To fulfill the demands for higher quality,efficiency and flexibility in aviation industry,a multi-functional end effector is designed to automate the drilling and riveting processes in assembling carbon fiber reinforc...To fulfill the demands for higher quality,efficiency and flexibility in aviation industry,a multi-functional end effector is designed to automate the drilling and riveting processes in assembling carbon fiber reinforced polymer(CFRP)and aluminum components for a robotic aircraft assembly system.To meet the specific functional requirements for blind rivet installation on CFRP and aluminum materials,additional modules are incorporated on the end effector aside of the basic processing modules for drilling.And all of these processing modules allow for a onestep-drilling-countersinking process,hole inspection,automatic rivet feed,rivet geometry check,sealant application,rivet insertion and installation.Besides,to guarantee the better quality of the hole drilled and joints riveted,several online detection and adjustment measures are applied to this end effector,including the reference detection and perpendicular calibration,which could effectively ensure the positioning precision and perpendicular accuracy as demanded.Finally,the test result shows that this end effector is capable of producing each hole to a positioning precision within ±0.5 mm,aperpendicular accuracy within 0.3°,a diameter tolerance of H8,and a countersink depth tolerance of±0.01 mm.Moreover,it could drill and rivet up to three joints per minute,with acceptable shearing and tensile strength.展开更多
Carbon fiber reinforced plastic(CFRP)and aluminum stacks are widely used in aviation industry due to light weight and high performance.Millions of rivet holes need to be drilled on body materials,and more than 80%of f...Carbon fiber reinforced plastic(CFRP)and aluminum stacks are widely used in aviation industry due to light weight and high performance.Millions of rivet holes need to be drilled on body materials,and more than 80%of fatigue cracks occur at the connection holes,so the damage and residual stress of hole surface have crucial effect on the riveting fatigue life of CFRP/aluminum stacks and the flight performance.Recently,robotic rotary ultrasonic drilling(RRUD)technology is a promising method to machine the stacks.However,the hole surface strengthening mechanism in RRUD and the service performance of the riveting joint are not verified.Thus,in this paper,the hole surface strengthening mechanism of RRUD for CFRP/aluminum stacks is investigated,a theoretical residual stress model is established,and the fatigue life experiment of riveted joints is conducted.Firstly,analysis on residual stress in RRUD is carried out with consideration of strengthening force and cutting temperature.Residual stress model is established based on the calculation of elastic stress,plastic stress and stress release.Validation experiment results show that ultrasonic vibration changes residual stress from tensile stress to compressive stress.At the same time,comparative damage analysis of CFRP hole exit and hole surface in robotic conventional drilling(RCD)and RRUD is presented.Finally,fatigue strength experiments of riveted joints are conducted for performance verification.Experimental results indicate that fatigue life of single-hole riveted joints is increased by 68%with ultrasonic vibration,and four-hole riveted joint arranged according to aerospace design standards is increased by more than 86%.展开更多
An iterative method is introduced successfully to solve the inverse kinematics of a 6-DOF manipulator of a tunnel drilling rig based on dual quaternion, which is difficult to get the solution by Denavit-Hartenberg(D-H...An iterative method is introduced successfully to solve the inverse kinematics of a 6-DOF manipulator of a tunnel drilling rig based on dual quaternion, which is difficult to get the solution by Denavit-Hartenberg(D-H) based methods. By the intuitive expression of dual quaternion to the orientation of rigid body, the coordinate frames assigned to each joint are established all in the same orientation, which does not need to use the D-H procedure. The compact and simple form of kinematic equations, consisting of position equations and orientation equations, is also the consequence of dual quaternion calculations. The iterative process is basically of two steps which are related to solving the position equations and orientation equations correspondingly. First, assume an initial value of the iterative variable; then, the position equations can be solved because of the reduced number of unknown variables in the position equations and the orientation equations can be solved by applying the solution from the position equations, which obtains an updated value for the iterative variable; finally, repeat the procedure by using the updated iterative variable to the position equations till the prescribed accuracy is obtained. The method proposed has a clear geometric meaning, and the algorithm is simple and direct. Simulation for 100 poses of the end frame shows that the average running time of inverse kinematics calculation for each demanded pose of end-effector is 7.2 ms on an ordinary laptop, which is good enough for practical use. The iteration counts 2-4 cycles generally, which is a quick convergence. The method proposed here has been successfully used in the project of automating a hydraulic rig.展开更多
基金supported by the National Natural Science Foundations of China(Nos.5157051626,51475225)
文摘To fulfill the demands for higher quality,efficiency and flexibility in aviation industry,a multi-functional end effector is designed to automate the drilling and riveting processes in assembling carbon fiber reinforced polymer(CFRP)and aluminum components for a robotic aircraft assembly system.To meet the specific functional requirements for blind rivet installation on CFRP and aluminum materials,additional modules are incorporated on the end effector aside of the basic processing modules for drilling.And all of these processing modules allow for a onestep-drilling-countersinking process,hole inspection,automatic rivet feed,rivet geometry check,sealant application,rivet insertion and installation.Besides,to guarantee the better quality of the hole drilled and joints riveted,several online detection and adjustment measures are applied to this end effector,including the reference detection and perpendicular calibration,which could effectively ensure the positioning precision and perpendicular accuracy as demanded.Finally,the test result shows that this end effector is capable of producing each hole to a positioning precision within ±0.5 mm,aperpendicular accuracy within 0.3°,a diameter tolerance of H8,and a countersink depth tolerance of±0.01 mm.Moreover,it could drill and rivet up to three joints per minute,with acceptable shearing and tensile strength.
基金the the Project on the Technological Leading Talent Teams Led by Frontiers Science Center for Complex Equipment System Dynamics(No.FSCCESD220401)the Jiangsu Funding Program for Excellent Postdoctoral Talent(No.2022ZB264).
文摘Carbon fiber reinforced plastic(CFRP)and aluminum stacks are widely used in aviation industry due to light weight and high performance.Millions of rivet holes need to be drilled on body materials,and more than 80%of fatigue cracks occur at the connection holes,so the damage and residual stress of hole surface have crucial effect on the riveting fatigue life of CFRP/aluminum stacks and the flight performance.Recently,robotic rotary ultrasonic drilling(RRUD)technology is a promising method to machine the stacks.However,the hole surface strengthening mechanism in RRUD and the service performance of the riveting joint are not verified.Thus,in this paper,the hole surface strengthening mechanism of RRUD for CFRP/aluminum stacks is investigated,a theoretical residual stress model is established,and the fatigue life experiment of riveted joints is conducted.Firstly,analysis on residual stress in RRUD is carried out with consideration of strengthening force and cutting temperature.Residual stress model is established based on the calculation of elastic stress,plastic stress and stress release.Validation experiment results show that ultrasonic vibration changes residual stress from tensile stress to compressive stress.At the same time,comparative damage analysis of CFRP hole exit and hole surface in robotic conventional drilling(RCD)and RRUD is presented.Finally,fatigue strength experiments of riveted joints are conducted for performance verification.Experimental results indicate that fatigue life of single-hole riveted joints is increased by 68%with ultrasonic vibration,and four-hole riveted joint arranged according to aerospace design standards is increased by more than 86%.
基金Project(2013CB035504)supported by the National Basic Research Program of China
文摘An iterative method is introduced successfully to solve the inverse kinematics of a 6-DOF manipulator of a tunnel drilling rig based on dual quaternion, which is difficult to get the solution by Denavit-Hartenberg(D-H) based methods. By the intuitive expression of dual quaternion to the orientation of rigid body, the coordinate frames assigned to each joint are established all in the same orientation, which does not need to use the D-H procedure. The compact and simple form of kinematic equations, consisting of position equations and orientation equations, is also the consequence of dual quaternion calculations. The iterative process is basically of two steps which are related to solving the position equations and orientation equations correspondingly. First, assume an initial value of the iterative variable; then, the position equations can be solved because of the reduced number of unknown variables in the position equations and the orientation equations can be solved by applying the solution from the position equations, which obtains an updated value for the iterative variable; finally, repeat the procedure by using the updated iterative variable to the position equations till the prescribed accuracy is obtained. The method proposed has a clear geometric meaning, and the algorithm is simple and direct. Simulation for 100 poses of the end frame shows that the average running time of inverse kinematics calculation for each demanded pose of end-effector is 7.2 ms on an ordinary laptop, which is good enough for practical use. The iteration counts 2-4 cycles generally, which is a quick convergence. The method proposed here has been successfully used in the project of automating a hydraulic rig.
