechanisms of forging manipulator are taken as examples, the degree of freedom of thewhole mechanism of forging manipulator is calculated by using the modifiedGrübler-Kutzbach criterion. Taking minimum gravitational potential energy of themechanism as the constraint condition, optimization analysis of the mechanism isperformed, and the actual motion law is obtained. Kinematic analysis of the wholemechanism of forging manipulator is carried out, and the mechanism is simulated byAdams software to testify the correctness of the theoretical analysis results.
A modified scaling factor method for force capabilities analysis of the planar parallelmanipulators is presented, by which the solution of the largest force and the largestmoment can be derived. For this modified method, the process is computationally smalland the results obtained are more exact. The largest weight of the forged piece and thelargest moment generated by the eccentricity of the forged piece that a new mechanism offorging manipulator is analyzed by using this modified scaling factor method.
A new approach for establishing simulation model of the parallel mechanism basedon Adams software is proposed.This modeling method is simple, fast and versatile, whichcan realize kinematic simulation and dimensional optimization analysis of the parallelmechanism quickly. And then, parametric model of the main motion mechanism of a newforging manipulator is established by using the new approach, dimensional optimization ofthe mechanism is carried out.
Experimental model with ratio1/20of a new forging manipulator is developed, andexperimental study on completing various forging operation action and force performancetesting is performed. The experimental results show that the new forging manipulator canachieve all the forging operation action as the configuration theory analyzed, and verifythe conclusion that the lifting cylinder’s driving force of paralle link mechanism of forgingmanipulator is independent of the eccentricity of the forged piece.
引文
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