| As the costs of human recourses grow higher and higher, robots will be used to replace workers in manufacture. Robot has been an important role of high-tech and one of the key technologies to achieve automation.In this paper, with the research and development of aluminum casting deburring automated systems, we designed an aluminum castings deburring system with a manipulator which is the core, and specially designed peripheral equipments. First, we identified the system parameters according to the characteristics and experience in deburring aluminum products. This system includes a manipulator, a two-dimensional sawing machine and a pneumatic processing unit. Then the virtual assembly technology is used to analyze the coordinated movements of the system. In order to guarantee processing quality the pneumatic system is designed to control the force between the grinding wheel and the products. In MATLAB/SIMIULINK platform, the commissioning of the co-work of the manipulator, sawing machine and the pneumatic processing unit. Finally a prototype of the system is built and is used to process the product. With the results of the processing, ideal processing parameters are analyzed.In chapter 1, the development of the applications of industrial robots are described, and the prospects is analyzed. Then the technology of commonly used aluminum casting cleaning is introduced, as long as the introduction of the development of industrial robots applications in this area. Finally, the main research and design content is put forward.In chapter 2, according to the aluminum casting deburring process, a system with an industrial robot supported by a two-dimensional sawing platform and a pneumatic grinding system. With the requirements of the process, a six degree of freedom robot is selected. After calculating the force between the riser and the saw, a two-dimensional sawing platform is identified. The platform is a motor servo system. For deburring, a pneumatic system is proposed considering the advantages in cushioning and force control. Parts of the system is selected. Finally, a 3D virtual assembling model in Solidworks is built.In chapter 3, virtual assembly technology is used to build the kinematic simulation models of the manipulator and the peripherals. This model is used to simulate the planning and the kinematics of the manipulator. Then the motor-driven saw feeding system in sawing machine is analyzed. The module is built with the PID control and tricyclic tuning is completed. The effect of different parameters of the feeding system is compared with the analysis in MATLAB/SIMULINK, and then the best parameter is chosen. Then the mathematical models of the pneumatic system is built. The pressure of the system is controlled in order to control the force between the grinding wheel and the products. And finally the speed of the robot and peripheral equipment is simulated to design optimal tact of the manufacture in MATLAB.In chapter 4, devices and controllers of the system is chosen including the industrial robot controller and PLC other peripherals. The interface of controllers and sensors are designed also. In the selected hardware foundation, the control framework is established. The program flow of cutting riser and deburring is designed. Based on it, the coordinated control programs in PLC and the robot program in KEBA controller is introduced. And an experimental station is assembled. By using this station, the work finished by workers before now can be finished by the industrial robot with qualified quality. By the results obtained after processing, the factors that influence the effectiveness and efficiency of the process is discussed for future applications. |
PDF Full Text Request