Constant force control for aluminum wheel hub grinding based on ESO + backstepping

Dai, Shijie; Zhao, Yong; Ji, Wenbin; Mu, Jiaheng; Hu, Fengbao

doi:10.1108/ir-09-2021-0193

Cited by 4 publications

(2 citation statements)

References 18 publications

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“…Xu et al reported a hybrid active/passive force-control strategy [9] and hybrid force/position anti-disturbance control strategy [10] for grinding marks suppression in robotic belt grinding of turbine blade. Dai et al proposed a constant force control strategy combined by extended state observer and backstepping control [11]. Kuma and Rani developed a neural network-based hybrid force/position control [12].…”

Section: Introductionmentioning

confidence: 99%

Development of a Grinding Tool with Contact-Force Control Capability

2022

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The grinding normal force is one of the main factors that affect grinding quality. We report on the development of a compact grinding tool which not only can rotate the grind wheel but also can actively control the wheel in the fore/aft direction to modulate the contact force. The two motion degrees of freedom are coupled in the sense of mechanism yet their motions are independent. The designed grinding tool was modeled and its parameters were systemically identified. A repetitive controller was designed to suppress periodic force variation, which was mainly caused by the rotational motion of the grinding wheel, and the results were compared with other control methods. The selection of the grinding parameters was conducted using the Taguchi method. Finally, the grinding tool and the repetitive controller were experimentally evaluated, and the experimental results confirm that the proposed control strategy can reduce the force disturbance and improve the surface quality of the flat and curvy workpieces.

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Section: Introductionmentioning

confidence: 99%

Development of a Grinding Tool with Contact-Force Control Capability

2022

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“…Burghardt et al (2016) introduced dual robots to implement robotic automation of the turbo-propeller engine blade grinding process. Workpiece calibration and force control in robotic polishing systems have also received considerable attention (Dai et al , 2022; Dai et al , 2021; Mu et al , 2022). A typical robotic polishing system mainly comprises an industrial robot, a machining spindle, a polishing tool, measuring equipment and a control system.…”

Section: Introductionmentioning

confidence: 99%

A robotic polishing trajectory planning method for TBCs of aero-engine turbine blade using measured point cloud

Liang

Cai

Zeng

et al. 2022

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Purpose The application of thermal barrier coatings (TBCs) allows aero-engine blades to operate at higher temperatures with higher efficiency. The preparation of the TBCs increases the surface roughness of the blade, which impacts the thermal cycle life and thermal insulation performance of the coating. To reduce the surface roughness of blades, particularly the blades with small size and complex curvature, this paper aims to propose a method for industrial robot polishing trajectory planning based on on-site measuring point cloud. Design/methodology/approach The authors propose an integrated robotic polishing trajectory planning method using point cloud processing technical. At first, the acquired point cloud is preprocessed, which includes filtering and plane segmentation algorithm, to extract the blade body point cloud. Then, the point cloud slicing algorithm and the intersection method are used to create a preliminary contact point set. Finally, the Douglas–Peucker algorithm and pose frame estimation are applied to extract the tool-tip positions and optimize the tool contact posture, respectively. The resultant trajectory is evaluated by simulation and experiment implementation. Findings The target points of trajectory are not evenly distributed on the blade surface but rather fluctuate with surface curvature. The simulated linear and orientation speeds of the robot end could be relatively steady over 98% of the total time within 20% reduction of the rest time. After polishing experiments, the coating roughness on the blade surface is reduced dramatically from Ra 7–8 µm to below Ra 1.0 µm. The removal of the TBCs is less than 100 mg, which is significantly less than the weight of the prepared coatings. The blade surface becomes smoothed to a mirror-like state. Originality/value The research on robotic polishing of aero-engine turbine blade TBCs is worthwhile. The real-time trajectory planning based on measuring point cloud can address the problem that there is no standard computer-aided drawing model and the geometry and size of the workpiece to be processed differ. The extraction and optimization of tool contact points based on point cloud features can enhance the smoothness of the robot movement, stability of the polishing speed and performance of the blade surface after polishing.

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