A Review on Robotized Automated Lay-up Technology for Composite Material Manufacturing
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摘要: 碳纤维增强复合材料(Carbon fiber-reinforced composite, CFRC)因具有轻质高强、耐腐蚀、耐冲击等优越性能, 在生产生活中的应用已越来越广泛, 然而复材产品的生产制造仍是劳动密集性产业, 主要依靠人工. 机械臂自上世纪50年代进入工业生产中以来, 极大提高了生产效率和质量, 然而目前机械臂在复材产品制造中的应用是少见的, 主要集中在机械臂形式的自动铺丝(Automated fiber placement, AFP)中. 复材产品制造工艺繁琐, 将复合材料铺放在模具上是复材产品制造过程中的一个重要环节, 本文称之为“铺层”, 使用机械臂完成复合材料自动铺层将是未来复材产品制造自动化、智能化发展的一个关键方向. 本文将机械臂进行复合材料自动铺层操作分为两种主要形式: 铺片和铺带(丝), 通过案例调研和分析, 归纳总结现有的设计理念和技术方法, 提出未来发展趋势, 以期对机械臂的应用和研究、复材产品的智能化制造和工业4.0的发展形成参考.Abstract: Carbon fiber-reinforced composite (CFRC) has been widely used in production and life because of its superior properties such as light weight and high strength, corrosion resistance and impact resistance. However, the manufacturing of composite products is still a labor-intensive industry, mainly relying on manual labor. Since the robot arm entered the industrial production in the 1950s, it has greatly improved the production efficiency and quality, however, the current application of robot arm in the manufacturing of composite products is rare, mainly focusing on the robot arm form of automated fiber placement (AFP). The manufacturing process of composite products is tedious, and laying the composite material on the mold is an important part of the manufacturing process of composite products, which we call “lay-up”, and the use of robot arm to complete the automated lay-up operation will be a key direction for the future automation and intelligent development of the manufacturing of composite products. This paper offers a thorough examination of automated lay-up operation for robot arm, and categorizes them into two primary types: Lay-up sheets and lay-up tapes (fibers). Through case study and analysis of existing design concepts and technical methods, this paper identifies trend and suggests future development direction. The insights are of significant value for application and research related to robot arm, intelligent manufacturing of composite products, and the progression of Industry 4.0.
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图 1 复材产品制造工艺的生产流程图
Fig. 1 Production flow chart of the manufacturing process of composite products
图 6 面向工业生产的多机械臂协同铺层研究案例
Fig. 6 Multi-robot arms collaborative lay-up study cases for industrial production
表 1 机械臂在传统工业场景和复材产品制造场景应用特点对比
Table 1 Comparison of the application characteristics of robot arm in traditional industrial scenario and composite products manufacturing scenario
对比 特点 传统工业场景 复材产品制造场景 喷涂 点焊 搬运 装配 铺片 铺带(丝) 相同之处 重复定位精度 高 位置跟踪要求 高 不同之处 操作是否接触 否 是 是 是 是 是 操作材料特性 气体 高温 硬质 硬质 柔软粘性 柔软粘性 是否需要加热 否 是 否 否 是 是 是否有接触力 否 否 是 是 是 是 末端构造 喷嘴 焊钳 夹持 各类工具 夹持悬垂拾取 专有铺放头 
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表 2 不同拾取原理的优劣对比
Table 2 Comparison of the advantages and disadvantages of different pick-up principles
拾取原理 对材料的损坏程度 成本 实现难度 易操作性 针刺 高 低 低 高 低温 中 中 中 中 真空吸取 无 高 中 中
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表 3 单机械臂铺层研究案例对比
Table 3 Comparison of single robot arm lay-up study cases
研究机构 研究重点 路径规划 运动规划 工艺参数 系统软件 使用的机械臂 相关文献 德国宇航中心 全过程自动化 基于视觉生成 系统生成 未知 独立开发 KUKA [45−46, 71−72] 汉堡科技大学 工艺流程优化 未知 未知 未知 未知 ABB [73−76] 慕尼黑工业大学 全过程自动化 人类专家设计 控制器生成 人类专家设计 CFK-Tex.Office KUKA KR-500 [32−34, 77] 布里斯托大学 铺放自动化 未知 未知 人类专家设计 未知 ABB [62] 德国宇航中心 全过程自动化 系统生成 系统生成 未知 独立开发 KUKA [78−79] 南丹麦大学 铺放自动化 基于模拟方法 系统生成 未知 独立开发 KUKA KR-360 [60, 80−84]
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表 4 多机械臂协同铺层研究案例对比
Table 4 Comparison of multi-robot arms collaborative lay-up study cases
研究机构 机械臂数量 研究内容 路径规划 运动规划 系统软件 使用的机械臂 相关文献 南卡罗莱纳大学 3 路径规划 运动规划 算法生成 控制器生成 独立开发 KUKA-iiwa [85−87, 89−91] 斯图加特大学 3 系统搭建 路径规划 人类专家设计 系统生成 独立开发 ABB [64, 92] 德国宇航中心 2 系统搭建 路径规划 算法生成 系统生成 独立开发 KUKA-KR270 [93−101] 空客集团 2 系统搭建 末端开发 人类专家设计 系统生成 独立开发 KUKA [41−42, 106] 林雪平大学 2 技术验证 末端开发 未知 未知 未知 KUKA-KR10, ABB [107−108] 慕尼黑工业大学 2 系统搭建 路径规划 算法生成 系统生成 独立开发 Staubli, KUKA [24] 思克莱德大学 1 技术验证 人类专家设计 系统生成 独立开发 KUKA-KR6 [110] 维也纳技术大学 2 技术验证 人类专家设计 系统生成 未知 自制 [111−112]
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表 5 铺带(丝)头中采用的切割方式对比
Table 5 Comparison of cutting methods used in tape (fiber) lay-up heads
切割方式 成本 优点 缺点 机械道具切割 低 结构简单, 切割效率高, 适用于多种复杂环境,
维修更换比较方便难以控制切割深度且切口毛糙, 损伤预浸料,
无法保证切口质量激光切割 较高 切割效率高, 非接触式切割, 产品边缘光滑平整,
激光对位精准, 切割精度高温度较高, 使复合材料发生变质且
切割深度不易控制水喷射切割 低 设备结构简单, 操作容易, 工作机构具有喷头体积小、
后坐力小、移动方便、生产效率高等特点给整个铺带环境带来大量污染液体,
影响复合材料成型, 铺带工作不便超声波切割 较高 切割效率高, 切口平整; 合适的切割速度、
切割深度满足不同工况下的切割易受负载、温度等因素影响, 引起谐振频率、
等效阻抗等参数漂移变化
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表 6 铺带(丝)头中采用的加热方式对比
Table 6 Comparison of heating methods used in tape (fiber) lay-up heads
加热方式 成本 优点 缺点 电阻丝加热 低 加热均匀, 实现简单 热损失大, 功率密度低, 使用寿命短 激光加热 高 激光加热效率高, 响应快 温度难以控制, 容易产生局部过热 热风加热 低 温度场均匀, 调节范围广 加热升温时间长, 热效率较低 红外加热 高 热效率高, 加热均匀, 响应速度快 辐射面存在一定限制, 温度场不均匀
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表 7 路径规划方法对比
Table 7 Comparison of path planning methods
分类 方法 优点 缺点 参考路径生成 自然路径法 可以避免纤维起皱, 轨迹可铺放性良好 计算量大, 仅适用于低曲率表面 定角度路径法 原理及计算过程简单 仅适用于整体曲率波动较小的曲面 变角度路径法 能够自适应芯模曲面不规则情况 算法计算量大 路径密化 等距偏置算法 算法简单, 能够覆盖整个芯模表面 在复杂表面上可能存在间隙和重叠 等角度算法 算法实现简单, 适应各种复杂构件 易存在间隙和重叠
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关键技术 研究内容 研究目标 轨迹规划 根据构件3D表面设计相应路径规划算法, 自适应生成铺放轨迹 满足构件结构的方向性、铺放顺序和铺叠层数要求 铺放路径覆盖 根据曲面上相邻路径的间距, 对铺丝路径的覆盖性进行检验与优化 实现对模具的满覆盖、不重叠, 满足空隙容差 边界处理 根据构件的边界轮廓信息, 设计边界处理算法, 控制边缘和角部的铺放方式与形态 确保铺放边界质量和表面光洁度 后置处理 数控代码生成、代码优化与合成、加工仿真技术等 机器人能够识别执行的指令
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表 9 现有自动化缺陷检测技术优劣对比
Table 9 Comparison of the advantages and disadvantages of existing automated defect detection technologies
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