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Research on Hybrid Manufacturing Using Industrial Robot Scholars' Mine Doctoral Dissertations Student Theses and Dissertations Fall 2016 Research on hybrid manufacturing using industrial robot Zhiyuan Wang Follow this and additional works at: https://scholarsmine.mst.edu/doctoral_dissertations Part of the Mechanical Engineering Commons Department: Mechanical and Aerospace Engineering Recommended Citation Wang, Zhiyuan, "Research on hybrid manufacturing using industrial robot" (2016). Doctoral Dissertations. 2548. https://scholarsmine.mst.edu/doctoral_dissertations/2548 This thesis is brought to you by Scholars' Mine, a service of the Missouri S&T Library and Learning Resources. This work is protected by U. S. Copyright Law. Unauthorized use including reproduction for redistribution requires the permission of the copyright holder. For more information, please contact [email protected]. RESEARCH ON HYBRID MANUFACTURING USING INDUSTRIAL ROBOT by ZHIYUAN WANG A DISSERTATION Presented to the Faculty of the Graduate School of the MISSOURI UNIVERSITY OF SCIENCE AND TECHNOLOGY In Partial Fulfillment of the Requirements for the Degree DOCTOR OF PHILOSOPHY in MECHANICAL ENGINEERING 2016 Approved Dr. Frank Liou, Advisor Dr. Ashok Midha Dr. Heng Pan Dr. Lian Duan Dr. Joseph W Newkirk 2016 Zhiyuan Wang All Rights Reserved iii PUBLICATION DISSERTATION OPTION This dissertation consists of the following five articles that have been published or submitted for publication as follows: Pages 6-65 are intended for submission to Robotics and Computer-Integrated Manufacturing. Pages 66-96 are intended for submission to International Journal of Robotics and Automation Technology. Pages 97-113 have been published in International Journal of Computer Applications in Technology. Pages 114-132 have been published in Precision Engineering. Pages 133-156 have been published in 3D Printing and Additive Manufacturing. All of them have been prepared in the format of Missouri S&T specs. iv ABSTRACT The applications of using industrial robots in hybrid manufacturing overcome many restrictions of the conventional manufacturing methods, such as small part building size, long building period, and limited material choices. However, some problems such as the uneven distribution of motion accuracy within robot working volume, the acceleration impact of robot under heavy external loads, few methods and facilities for increasing the efficiency of hybrid manufacturing process are still challenging. This dissertation aims to improve the applications of using industrial robot in hybrid manufacturing by addressing following three categories research issues. The first research issue proposed a novel concept view on robot accuracy and stiffness problem, for making the maximum usage of current manufacturing capability of robot system. Based on analyzing the robot forward/inverse kinematic, the angle error sensitivity of different joint and the stiffness matrix properties of robot, new evaluation formulations are established to help finding the best position and orientation to perform a specific trajectory within the robot’s working volume. The second research issue focus on the engineering improvements of robotic hybrid manufacturing. By adopting stereo vision, laser scanning technology and curved surface compensation algorithm, it enhances the automation level and adaptiveness of hybrid manufacturing process. The third research issue extends the robotic hybrid manufacturing process to the broader application area. A mini extruder with a variable pitch and progressive diameter screw is developed for large scale robotic deposition. The proposed robotic deposition system could increase the building efficiency and quality for large-size parts. Moreover, the research results of this dissertation can benefit a wide range of industries, such as automation manufacturing, robot design and 3D printing. v ACKNOWLEDGMENTS First and foremost, I would like to express my sincere gratitude to my advisor, Dr. Frank Liou, for his encouragement, insightful guidance, and support during my PhD study at Missouri University of Science and Technology. He patiently guided me through every stage of my research while granted me a great deal of independence. His encouragement endowed me with tremendous confidence in exploring unknown scientific territory and challenging myself to be my best. His diligence and rigorous altitude to research and work will have a significant influence on my future life. It has been a privilege and a great honor to have worked with him. I would also like to extend my appreciation to all my dissertation committee members, Dr. Ashok Midha, Dr. Heng Pan, Dr. Lian Duan and Dr. Joseph W Newkirk. Without their guidance and valuable comments, it is impossible for me to complete my dissertation. The dissertation was supported by the Laser Aided Manufacturing Processes (LAMP) Laboratory, and the Intelligent System Center of Missouri S&T, which are gratefully acknowledged. I would like to express my deep thanks to my lab-mates and friends, Mr. Todd Sparks, Ms. Lisa, Mr. Renwei Liu, Mr. Sreekar Karnati, Mr. Yunlu Zhang, Ms. Xueyang Chen, Mr. Zhiqiang Fan, Mr. Max Mulholland, Mr. Jingwei Zhang, Mr. Xinchang Zhang and Mr. Lei Yan for their support during my study in Rolla. Last but not the least, I wish to extend my special and sincere thanks to my parents and all the family members, for their love and unwavering support. vi TABLE OF CONTENTS Page PUBLICATION DISSERTATION OPTION……………………………………………iii ABSTRACT ....................................................................................................................... iv ACKNOWLEDGMENTS .................................................................................................. v LIST OF ILLUSTRATIONS .............................................................................................. x LIST OF TABLES ........................................................................................................... xiv SECTION 1. INTRODUCTION ...................................................................................................... 1 1.1. BACKGROUND ................................................................................................ 1 1.2. RESEARCH OBJECTIVES............................................................................... 2 1.3. ORGANIZATION OF DISSERTATION .......................................................... 4 PAPER I. INDUSTRIAL ROBOT TRAJECTORY ACCURACY EVALUATION MAPS FOR HYBRID MANUFACTURING PROCESS BASED ON JOINT ANGLE ERROR ANALYSIS ................................................................................................... 6 ABSTRACT ............................................................................................................... 6 1. INTRODUCTION ................................................................................................. 7 2. RIGID BODY REPRESENTATION AND HOMOGENEOUS TRANSFORMATION MATRIX ........................................................................ 11 3. D-H REPRESENTATION OF 6-DOF INDUSTRIAL ROBOT ......................... 14 4. ROBOT KINEMATIC ......................................................................................... 21 4.1. FORWARD KINEMATIC OF ROBOT ................................................... 21 4.2. INVERSE KINEMATIC OF ROBOT ...................................................... 23 5. JOINT ANGLE ERROR ON EFFECTOR’S POSITION ACCURACY ............ 33 vii 6. INDUSTRIAL ROBOT TRAJECTORY ACCURACY MAPPING .................. 41 7. SIMULATION: TRAJECTORY ACCURACY MAPPING OF A ROBOTIC HYBRID MANUFACTURING WORKING PATH .......................................... 52 8. CONCLUSION .................................................................................................... 61 ACKNOWLEDGEMENTS ..................................................................................... 62 REFERENCES ........................................................................................................ 63 II. INDUSTRIAL ROBOT TRAJECTORY STIFFNESS MAPPING FOR HYBRID MANUFACTURING ............................................................................... 66 ABSTRACT ............................................................................................................. 66 1. INTRODUCTION ............................................................................................... 67 2. KINEMATIC JACOBIAN OF ROBOT .............................................................. 70 3. SOLUTION OF THE JACOBIAN MATRIX OF ROBOT ................................. 72 4. FORCE JACOBIAN MATRIX OF ROBOT ....................................................... 79 5. CARTESIAN STIFFNESS MATRIX FORMULATION OF ROBOT SYSTEM ............................................................................................... 81 6. ROBOT TRAJECTORY STIFFNESS EVALUATION FORMULATION ....... 85 7. SIMULATION: STIFFNESS MAPPING OF A ROBOTIC HYBRID MANUFACTURING WORKING PATH ........................................................... 87 8. CONCLUSION .................................................................................................... 93 ACKNOWLEDGEMENTS ..................................................................................... 94 REFERENCES ........................................................................................................ 95 III. REALIZATION OF ROBOT INK DEPOSITION ON A CURVED SURFACE ............................................................................................. 97 ABSTRACT ............................................................................................................
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