Impact of bending dies with different friction forms on forming force and quality of tubes manufactured by free bending technology

In the 3D free bending forming system, the bending die can be designed either in a sliding type or rolling friction type. Bending die-based sliding friction type is often called normal bending dies; however, the bending dies-based rolling friction type includes bending die-based roller type and ball type in structure. In the current study, the impact of three bending dies on the forming force, and the bent tube quality was investigated. The obtained results showed that the tangential stresses and strains of the tubes formed by the bending die-based roller type were the smallest among the three bending dies. Besides, the spherical bearing force P_U was reduced drastically after using the roller type and ball type compared to the sliding friction type. Moreover, the uniformity of the wall thickness distribution of the tubes formed by the roller type and ball type was better than those obtained from the sliding friction type. In addition, the cross-section distortion rate was reduced by 2.8% using the roller type, and 1.8% using ball-type compared to the sliding friction type.     

Grinding force and surface quality in creep feed profile grinding of turbine blade root of nickel-based superalloy with microcrystalline alumina abrasive wheels

Creep feed profile grinding of the fir-tree blade root forms of single crystal nickel-based superalloy was conducted using microcrystalline alumina abrasive wheels in the present study. The grinding force and the surface quality in terms of surface topography, subsurface microstructure, microhardness and residual stress obtained under different grinding conditions were evaluated comparatively. Experimental results indicated that the grinding force was influenced significantly by the competing predominance between the grinding parameters and the cross-sectional root workpiece profile. In addition, the root workpiece surface, including the root peak and valley regions, was produced with the large difference in surface quality due to the nonuniform grinding loads along the root workpiece profile in normal section. Detailed results showed that the surface roughness, subsurface plastic deformation and work hardening level of the root valley region were higher by up to 25%, 20% and 7% in average than those obtained in the root peak region, respectively, in the current investigation. Finally, the superior parameters were recommended in the creep feed profile grinding of the fir-tree blade root forms. This study is helpful to provide industry guidance to optimize the machining process for the high-valued parts with complicated profiles.     

基于工业机器人的飞机柔性装配技术

研究了基于工业机器人的飞机柔性装配技术,着重讨论了机器人精度补偿、末端执行器设计、法线检测与找正、系统控制、离线编程等关键技术。通过在小翼部件加工中的应用,达到了孔位精度±0.5mm、法向精度±0.5°等关键技术指标。结果表明,对于特定应用对象采用机器人技术进行飞机部件自动装配为一个理想、低成本的解决方案,随着当今工业机器人性能不断增强,配以末端执行器和相关的补偿系统,在航空工业作为装配平台是可行的。     

Dynamics and control of spacecraft hovering using the geomagnetic Lorentz force

To achieve hovering, a spacecraft thrusts continuously to induce an equilibrium state at a desired position. Due to the constraints on the quantity of propellant onboard, long-time hovering around low-Earth orbits (LEO) is hardly achievable using traditional chemical propulsion. The Lorentz force, acting on an electrostatically charged spacecraft as it moves through a planetary magnetic field, provides a new propellantless method for orbital maneuvers. This paper investigates the feasibility of using the induced Lorentz force as an auxiliary means of propulsion for spacecraft hovering. Assuming that the Earth’s magnetic field is a dipole that rotates with the Earth, a dynamical model that characterizes the relative motion of Lorentz spacecraft is derived to analyze the required open-loop control acceleration for hovering. Based on this dynamical model, we first present the hovering configurations that could achieve propellantless hovering and the corresponding required specific charge of a Lorentz spacecraft. For other configurations, optimal open-loop control laws that minimize the control energy consumption are designed. Likewise, the optimal trajectories of required specific charge and control acceleration are both presented. The effect of orbital inclination on the expenditure of control energy is also analyzed. Further, we also develop a closed-loop control approach for propellantless hovering. Numerical results prove the validity of proposed control methods for hovering and show that hovering around low-Earth orbits would be achievable if the required specific charge of a Lorentz spacecraft becomes feasible in the future. Typically, hovering radially several kilometers above a target in LEO requires specific charges on the order of 0.1 C/kg.     

壁面吊挂清洗机器人碰壁缓冲问题研究

从机器人自动上壁及缓冲的需求出发,分析了机器人拉力形成的机理、碰壁的原因和过程.利用空气动力学原理,给出了拉力的计算方法,采用机器人物理样机进行实验,对计算结果进行了验证.在拉力的作用下机器人与壁面贴合,同时伴随碰撞,其间冲击能量的吸收由机器人裙边和支撑机构所构成的缓冲装置承担.前者还要保证机器人贴壁后的密封,因此刚度不宜过大,后者还要保证机器人在壁面上稳定行走,因此它的刚度又不宜过小.给出了缓冲装置刚度的确定方法及其在裙边和支撑机构上的分配准则,可用于工程分析.     

轴向通流旋转盘腔内流动不稳定性研究

为了研究旋转腔内流动不稳定性问题,采用旋转坐标系稳态方程,用数值模拟的方法分析了轴向通流旋转盘腔内的流动,得到了旋转系下哥氏力和离心浮升力分别对流动不稳定的作用,以及这两个力的非线性综合作用对流动不稳定的影响.结果表明:哥氏力是恢复力,不影响流动稳定性;离心浮升力是造成流动不稳定的主要因素,盘腔内的流动是离心力场下的Rayleigh-Benard对流和强迫对流的混合流,随着浮升力的增强流动由稳态发展为非稳态;哥氏力与离心浮升力的综合作用加剧了流动不稳定性,盘腔内r-θ面出现了明显的旋向相反的对涡.     

空间机器人在轨更换ORU的力/位混合控制方法

针对ORU在轨更换任务,首先推导了空间机械臂末端自由、末端与环境接触等情况下的动力学方程,并提出了相应的接触力计算方法;其次,改进了传统的R\|C控制方法,采用加权选择矩阵代替原有的选择矩阵,实现了力控制与位置控制之间的平滑切换;最后,开发了基于Matlab/Simulink的闭环控制仿真系统,该系统由多体动力学、接触动力学、轨迹规划、力/位混合控制、3D显示等模块组成。利用该系统开展了ORU转移与安装过程的闭环控制仿真,仿真结果校验了所提方法的有效性。     

翼型测力天平的研制

为研究翼型结冰状态下的载荷变化规律,对翼型进行测力实验.研制一台三分量翼型测力天平.天平设计的突出难点为设计载荷极不匹配,阻力测量载荷很小.设计时,针对翼型载荷的特点,采用片梁组合方式测量阻力,四柱梁测量法向力及俯仰力矩,并采用有限元方法对结构进行了验证计算.主要介绍天平的设计、校准及应用情况.     

过渡状态倾转旋翼气动力模拟的高效CFD方法

为显著减少倾转旋翼过渡飞行时气动力CFD模拟的计算代价,提出并建立了适合倾转旋翼过渡状态气动特性分析的高效混合CFD方法。首先,提出了适合于过渡状态模拟的嵌套网格系统,并发展了相应的挖洞和贡献单元搜寻方法。在此基础上,结合叶素理论和动量理论建立了旋翼气动力模拟的简化虚拟桨盘模拟方法(Virtual rotor model,VBM)。为了能够分析倾转旋翼气动力的细节特性,多层运动嵌套网格系统和单指令多数据流(Single program multiple data,SPMD)并行技术被引入来建立精确的旋翼模拟方法(Real blade model,RBM)。然后,通过将VBM和RBM方法结合,构建了适合倾转旋翼过渡状态气动特性分析的高效(Hybrid blade model,HBM)方法。最后,通过对有试验值对比的悬停状态典型旋翼和7A旋翼分别验证了VBM和RBM方法的有效性。分别采用3种方法预测了过渡状态不同倾转角下旋翼的气动特性,VBM表现出最优的计算效率,能用于倾转旋翼总体气动性能的分析。HBM方法在保证流场求解精度的基础上,相对于高精度的RBM方法节省了1/3的计算时间。     

多模式柔索驱动航天员训练机器人力控制

为解决长期在失重环境下生活和工作的航天员的康复训练问题,针对现有的航天员训练设备功能单一、训练效果不理想的现状,研制了多模式柔索驱动航天员训练机器人。基于模块化、可重构的机器人构型,通过机器人模拟重力环境的负载特征,把相应的载荷施加到人体上,实现航天员在失重环境下进行跑步、卧推和负重深蹲等体育训练,帮助航天员减轻或者克服空间适应综合征带来的不利影响;在此基础上提出一种机器人双闭环力控制策略,人机跑步训练实验结果表明,本文研制的多模式航天员训练机器人构型合理,控制策略有效,可以辅助在失重环境下生活和工作的航天员开展体育训练。