自动铺丝机多自由度机械手

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摘要

在《国家中长期科学和技术发展规划纲要(2006—2020)》中，已经把大型飞

机项目确定为“未来 15 年力争取得突破的 16 个重大科技专项”之一。大飞机项

目明确为大型客机和大型军用运输机，其前期规划复合材料用量为 15%，随着技

术的发展和成熟，复合材料用量将会进一步扩大。纤维铺放技术是解决复合材料

零件制造的关键，目前只有美国、法国、西班牙等少数几个西方国家掌握该技术

的核心，而西方国家在高性能多自由度复合材料铺放设备方面，对我国实行技术

封锁。如何实现复合材料的“高性能”制造，是摆在我们面前的难题，大型铺丝

机的研制迫在眉睫。

本研究课题来源于上海理工大学与上海重型机床厂产学研合作项目——铺缠

一体机设计，属于大飞机项目。我校主要参与控制铺放头姿态的机械手方案制定

及设计。本论文首先介绍了自主研发大型复合材料铺放设备的紧迫性、国内外复

合材料铺放的发展现状及趋势。就自动铺丝机上用于控制铺丝头进行复合材料铺

放的三自由度机械手而展开，提出了一种用于大型铺丝机的铺丝头机械手设计方

案；详细分析了各种消除齿轮回程误差的原理，通过对比，最终采用了双伺服电

机驱动；运用 PRO/E4.0 对各零件进行三维建模，并进行装配，对结构进行了静

态干涉检查；利用 PRO/E 机构模块进行动态仿真和碰撞检查，得出铺丝头铺放部

位运动轨迹曲线；建立了机械手有限元模型，利用 PRO/E Mechanica 对机械手 A

轴组件进行模态分析，得出前四阶固有频率和振型；对机械手主要零件基座和 A

轴支架进行静力分析，并根据分析结果对结构提出改进；最后，对机械手装配体

进行静刚度分析和模态分析，得出机械手应力变形和前四阶固有频率，找出结构

的薄弱环节。

研究结果表明，该机械手方案可行，结构合理可以满足铺丝机机械手的设计

要求。希望该课题的研究能为复合材料铺放设备的研制提供有益的参考, 对于课

题的进一步深入研究和拓展，能起到一定的启示意义。

关键词：复合材料纤维铺放有限元分析机械手

ABSTRACT

In the " long-term science and technology develop program outline in the country

(2006-2020) ", the project has seen the large aircraft as one of the 16 national science

and technology major projects ,which we strive to obtain a breakthrough in the next

15 years. Aircraft Project already was made clear to be airliners and large-scale combat

transports. The prophase planning is that 15% of the plane is made of composite

material, and with the development of technology and becoming mature, composite

materials consumption will further expand. Fiber placement technology is a key

method of producing composite structures. The core technology in fiber placement is

mastered by only a few western developed countries, such as America, France, Spain

and so on. Western countries impose the policy of locking technology in fiber

placement equipment with high-powered and multi-freedom degree on our country.

How to achieve "high-performance" manufacture of composite parts of aircrafts is an

urgent problem, so the design of the big fiber placement is our most pressing task.

This thesis comes from the research and design of fiber placement and winding

machine, which is university industry cooperation project between University of

Shanghai for Science and Technology and Shanghai Heavy Duty Machine Tool Works

Co., Ltd. and belongs to the large plane project. Our school mainly participates in plan

establishment and designing of the manipulator which controls the fiber placement

head. The paper expounds the urgency of the independent research and development of

big fiber placement，the developing situation of composite material placement at home

and abroad. It is based on the three degrees of freedom of the manipulator in fiber

placement machine, and provided a design scheme of manipulator used in the big fiber

placement. The theory of how to eliminate gear hysteresis error is specifically analyzed,

by contrast, the method of double servo motor-driven double-gear eliminates backlash

is adopted finally. Using 3D software PRO/E4.0 to build a three-dimensional model for

all parts of the mechanical hand, and check statically interposition analysis for the

assemble structure; Dynamic simulation and collision check is made by using PRO/E

MOTION，and the trace curve of the point of the fiber placement head is acquired.

Having established the finite element model of the manipulator, the modal analysis and

static analysis of the key parts is discussed. The base and A shaft are the main parts of

the manipulator and the static analysis of them is made, as well as an improvement

scheme is suggested, according to the analysis result. Finally, the whole manipulator

model is used in stiffness analysis and modal analysis, and we get the deformation and

stress as well as the sensors first four modes of vibration and its natural frequencies.

Furthermore, the weakness of the structure is found.

The research results show that this design scheme of manipulator is feasible. And

it has rational construction and satisfied the design requirements of fiber placement

manipulator. I hope that the research results provide the available references for the

design of composite placement and can get up certain enlightenment meaning to the

further deepening and expanding this subject.

Key Words：Composite, Fiber placement, Finite Element Analysis，

Manipulator

中文摘要

ABSTRACT

第一章绪论 ......................................................... 1

§1.1 纤维铺放技术 ............................................... 1

§1.1.1 纤维铺放技术简介 ..................................... 1

§1.1.2 纤维铺放技术应用 ..................................... 1

§1.1.3 纤维铺放技术的发展趋势 ............................... 2

§1.2 纤维铺放技术发展概况 ....................................... 2

§1.2.1 国外纤维铺放技术研究 ................................. 2

§1.2.2 国内纤维铺放技术研究 ................................. 4

§1.3 课题来源、研究内容及意义 ................................... 5

§1.3.1 课题来源 ............................................. 5

§1.3.2 研究内容和意义 ....................................... 5

第二章铺丝机整体结构概述 ........................................... 7

§2.1 铺丝机典型配置 ............................................ 8

§2.1.1 立柱式 ............................................... 8

§2.1.2 龙门式 ............................................... 9

§2.2 铺丝机总体方案 ............................................ 9

§2.3 铺丝头 ................................................... 10

§2.3.1 铺放工艺 ............................................ 11

§2.3.2 铺丝头工作原理 ...................................... 13

§2.3.3 铺丝机机械手 ........................................ 14

§2.4 本章小结 .................................................. 15

第三章铺丝机机械手设计 ............................................ 16

§3.1 机械手驱动系统的选择 ...................................... 16

§3.1.1 各类驱动系统的特点 .................................. 16

§3.1.2 驱动系统选择的原则 .................................. 16

§3.1.3 铺丝机机械手驱动系统选择 ............................ 17

§3.2 机械手传动机构 ............................................ 18

§3.2.1 传动的重要性 ........................................ 18

§3.2.2 传动类型选择概要 .................................... 18

§3.2.3 机械手传动机构设计 .................................. 19

§3.3 传动方案分析 .............................................. 21

§3.3.1 传动精度分析 ........................................ 21

§3.3.2 回程误差消除方法及原理分析 .......................... 21

§3.4 铺丝机机械手总体方案 ...................................... 25

§3.5 机械手结构设计 ............................................ 25

§3.5.1 伺服电机及减速机选用 ................................ 26

§3.5.2 各轴连接方式 ........................................ 28

§3.5.3 各轴结构 ............................................ 31

§3.6 本章小结 .................................................. 33

第四章铺丝机机械手运动仿真 ........................................ 34

§4.1 PRO/E 运动仿真分析流程 .................................... 34

§4.2运动仿真模型建立 .......................................... 35

§4.2.1 机械手各零件建模 .................................... 36

§4.2.2 模型接头连接 ........................................ 41

§4.3 机械手运动学分析 .......................................... 42

§4.3.1 机械手各轴电机设置 .................................. 42

§4.3.2 机械手运动仿真检测 .................................. 44

§4.4 本章小结 .................................................. 46

第五章铺丝机机械手有限元分析 ...................................... 47

§5.1 有限单元法 ................................................ 47

§5.1.1 有限单元法简介 ...................................... 47

§5.1.2 有限单元法求解基本步骤 .............................. 48

§5.1.3 有限元模型的建立 .................................... 49

§5.2 Pro/Mechanica 概述 ........................................ 49

§5.2.1 Pro/E 软件简介 ....................................... 49

§5.2.2 Pro/Mechanica 有限元分析 ............................. 50

§5.3 铺丝机机械手有限元分析 .................................... 51

§5.3.1 A轴组件的模态分析 ................................... 51

§5.3.2 基座及支架静力分析 .................................. 53

§5.3.3 机械手装配体静刚度分析 .............................. 57

§5.3.4 机械手装配体模态分析 ................................ 58

§5.4 本章小结 .................................................. 60

第六章总结与展望 .................................................. 61

§6.1 总结 ...................................................... 61

§6.2 展望 ...................................................... 61

参考文献 ........................................................... 62

在读期间公开发表的论文和承担科研项目及取得成果 ..................... 65

致谢 ............................................................. 66

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摘要：

摘要在《国家中长期科学和技术发展规划纲要(2006—2020)》中，已经把大型飞机项目确定为“未来15年力争取得突破的16个重大科技专项”之一。大飞机项目明确为大型客机和大型军用运输机，其前期规划复合材料用量为15%，随着技术的发展和成熟，复合材料用量将会进一步扩大。纤维铺放技术是解决复合材料零件制造的关键，目前只有美国、法国、西班牙等少数几个西方国家掌握该技术的核心，而西方国家在高性能多自由度复合材料铺放设备方面，对我国实行技术封锁。如何实现复合材料的“高性能”制造，是摆在我们面前的难题，大型铺丝机的研制迫在眉睫。本研究课题来源于上海理工大学与上海重型机床厂产学研合作项目——铺缠一体机设计，...

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