Research On Hardware Integration And Software Design Of The Robotized Ultrasonic Shot Peening System

In the production process of workpieces like wheel hubs,it is necessary to correct the deformation caused by the heat treatment process.Compared with shaping techniques such as molding and rolling,ultrasonic shot peening technology is more outstanding because of low equipment investment and maintenance costs,high shaping accuracy and efficiency,and not causing internal damage to the wheel hubs.The ultrasonic shot peening automation equipment that is developed based on the industrial robot platform has the advantages of strong controllability and function expandability.It is expected to promote the application of ultrasonic shot peening technology in the field of precision processing of large aluminum workpieces.However,there still exist some problems,such as unreasonable workstation layouts,poor compatibility of robot control software with peripheral equipment,and too strict accuracy requirement of tooling in the measurement of workpiece profile.Based on an industrial robot,an ultrasonic shot peening gun,a 2D laser profiler,a motorized vertical stage,a workpiece turntable and other equipment,the robotized ultrasonic shot peening system is designed in this project.Firstly,the forward and inverse kinematics models are established based on the KUKA KR60-3 industrial robot,and workspace and singular configuration are analyzed.Combining with KUKA Sim Pro simulation software,workspace constraints,singular configuration and interference simulations are performed based on a given working trajectory,which determines the reasonability of workstation layout and helps to realize the efficient operation of the robot,so as to solve the problem that the existing commercial software is difficult to directly apply to the design of workstation layout.Secondly,according to the workstation layout,hardware integration design of the system including the shape measurement of workpiece module,the calculation of deformation module and the robot control module is completed.And the queue message state machine architecture is established in the Lab VIEW development environment to realize the state switching in the automated processing process and data transmission between devices,which solves the problem of poor compatibility of existing robot control software with third-party peripheral devices.Next,in the situation that the axis of the workpiece turntable is not parallel to the slideway of the motorized vertical stage,it is proposed to fit line equations of the axis of the turntable and the slideway of the motorized vertical stage,combining with sizes of the equipment,to solve the accurate distance from the 2D laser profiler to the axis of the turntable,so as to complete the 2D-into-3D transformation of point cloud coordinates accurately and establish the 3D shape of the workpiece,which reduces the influence of installation errors on the measurement results of the 3D shape of hub.Finally,based on the developed robotized ultrasonic shot peening system,the shape measurement and processing experiments of workpiece are carried out on the plate and the hub,which verifies the effectiveness of the system.The robotized ultrasonic shot peening system improves the production efficiency of the wheel hubs,reduces the labor cost in the manufacturing industry,and promotes the development of the automobile manufacturing industry.In addition,the robotized ultrasonic shot peening system provides a reference for the intelligent application of ultrasonic impact,and contribute to the development of the Made in China 2025 strategy.