شبیه سازی و راستی آزمایی تسمه سندرز با روبات های صنعتی

A new simulation and verification system of belt grinding with industrial robots is presented in this paper. The workpiece surface is represented by a discrete height field, an array of extended height segments, and a fast collision detection algorithm using k-DOP bounding volumes is adopted to accelerate the localization of the contact area. A local grinding model is incorporated to decide the real material removal. Unlike the usual global linear model, it determines the removed material in the contact area based on the acting force distribution and some other grinding parameters. With this new system, robot programmers can improve the path planning by visualizing the manufacturing process, predicting potential problems and measuring dimensional errors.

The simulation and verification technologies of numerical controlled (NC) manufacturing processes have been developed since the end of 1970 s and a lot of significant accomplishments have been achieved. This kind of technology has an important impact on the product development and quality control. The production process can be simulated on the computer to avoid expensive and time-consuming experiments. If any potential problem, such as collision, improper parameters or gouge, is found during the simulation, the manufacturing process can be adjusted to meet the quality demands. Due to these features, simulation and verification hold the tremendous promise for cost reduction, quality improvement and time-to-market shortening. Many methods have been developed to simulate turning, milling and wire-EMD during the last decades. But little work has been done in the area of belt grinding with industrial robot. With the introduction of industrial robot as manipulator, it is especially suitable to process free-form surfaces with complicate geometry like turbine blades and water taps.

We have presented a general framework of robot-controlled belt grinding simulation. An enhanced geometric representation technology based on the surface approximation points set is developed, which facilitates the simulation implementation and improves the contact detection speed through a DOP-tree localization algorithm. By integrating a local grinding model, the material removal process can be visualized in a interactive way. This system is capable of efficiently simulating and verifying the robot programs. The evaluation experiments show that the difference between the simulation and real machining is acceptable. In addition, based on the error analysis of the resulting surface, the planned grinding paths can be optimized or automatically corrected in case any unexpected situation such as undercut, gouge or singularity point occurs. Finally, research is under way towards the automatic robot program generation with the help of this simulation system.