Type Design for Heavy-payload Forging Manipulators

Heavy-payload forging manipulators are mainly characterized by large load output and large capacitive-load input.The relationship between outputs and inputs,which will greatly influence the control and the reliability,is the key issue in type design for heavy-payload forging manipulators.In this paper,a type design method by considering the incidence relationship between output characteristics and actuator inputs is presented and used to design the mechanism for forging manipulators.The concept of modeling method based on the outputs tasks is defined and investigated.The principle of type design from the viewpoints of the relationship between output characteristics and actuator inputs is discussed.An idea of establishing the incidence relationship between output characteristics and actuator inputs is proposed.The incidence relationship matrix between outputs and inputs is also given.The design flow is obtained,and the incidence relationship between outputs and inputs for heavy-payload forging manipulators is divided into three parts after detailed understanding of the functional properties.Four types of mechanisms for heavy-payload forging manipulators are given,and the corresponding spatial mechanical sketches are also drawn,some new designed mechanisms have been adopted by company or used as prototype.These novel forging manipulators which satisfy certain functional requirements provide an effective help for the design of forging manipulators and patent application.

Optimization and Mechanical Accuracy Reliability of a New Type of Forging Manipulator

Researches on forging manipulator have enormous influence on the development of the forging industry and national economy.Clamp device and lifting mechanism are the core parts of forging manipulator,and have been studied for longer time.However,the optimization and mechanical accuracy reliability of them are less analyzed.Based on General Function（G_F）set and parallel mechanism theory,proper configuration of 10t forging manipulator is selected firstly.A new type of forging manipulator driven by cylinders is proposed.After solved mechanical analysis of manipulator＇s core mechanisms,expressions of force of cylinders are carried out.In order to achieve smaller force afforded by cylinders and better mechanical characteristics,some particular sizes of core mechanisms are optimized intuitively through the combined use of the genetic algorithms（GA）and GUI interface in MATLAB.Comparing with the original mechanisms,optimized clamp saves at least 8 percent efforts and optimized lifting mechanism 20 percent under maximum working condition.Finally,considering the existed manufacture error of components,mechanical accuracy reliability of optimized clamp,lifting mechanism and whole manipulator are demonstrated respectively based on fuzzy reliability theory.Obtained results show that the accuracy reliability of optimized clamp is bigger than 0.991 and that of optimized lifting mechanism is 0.995.To the whole manipulator under maximum working condition,that value exceeds 0.986 4,which means that optimized manipulator has high motion accuracy and is reliable.A new intuitive method is created to optimize forging manipulator sizes efficiently and more practical theory is utilized to analyze mechanical accuracy reliability of forging manipulator precisely.

Study on co-simulation model of forging manipulator based on virtual prototyping

Based on the characteristics of integrated virtual prototype technology, the mechanical system sub-model, the hydraulic system sub-model and the control system sub-model of a forging manipula- tor system have been built using a variety of software, and a forging manipulator mtrltidisciplinary co- simulation model has been also built using a method of simulation models interface. Then the simu- lation and experiment are finished, and the result of the experiment is in good agreement with the re- sult of the simulation. It shows that the co-simulation model established can simulate accurately pa- rameter changes in real time during the moving of the forging manipulator such as displacement, ve- locity and pressure flow, which is of important significance for the optimized design of the forging manipulator system to establish the models.

Entirety transformation mechanism and topological-type synthesis for heavy-duty gripping devices

Force closure and stability problems exist in heavy gripping devices.Based on a typical gripping device for forging operations, the workpiece and the gripping device are innovatively considered as a single mechanism in this paper,and its global topological configuration is obtained.The changing element method is used to establish the optimized topology geometry of the gripping device by decreasing the degrees of freedom of the gripping mechanism and improving the force closure performance. Therefore,a new idea for the innovative design of heavy-duty forging gripping devices is provided.As the effect of revolute joint friction on loading capacity of the gripping device cannot be ignored,a unified mechanical equation including friction in terms of the topological adjacency matrix is established to analyze the force closure performance and calculate the loading capacity.The conclusions are provided by experiments.