Master-slave Robot System and Its Teleoperation Machining Approach for Medium and Large Casting Parts

doi:10.3901/JME.2022.14.093

Abstract

Abstract: The residual features such as mould closing lines and pouring risers of medium and large castings are random in size, morphology and distribution, so there are great challenges in safe, efficient and high-quality removal. For this difficulty, a teleoperation machining method based on master and slave robots is proposed. A five degrees of freedom hybrid robot with both high stiffness and high dexterity is used as the slave machining robot and a three-translational parallel robot with force feedback is utilized as the master control robot. Firstly, the parametric, online adjustable forbidden region virtual fixture(FRVF) is constructed to solve the problem of excessive machining caused by shake, communication delay and other factors during the teleoperation process. Secondly, a teleoperation control model based on incremental position following and artificial potential field is established, which is convenient for constraining and guiding the master robot and slave robot. Finally, the simulation analysis and experimental verification are carried out. The results show that FRVF has a high degree of fit to the complex surface, and the teleoperation control model can ensure that the machining area does not exceed the boundary of FRVF. The removal rate of residual features of gray cast iron casting part with a size of 2.32 m×1.65 m×1.24 m is more than 95%, the surface roughness after one-time machining is 2.1 μm, and the machining efficiency is increased by 4 times. The proposed master-slave robot system and its teleoperation machining approach can effectively realize the high-quality and high-efficiency removal of the residual features of medium and large casting parts, and provide a new solution for the efficient machining of other medium and large parts.

Key words: medium and large casting parts, robotic machining, teleoperation, virtual fixture, artificial potential field

CLC Number:

TP242

WANG Meng, SONG Yimin, WANG Panfeng, ZHAO Xueman, LIAN Binbin, CHEN Yuecheng, SUN Tao. Master-slave Robot System and Its Teleoperation Machining Approach for Medium and Large Casting Parts[J]. Journal of Mechanical Engineering, 2022, 58(14): 93-103.

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