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...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.展开更多
In the field of heavy forging, there are numerous researches on deformation rule in forging process by FEM simulation, however, not many scholars take the equipment constraint and the mutual reaction load between the ...In the field of heavy forging, there are numerous researches on deformation rule in forging process by FEM simulation, however, not many scholars take the equipment constraint and the mutual reaction load between the forging manipulator clamp and the forging blank into account, which will impact on safety of manipulator body and quality of forging blank. This paper presents an impedance model to describe the load and formulates compliance strategies correspondingly to reduce the mutual reaction load for forging manipulator. Firstly, an FEM model of forging process is built. Meanwhile, the clamp of forging manipulator is added to the model as movement constraint and interaction part between the manipulator and the forming process. Secondly, a typical forging process is simulated by changing the movement constraint, and then an impedance model is established to describe the relationship between the load and movement constraint. Finally, two kinds of compliance strategies are formulated according to the impedance model, one is called free compliance, and the other is initiative/passive compliance. The simulation results show that compliance strategies reduce the load amounting to 5 000 kN in z direction between the manipulator clamp and the forging blank obviously, which may lead to serious accidents, such as the capsizing of forging manipulator, the fracture of manipulator clamp, and so on. The proposed research simulates the more real forging process, gets the initiative/passive compliance strategy which is more simple and suitable to the real producing and better for forming a forging process planning and control system in the modern production, and improves the quality and efficiency of heavy forging.展开更多
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 stud...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.展开更多
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 bui...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.展开更多
基金supported by National Key Basic Research Program of China (973 Program,Grant No. 2006CB705402)Important National Science & Technology Specific Projects (Grant No. 2009ZX04002-061)National Hi-tech Research and Development Program of China (863Program,Grant No. 2008AA04XK1478950)
文摘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.
基金supported by National Basic Research Program of China(973 Program, Grant No. 2006CB705400)
文摘In the field of heavy forging, there are numerous researches on deformation rule in forging process by FEM simulation, however, not many scholars take the equipment constraint and the mutual reaction load between the forging manipulator clamp and the forging blank into account, which will impact on safety of manipulator body and quality of forging blank. This paper presents an impedance model to describe the load and formulates compliance strategies correspondingly to reduce the mutual reaction load for forging manipulator. Firstly, an FEM model of forging process is built. Meanwhile, the clamp of forging manipulator is added to the model as movement constraint and interaction part between the manipulator and the forming process. Secondly, a typical forging process is simulated by changing the movement constraint, and then an impedance model is established to describe the relationship between the load and movement constraint. Finally, two kinds of compliance strategies are formulated according to the impedance model, one is called free compliance, and the other is initiative/passive compliance. The simulation results show that compliance strategies reduce the load amounting to 5 000 kN in z direction between the manipulator clamp and the forging blank obviously, which may lead to serious accidents, such as the capsizing of forging manipulator, the fracture of manipulator clamp, and so on. The proposed research simulates the more real forging process, gets the initiative/passive compliance strategy which is more simple and suitable to the real producing and better for forming a forging process planning and control system in the modern production, and improves the quality and efficiency of heavy forging.
基金Supported by Special Fund of Jiangsu Province for the Transformation of Scientific & Technological Achievements,China(Grant No.BA2012110)
文摘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.
基金Supported by the National Natural Science Foundation of China(No.51575471)Collaborative Innovation Program Topics of Heavy Machinery of Yanshan University(2011 Program,No.ZX01-20140400-01)
文摘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.
