CN113985809A - Control system of dry fiber pressure container robot winding workstation - Google Patents
Control system of dry fiber pressure container robot winding workstation Download PDFInfo
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- 238000004804 winding Methods 0.000 title claims abstract description 66
- 239000000835 fiber Substances 0.000 title claims abstract description 55
- 238000000034 method Methods 0.000 claims abstract description 44
- 239000002131 composite material Substances 0.000 claims abstract description 15
- 238000001914 filtration Methods 0.000 claims abstract description 5
- 238000005259 measurement Methods 0.000 claims abstract description 4
- 238000009730 filament winding Methods 0.000 claims description 20
- 230000008569 process Effects 0.000 claims description 14
- 238000011156 evaluation Methods 0.000 claims description 11
- 238000005457 optimization Methods 0.000 claims description 6
- 238000004088 simulation Methods 0.000 claims description 5
- 238000007667 floating Methods 0.000 claims description 3
- 238000002474 experimental method Methods 0.000 claims description 2
- 238000013178 mathematical model Methods 0.000 claims description 2
- 238000012360 testing method Methods 0.000 claims description 2
- 238000012546 transfer Methods 0.000 claims description 2
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- 238000006073 displacement reaction Methods 0.000 abstract description 4
- 238000010586 diagram Methods 0.000 description 7
- 239000013598 vector Substances 0.000 description 5
- 238000004519 manufacturing process Methods 0.000 description 4
- 239000000463 material Substances 0.000 description 4
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- 230000000694 effects Effects 0.000 description 2
- 230000003044 adaptive effect Effects 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 244000145845 chattering Species 0.000 description 1
- 238000011161 development Methods 0.000 description 1
- 238000007599 discharging Methods 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 239000003562 lightweight material Substances 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
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- G—PHYSICS
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- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B19/00—Programme-control systems
- G05B19/02—Programme-control systems electric
- G05B19/18—Numerical control [NC], i.e. automatically operating machines, in particular machine tools, e.g. in a manufacturing environment, so as to execute positioning, movement or co-ordinated operations by means of programme data in numerical form
- G05B19/19—Numerical control [NC], i.e. automatically operating machines, in particular machine tools, e.g. in a manufacturing environment, so as to execute positioning, movement or co-ordinated operations by means of programme data in numerical form characterised by positioning or contouring control systems, e.g. to control position from one programmed point to another or to control movement along a programmed continuous path
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B2219/00—Program-control systems
- G05B2219/30—Nc systems
- G05B2219/35—Nc in input of data, input till input file format
- G05B2219/35349—Display part, programmed locus and tool path, traject, dynamic locus
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Abstract
The invention discloses a control system for a dry fiber pressure container robot winding workstation, and relates to the technical field of composite materials; the method comprises the following steps: step one, a robot winding workstation and a control system are formed; analyzing a gas cylinder winding geometric model, and designing a motion track of the robot; step three, modeling the operation of the fiber winding robot; step four, establishing a tension control system model; the invention adopts the dry fiber pressure container winding based on the industrial robot, and adopts the combination of the air cylinder and the displacement sensor in the tension measurement, and the air cylinder has the characteristics of flexibility, adjustable force and the like; the tension control system has the advantages that the tension change is quickly buffered by the air cylinder, the tension change is quickly detected by the displacement sensor, and the fuzzy PID control algorithm which is based on Kalman filtering and does not depend on an accurate model is adopted in the algorithm.
Description
Technical Field
The invention belongs to the technical field of composite materials, and particularly relates to a control system of a dry fiber pressure container robot winding workstation.
Background
Composite materials are considered to be the most promising materials for this century. At present, with the ever increasing market demand for high strength lightweight materials for specific applications, composite materials reinforced with fibres of synthetic or natural materials are becoming more and more important, with the rapid development of the military and civil field industries, increasingly higher requirements are being put forward on the properties of the materials, making it increasingly difficult for traditional single materials to fully meet the requirements of strength, toughness, weight and stability.
In the dry fiber winding forming process, the basic principle of dry fiber winding forming is that continuous yarns are uniformly wound on a rotary core mold according to a preset line type under the tension control effect, and then the surface of a product is subjected to process treatment so as to meet the production requirement, and the traditional winding machine has the defects of low degree of freedom, poor operation flexibility, poor equipment adaptability and difficulty in adapting to diversified production of the product; the core mould is inconvenient to install and clamp, auxiliary equipment such as a crane is needed for the core mould with large mass, the inertia of the moving trolley is large, and yarn shaking is easily caused. Low production efficiency, poor product quality, inconsistent product performance and the like. However, the industrial robot has the characteristics of good flexibility, strong universality, convenient core die assembly and clamping and the like, and can replace the traditional two-six-degree-of-freedom winding equipment to realize the winding and forming of multiple types of composite products with two-six degrees of freedom; the industrial robot has multiple degrees of freedom, aiming at the winding operation of a low-degree-of-freedom composite material product, the redundant degree of freedom of the robot can achieve good kinematic characteristics through motion trajectory planning, and can realize the optimal dynamic performance by utilizing the structure of the robot. In the winding process of the industrial robot dry fiber pressure container, the trajectory planning and tension control of the robot are particularly important. In the production of wound products, the tension is shaken due to the smoothness of the track of the yarn outlet point of the robot, so that the quality of the products is affected. Due to the many factors that affect the tension. Such as the model having characteristics of non-line, time varying, etc. Therefore, it is difficult to establish an accurate model of the control object, the speed and tension are strongly coupled, and the interference sources are many, such as: tension control is an important and difficult-to-solve key technology because tension changes rapidly due to (core mold out-of-roundness, fiber sliding, speed jitter, etc.) uneven winding track of the robot, and changes in the radius and inertia of the unwinding roller. The control of the winding tension is a key factor for ensuring the air tightness, fatigue resistance and other performances of the dry fiber wound pressure container product and obtaining the good quality of the finished dry fiber wound product. Therefore, a set of high-precision tension controllers is needed.
Disclosure of Invention
To solve the problems in the background art; the invention aims to provide a control system of a dry fiber pressure container robot winding workstation.
The invention discloses a dry fiber pressure container robot winding workstation control system, which comprises the following steps:
the method comprises the following steps of firstly, forming a robot winding workstation and a control system:
the winding robot system consists of a six-axis robot, a creel with a tension controller, an expansion axis synchronously controlled with the robot, a control system and upper computer software; the upper computer software is divided into three subsystems of CAD, CAM and simulation;
analyzing a gas cylinder winding geometric model, and designing a motion track of the robot:
firstly, obtaining a functional relation between the size of a core mold and winding process parameters, and solving a robot operation track in a mode that a thread guide head fixes the robot to hold the core mold; the method comprises the steps that by analyzing the operation track of a fiber winding robot for a composite material product of a rotary shell, the operation track of the fiber winding robot is uniformly classified and planned based on an envelope form; the method comprises the steps of establishing a filament winding robot motion track planning target optimization model, establishing a filament winding robot track optimization objective function and evaluation indexes, and comparing the stability and smoothness of three envelope type filament winding robot operation tracks; the method comprises the following steps of (1) planning robot tracks which can be selected to adapt to various winding operation tasks;
2.1, establishing a geometric model of the rotary shell, determining the position of a doffing point in the set model, and parameterizing the position information of the doffing point;
2.2, solving the motion track of the rotary shell core mold robot:
obtaining the godet X by solvingB,YB,ZBSo as to obtain the movement tracks X, Y and Z of the core model of the tail end rotating shell of the filament winding robot;
2.3, analyzing the operation track of the robot: based on the operation track of the fiber winding robot in the envelope form;
2.4, establishing an operation track curve smoothness evaluation function:
fitting a large amount of motion track data into a curve by adopting a data fitting method to establish a smoothness evaluation function of the fitted operation track curve;
2.5, performing interpolation planning on the operation track in the envelope form and the motion track of the robot:
the operation track scheme is simulated by utilizing Matlab, the operation tracks of 3 envelope forms of the operation tracks of the filament winding robot and the free random operation track scheme are evaluated by curve smoothness evaluation functions according to motion characteristic curves of all axes of the operation tracks in different envelope forms, and the rule of the operation tracks of the filament winding robot of the composite material product in the envelope forms and the applicable composite material product of the rotary shell are obtained;
step three, modeling the operation of the fiber winding robot:
carrying out forward and reverse kinematic modeling of operation of the filament winding robot, and solving the motion trail of each joint of the robot according to the determined stable filament winding robot operation trail;
aiming at a designed dry fiber winding series robot operation structure, establishing a connecting rod reference coordinate system and a kinematics model of a researched robot based on a D-H reference coordinate system establishing method, and solving each joint corner of the robot according to an expected pose of a core mould at the tail end of the robot;
step four, establishing a tension control system model:
4.1, in the control of fiber winding tension, the model has nonlinearity and time-varying property;
4.2, mathematical modeling of the floating roller:
the transfer function of theta (s)/T1(s) can be obtained by the formula, and the bode graphs of Lj/Ld and Jd are drawn by matlab simulation experiments to analyze the influence of the values on the whole system;
the method is characterized in that a nominal model of the system is obtained by using an experimental method of system identification, a mathematical model of a dynamic system is developed by the method from measurement input and output data of the system, and the process of accurately obtaining the nominal model is important;
4.3, designing a filter:
firstly, establishing a state space model theta (s)/T1(s) of a linear system; then, estimating the state variable of the system by using a state space model and a measured value of the target system through a Kalman filtering algorithm; the kalman filter algorithm has two steps: a prediction process and an estimation process;
4.4, determination of a control algorithm:
the fuzzy PID composite control is adopted, the PID control and the fuzzy control are combined, and in a testing machine system, a fuzzy self-adaptive PID parameter controller establishes a parameter K by applying a fuzzy set theory on the basis of a conventional PID controllerP、KI、KDA binary continuous function therebetween, and an absolute deviation value | E | and an absolute variation value | E |C|。
Compared with the prior art, the invention has the beneficial effects that:
the dry fiber pressure container winding based on the industrial robot is adopted, the cylinder is combined with the displacement sensor in tension measurement, and the cylinder has the characteristics of flexibility, force adjustability and the like. The tension control system has the advantages that the tension change is quickly buffered by the air cylinder, the tension change is quickly detected by the displacement sensor, and the fuzzy PID control algorithm which is based on Kalman filtering and does not depend on an accurate model is adopted in the algorithm.
Drawings
For ease of illustration, the invention is described in detail by the following detailed description and the accompanying drawings.
FIG. 1 is a schematic view of a robotic wrapping station of the present invention;
FIG. 2 is a schematic diagram of a winding robot control system of the present invention;
FIG. 3 is a geometric model of a rotating housing according to the present invention;
FIG. 4 is a schematic view of a fiber bundle pattern on the surface of the shell according to the present invention;
FIG. 5 is a diagram showing the movement locus of the core mold according to the present invention;
FIG. 6 is a schematic diagram of an open cylindrical envelope of the present invention;
FIG. 7 is a schematic diagram of the envelope of the mandrel profile of the present invention;
FIG. 8 is a schematic view of the constant suspension yarn length of the present invention;
FIG. 9 is a schematic view of the winding robot according to the present invention;
FIG. 10 is a schematic view of a D-H reference coordinate system of the present invention;
FIG. 11 is a schematic view of a tension controller of the present invention;
FIG. 12 is a schematic diagram of a floating roll model in accordance with the present invention;
FIG. 13 is a block diagram of Kalman filtering in the present invention;
fig. 14 is a block diagram of a three-dimensional adaptive fuzzy controller according to the present invention.
Detailed Description
In order that the objects, aspects and advantages of the invention will become more apparent, the invention will be described by way of example only, and in connection with the accompanying drawings. It is to be understood that such description is merely illustrative and not intended to limit the scope of the present invention. The structure, proportion, size and the like shown in the drawings are only used for matching with the content disclosed in the specification, so that the person skilled in the art can understand and read the description, and the description is not used for limiting the limit condition of the implementation of the invention, so the method has no technical essence, and any structural modification, proportion relation change or size adjustment still falls within the range covered by the technical content disclosed by the invention without affecting the effect and the achievable purpose of the invention. Moreover, in the following description, descriptions of well-known structures and techniques are omitted so as to not unnecessarily obscure the concepts of the present invention.
It should be noted that, in order to avoid obscuring the present invention with unnecessary details, only the structures and/or processing steps closely related to the scheme according to the present invention are shown in the drawings, and other details not so relevant to the present invention are omitted.
The specific implementation mode adopts the following technical scheme:
the robot winding workstation comprises the following components:
as shown in fig. 1 and 2, the winding robot system is composed of a six-axis robot, a creel with a tension controller, an expansion axis (core mold main axis) synchronously controlled with the robot, a control system and upper computer software; the upper computer software is divided into three subsystems of CAD, CAM and simulation.
Analyzing a gas cylinder winding geometric model, and designing a motion track of the robot:
aiming at the problems that the robot filament winding motion trajectory planning method is not uniform and the motion trajectory is poor in stability, the filament winding robot operation trajectory planning research is developed. Firstly, obtaining a functional relation between the size of a core mold and winding process parameters, and solving a robot operation track in a mode that a thread guide head fixes the robot to hold the core mold; the method is a unified classification planning method based on the operation track of the fiber winding robot in the envelope form by analyzing the operation track of the fiber winding robot for the composite material product of the rotary shell.
Aiming at the smoothness and the stationarity of the motion trail of the fiber winding industrial robot, the dynamic performance of the robot is influenced, and the tension fluctuates, so that the fiber possibly deviates from a doffing point, even the fiber slides, and the quality of a wound product is influenced. The stability and smoothness of the operation tracks of the fiber winding robots in the three envelope line modes are compared by establishing a fiber winding robot motion track planning target optimization model, establishing a fiber winding robot track optimization objective function and evaluation indexes. And (4) planning the robot track which can be selected and adapted to various winding operation tasks.
2.1, establishing a geometric model of the rotating shell, determining the position of the doffing point in the set model, and parameterizing the position information of the doffing point.
And acquiring the fiber winding track on the surface of the rotating shell according to the parameter description of the radial profile model. According to the basic geometry of the rotating shell, the fiber winding track and the characteristic indexes, angles and directions thereof are described. This model shown in fig. 3 has a fast solution in practice compared to conventional models.
The geometric model of the rotating shell is built by rotating a determined meridian contour 360 ° around a fixed axis, as shown in figure 4.
On the rotating housing, as shown in FIG. 4, two mutually perpendicular principal direction vectors, meridian direction vector T, are defined, the positions of which are determined by
Determining a value, the direction being along a meridian; a parallel direction vector B, the position of which is represented by the parameter t, the direction being along the rotationThe direction of rotation of the housing. The fiber bundles make an angle alpha with the meridian profile. In order to obtain a kinematic solution of fibers of each point on the fiber bundle in the winding process, the pose information of the fibers of each point on the fiber bundle on the surface of the shell needs to be determined. Therefore, the pose of each point fiber on the fiber bundle is determined by determining two main direction vectors T and B; therefore, the pose information of each point fiber on the fiber bundle can be obtained.
2.2, solving the motion track of the rotary shell core mold robot:
as shown in FIGS. 3 and 5, A is the doffing point of the fiber bundle on the surface of the core mold, B is the yarn discharging point of the godet, AB distance is the suspended yarn length of the fiber bundle, and L isSThe distance between a yarn outlet point of the yarn guide head and the axis of the core mold; the rotation angle of point A is
Beta is the angle formed by the tangent vector of the meridian direction of the point A and Z. The mandrel is movable in the X, Y, Z and about the Z direction. Obtaining the godet X by solvingB,YB,ZBThereby obtaining the movement tracks X, Y, Z of the core mold of the end rotating shell of the filament winding robot.
2.3, analyzing the operation track of the robot:
the operation track of the filament winding robot based on the envelope form is as follows:
the operation track of the fiber winding robot is summarized into the following 3 envelope forms:
2.31, open cylinder envelope, mandrel profile envelope, and constant suspended yarn length envelope, as shown in fig. 6.
2.32, core profile envelope form: the operation track of the fiber winding robot is constrained on a contour surface enveloping the contour of the core mold and moves smoothly around the contour surface of the core mold. As shown in fig. 7.
2.33, constant suspended yarn length envelope form: the distance between the contact point of the fiber winding core die and the yarn outlet point of the yarn guide head is kept constant. As shown in fig. 8.
Simultaneous determination of godet XB,YB,ZBThe coordinates of (a). And obtaining the operation track equation of the fiber winding robot in the core mold contour envelope form.
2.4, establishing an operation track curve smoothness evaluation function:
unsmooth operation track curve (more convex angles and undersize convex angles) easily causes the phenomenon of chattering, shaking and the like at the tail end in the winding process of the robot, so that the winding tension fluctuation is large, the falling point track of a product deviates, and the mechanical property of the product is influenced.
A data fitting method can be adopted to fit a large amount of motion track data into a curve to establish a smoothness evaluation function of the fitted operation track curve. Commonly used methods are polynomial fitting and piecewise low order fitting. However, for polynomial fitting, too high a polynomial degree may cause the appearance of a sick equation, and it is difficult to obtain a desired fitting result. For the piecewise low-order fitting, the fitting idea is to forcedly and continuously divide all discrete data points into a plurality of units, and fit each unit by adopting a least square method. The problem of ill-conditioned equation and curve oscillation is solved, but the characteristics of curve continuity and smoothness are sacrificed. In order to solve the defects of a polynomial fitting method and a piecewise low-order fitting method, a curve surface fitting method based on a moving least square method is applied to fitting of a robot fiber winding robot operation track.
Claims (1)
1. The utility model provides a dry fiber pressure vessel robot winding workstation control system which characterized in that: the method comprises the following steps:
the method comprises the following steps of firstly, forming a robot winding workstation and a control system:
the winding robot system consists of a six-axis robot, a creel with a tension controller, an expansion axis synchronously controlled with the robot, a control system and upper computer software; the upper computer software is divided into three subsystems of CAD, CAM and simulation;
analyzing a gas cylinder winding geometric model, and designing a motion track of the robot:
firstly, obtaining a functional relation between the size of a core mold and winding process parameters, and solving a robot operation track in a mode that a thread guide head fixes the robot to hold the core mold; the method comprises the steps that by analyzing the operation track of a fiber winding robot for a composite material product of a rotary shell, the operation track of the fiber winding robot is uniformly classified and planned based on an envelope form; the method comprises the steps of establishing a filament winding robot motion track planning target optimization model, establishing a filament winding robot track optimization objective function and evaluation indexes, and comparing the stability and smoothness of three envelope type filament winding robot operation tracks; the method comprises the following steps of (1) planning robot tracks which can be selected to adapt to various winding operation tasks;
2.1, establishing a geometric model of the rotary shell, determining the position of a doffing point in the set model, and parameterizing the position information of the doffing point;
2.2, solving the motion track of the rotary shell core mold robot:
obtaining the godet head by solving
So as to obtain the movement tracks X, Y and Z of the core model of the tail end rotating shell of the filament winding robot;
2.3, analyzing the operation track of the robot: based on the operation track of the fiber winding robot in the envelope form;
2.4, establishing an operation track curve smoothness evaluation function:
fitting a large amount of motion track data into a curve by adopting a data fitting method to establish a smoothness evaluation function of the fitted operation track curve;
2.5, performing interpolation planning on the operation track in the envelope form and the motion track of the robot:
the operation track scheme is simulated by utilizing Matlab, the operation tracks of 3 envelope forms of the operation tracks of the filament winding robot and the free random operation track scheme are evaluated by curve smoothness evaluation functions according to motion characteristic curves of all axes of the operation tracks in different envelope forms, and the rule of the operation tracks of the filament winding robot of the composite material product in the envelope forms and the applicable composite material product of the rotary shell are obtained;
step three, modeling the operation of the fiber winding robot:
carrying out forward and reverse kinematic modeling of operation of the filament winding robot, and solving the motion trail of each joint of the robot according to the determined stable filament winding robot operation trail;
aiming at a designed dry fiber winding series robot operation structure, establishing a connecting rod reference coordinate system and a kinematics model of a researched robot based on a D-H reference coordinate system establishing method, and solving each joint corner of the robot according to an expected pose of a core mould at the tail end of the robot;
step four, establishing a tension control system model:
4.1, in the control of fiber winding tension, the model has nonlinearity and time-varying property;
4.2, mathematical modeling of the floating roller:
the transfer function which can be solved by the formula is drawn by matlab simulation experiment and a bode graph is used for analyzing the influence of the value on the whole system;
the method is characterized in that a nominal model of the system is obtained by using an experimental method of system identification, a mathematical model of a dynamic system is developed by the method from measurement input and output data of the system, and the process of accurately obtaining the nominal model is important;
4.3, designing a filter:
firstly, establishing a state space model of a linear system; then, estimating the state variable of the system by using a state space model and a measured value of the target system through a Kalman filtering algorithm; the kalman filter algorithm has two steps: a prediction process and an estimation process;
4.4, determination of a control algorithm:
the fuzzy PID composite control is adopted, the PID control and the fuzzy control are combined, and in a testing machine system, a fuzzy self-adaptive PID parameter controller establishes a parameter K by applying a fuzzy set theory on the basis of a conventional PID controllerP、KI、KDA binary continuous function therebetween, and an absolute deviation value | E | and an absolute variation value | E |C|。
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