城市轨道交通车体表面油漆检修机器人技术可行性研究

Feasibility Study of Robot Technology for Vehicle Carbody Surface Paint Maintenance in Urban Rail Transit

[目的]由于城市轨道交通车辆在大修过程中对车体表面油漆进行清洁、打磨和抛光时的作业时间较长,而人工操作打磨机抛光时因打磨力分布不均易造成漆面损伤,降低了车体表面检修质量。而采用机器人打磨可缩短车体打磨作业时间且技术成熟,性能稳定,并能够满足绝大部分生产需求。因此,有必要对城市轨道交通车辆车体表面油漆检修机器人技术进行可行性研究。[方法]依据车体侧墙结构参数适配机器人构型,通过机器人代替现有人工打磨作业;在机器人末端安装力传感器夹持打磨工具进行作业,将力传感器采集数据作为输出并反馈至机器人运动关节坐标,以确保车体表面抛光打磨力基本稳定;通过仿真计算机器人工作空间并依据车体结构加装机器人外轴,可满足实际作业需要。[结果及结论]机器人技术运用至城市轨道交通车辆车体表面油漆质量检修工艺能够符合城市轨道交通车辆车体侧墙结构特征;在减少作业人数、满足现场车体侧墙打磨区域全覆盖需求的同时,通过引入力传感器的打磨工具,预计可提升车体表面打磨、抛光质量,满足现场工艺稳定性要求,并提升产线自动化率。

[Objective]In the maintenance process of urban rail transit vehicles,the cleaning,grinding and polishing of the vehicle carbody surface paint often require a long time when done manually.Moreover,manual polishing operations can lead to uneven distribution of polishing force,resulting in paint damage and reduced maintenance quality.The use of robotic polishing can shorten the operation time and is technically mature,stable in performance,and capable of meeting the majority of production needs.Therefore,it is necessary to study the feasibility of robot technology for surface paint maintenance on urban rail transit vehicle carbody.[Method]Based on the structural parameters of the vehicle side wall,robot configurations are adapted to replace manual polishing operations.Force sensors are installed at the end of the robot to hold the polishing tool for operation.The data collected by force sensors are used as output and fed back to the robot motion joint coordinates to ensure the basic stability of polishing force during carbody surface polishing.Simulation is used to calculate the robot workspace,and additional robot outer axes are installed based on the vehicle structure to meet actual operational needs.[Result&Conclusion]The application of robot technology in the quality maintenance process of surface paint on urban rail transit vehicle carbodies can meet the structural characteristics of the vehicle side wall.By reducing the number of operators and meeting the full coverage requirement of the vehicle side wall polishing area on-site,the introduction of force sensors in the polishing tool is expected to enhance the quality of carbody surface polish-ing and meet the stability requirements of on-site processes,thereby increasing the automation rate of the production line.