天然气己经成为现在社会的重要能源之一，而管道输送方式是一种高效低成本的输送方式。天然气管道的使用需要包含天然气管道的日常监测与维护。气体输送管道机器人是应用于天然气等输送管道中的机器人，其任务主要为清除输送管道壁上附着的污物并且测量输送管道壁厚度，通过监测管道壁厚的异常以检测管道状态防止泄露。本管道机器人基本结构采用轮式结构，利用升降机构可以实现工作部分中心轴线的水平高度的调整，可以实现在不同内径管道的清污和检测工作。管道机器人利用机械对心结构以及控制单元保持功能结构部分处于管道中心轴位置处。管道机器人利用超声波检测装置检测管壁厚度。机器人利用风力发电机产生电能，利用蓄电池储存电能，以实现机器人的工作续航能力。

关键词：基本结构：对心装置：动力系统：功能结构

The Design of The Robot Used for Gas Pipeline

Abstract

Natural gas has become one of the most important energy of this modern society,using the pipeline is a low-cost ,efficient way. While using the pipeline, the routine monitoring and maintenance is needed. The gas pipeline robot is designed for the maintenance of the pipeline. Its tasks include sweeping the surface inside and measuring the thickness of the pipeline. By analysing the change of the pipeline, we can find the location of the place that may leak gas. The basic structure of this design is with wheel, the hight of the axis can be adjusted by the elevating structure, then this robot can be used in the pipelines with different diameters. Mechanical structure and control unit are used to achieve the axis of the functional structure be coincided with the axis of the pipeline. The thickness of the pipeline is measured by the ultrasonic device. Wind generator is used in this design to offer power, batteries are used to store energy so the working hours of the robot can be extended.

Key Words:Basic Structure;Centering Device;Motion System;Functional Structure

l 引言l

2 管道机器人的发展l

2.l 天然气输送管道的发展l

2.2 管道机器人的发展状况2

2.2.l 国外管道机器人研究进展2

2.2.2 国内管道机器人研究进展2

3 设计的主体内容3

3.l 管道机器人的基本结构3

3.2 管道机器人的动力机构设计3

3.2.l 电机、变速器的选择3

3.2.2 差速器的设计5

3.2.3 轴的设计校核8

3.3 管道机器人供能系统设计9

3.3.l 发电机的设计选择9

3.3.2 蓄电池的设计选择l0

3.4 管道机器人升降机构设计l0

3.4.l 升降机的设计选择l0

3.4.2 圆柱导轨的设计选择ll

3.4.3 圆柱导轨支架的设计ll

3.5 管道机器人功能机构设计ll

3.5.l 定心机构的设计ll

3.5.2 清扫机构的设计l2

3.5.3 测量装置的选择与设计l2

3.6 管道机器人的定位l2

4 结果分析与讨论l4

5 结语l5

参考文献l6

致谢l7

1 引言

随着社会的发展，天然气作为一种清洁能源己经越来越多的应用在人们生活的许多方面。天然气的应用不仅是作为燃料，更是作为一种重要的化工原料得到了大量的应用。经过多年的探测，在我国 960 万平方公里的土地和 300 多万平方公里的管辖海域下，蕴藏着十分丰富的天然气资源。但是天然气的分布大多集中在人口稀少的油田中，因此，天然气的运输就成为一项十分重要的工作。管道输送过程中必须依靠日常的维护，天然气的日常维护其中就包括了管道内污物的清除以及泄露的防止。但是现阶段使用的管道机器人大多为进口，成本昂贵。

本设计主要是针对大口径气体输送管道的日常维护而进行。本设计能够实现的功能为管壁附着的污物的清扫以及壁厚的检测，通过壁厚的异常判断管道安全状况。为天然气的输送效率和安全提供保障。

2管道机器人的发展

2.1 天然气输送管道的发展

中国是最早用木竹管输送天然气的国家。l8 世纪以前，输气管道也使用木竹管。l9 世纪后期用铸铁管，l9 世纪 90 年代开始使用钢管。输气动力开始全靠天然气井口压力。 20 世纪 20～30 年代采用了双燃料发动机驱动的压气机给管内天然气加压，输气压力从原来 5883.6 帕上升到 27,400 帕～4l,l60 帕。输送距离也越来越长。后来又出现了规模巨大的管网系统。60 年代开始，在天然气进出口国之间，相继建成了许多跨国管道，如由苏联经原捷克和斯洛伐克、奥地利、德国的 l780 千米的输气管道：由奥地利到意大利的长 774 千米的管道：由阿尔及利亚经突尼斯、地中海和突尼斯海峡到意大利的全长 2,500 千米的管道等。到 l983 年时，世界输气管道总长达到 9l34 万千米。长距离输气管道普遍采用压气机增压输送。输气管道在管材选用、提高输送效率、实现全线自动化等方面的技术也有了迅速的发展

。我国的西气东输工程是一项具有战略意义的大工程，其目的为将西部地区天然气向东部地区输送，主要是新塔里木盆地的天然气输往长江三角洲地区。输气管道西起新塔里木的轮南油田，向东最终到达上海，延至杭州。途 ll 省区，全长 4000km。设计年输气能力 l20 亿立方米，最终输气能力 200 亿立方米。2004 年 l0 月 l 日全线贯通并投产。

天然气管道可分为矿场集输管道、长输管道和城市输配管网。我们可以用大口径、长距离长距离、巨输量来概括长输管道的特点。我国的西气东输工程管道:从新库尔勒至上海市全长 4400 多公里，管径φl0l6mm，最高输送压力 l0Mpa，年设计输量 l20 亿立方米／年，建成后可以解决沿线中东部地区 5 个省

L2』市大中城市的气化问题。

参考文献

Ll』百度网.天然气管道.http:／／／view／38l75l.htm.L20ll.5』

L2』严铭卿，盔亢琪，黎光华.天然气输自技术 LM』. 北京：化学工业出版社，2005.l2

L3』杨国量,等.城市排水管道自动清淤检测机器人设想方案 LJ』.中国市政工程,l998,83（ 4）: 43-45

L4』 Shigeo Hirose, Hidetaka Ohno, Takeo Mitsu,i Kiichi Suyama.Design of in pipe inspection vehicles for 25, 50, l50 pipes LJ』 IEEE International Conferenceon Robotics and Automation, l999.5: 2309-23l4

L5』http:／／／Templatecfm?Section二Past Issues&template二／Content Management／Content Display.cfm&ContentID二 6690

L6』 http:／／aisgmd.de／projects／Makro／makro engl／makroe html

L7』郭凤,许冯平,邓宗全,彭敏.管道机器人弯道处驱动力研究 LJ』.机器人,2006.8:l264-l266 L8』钱晋武,李毅, 沈林勇.柔软管道中机器人蠕动机构研究 LJ』.机械与电子,200l（l）: 37-38 L9』黄珊秋.机械设计课程设计. 北京：机械工业出版社，l999.8

Ll0』吴洪冲，雷秀. 管道机器人弯道通过性的分析. 机械制造与研究. 2007.8:57～59 Lll』邱宣怀，郭可谦，吴宗泽等.机械设计.北京：高等教育出版社,l997

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内容简介：: 山东大学 2011 届学生毕业论文（设计）中期汇报表学院机械工程学院系所机制所姓名葛顺鑫指导教师王经坤论文（设计）题目（天然气）管道机器人毕业论文（设计）前期工作完成情况1、完成设计所需的论文，标准，专利等资料的检索和搜集；2、完成英文论文翻译一篇；3、完成机构设计的总体尺寸确定；4、完成设计软件的准备工作；5、完成毕业实习及毕业实习的报告。指指导教师意见指导教师签名：年月日山东大学毕业设计（论文）任务书学院：机械工程学院专业：机械设计制造及其自动化年级：2007学生姓名葛顺鑫指导教师王经坤设计题目气体输送管道轮式式机器人设计设计内容1进行气体输送管道轮式式机器人的方案设计；2进行气体输送管道轮式式机器人的运动布局设计；3气体输送管道轮式式机器人的详细设计，完成装配图设计和所有部件的部件图设计及关键零件的零件图设计；4气体输送管道轮式式机器人的零部件设计计算；5气体输送管道轮式式机器人的设计说明书编写。设计的主要技术指标1适用管道流体：气体，如天然气；管道内径：600-1000mm2机器人行走方式：轮式；3机器人基本尺寸：长度：650mm；宽度：400mm；高度：600-1000mm；4行走速度：40mm/s；行走距离：10km-50km；5主电机功率：100w；主电机转速：1700rpm；6电池供电时间：48h-100h；带有发电系统；7机器人功能：检测和除污设计的基本要求1实现气体输送管道轮式式机器人的方案设计，详细设计；2实现气体输送管道轮式式机器人的设计计算；3撰写论文(A4打印、小四字体)40页以上。毕业论文（设计）篇幅为11.5万字；4英文翻译23万字符100，000字符，汉字不少于5，000字（附原文）。应收集的资料及主要参考文献1、严铭卿，宓亢琪. 天然气输配技术. 北京：化学工业出版社，2005.122、杨国量.城市排水管道自动清淤检测机器人设想方案.中国市政工程.19983、 Shigeo Hirose.Design of in pipe inspection vehicles for 25, 50, 150 pipes.IEEE International Conferenceon Robotics and Automation.1999.54、郭凤.管道机器人弯道处驱动力研究.机器人.2006.85、邱宣怀.机械设计.北京：高等教育出版社,1997 等填表时间：2011年3月附录 1:Design principles of reconfigurable machinesReuven KatzAbstract Reconfigurable machines form a new class of machines that are designed around a specific part family of products and allow rapid change in their structure. They are designed to allow changes in machine configuration according to changes in production requirements. The reconfiguration may be related to changes in machine functionality or its scalability, i.e., the change in production volumes or speed of operation. Reconfigurable machines represent a new class of machines that bridges the gap between the high flexibility and high cost of totally flexible machines and the low flexibility and low cost of fully dedicated machines. The design principles of reconfigurable machines follow a similar philosophy, which was derived for reconfigurable manufacturing systems, and present an approach for the design of machines to be used mainly in high-volume production lines. This paper introduces design principles for reconfigurable machines, which may be applied in different fields of manufacturing. Based on these design principles, three types of reconfigurable machines were designed for various types of production operations such as: machining, inspection and assembly. This paper shows how the suggested design principles were utilized in the design of several full-scale machine prototypes and tested experimentally.Keywords Machine design . Reconfigurable machines （RM） . Reconfigurable manufacturing systems （RMS） . Reconfigurable machine tool （RMT） . Reconfigurable inspection machine （RIM） . Reconfigurable assembly machine（RAM）Abbreviations RM: Reconfigurable machine. RMS:Reconfigurable manufacturing systems. RMT: Reconfigurable machine tool. RIM: Reconfigurable inspection machine . RAM: Reconfigurable assembly machine. DMS: Dedicated manufacturing systems. FMS:Flexible manufacturing systems. ERCRMS: Engineering Research Center for Reconfigurable Manufacturing Systems. CNC: Computer numeric control. CMM: Coordinate measurement machine. FRF: Frequency response function. FFT: Fast Fourier transform1 IntroductionThe two main traditional methods utilized by manufacturing industries in the production of medium and highvolume parts are dedicated manufacturing systems（DMS）Ll,2 and flexible manufacturing systems （FMS）L3-5. DMS is used when partproduction volumes are high and constant, and the part does not change. FMS is used when the required quantities are relatively lower and many modifications in the part design are foreseen, or more than one type of product is produced on the same line simultaneously. An innovative approach of customized manufacturing, termed reconfigurable manufacturing systems （RMS） is described in L6. The main advantageof this new approach is the customized flexibility of the system to produce a “partfamily” of products with lower investment cost than an FMS. A set of core characteristics: modularity, scalability, integrability, convertibility, customization and diagnosibility comprises the heart of an RMSL7. A typical RMS includes both conventional flexible machines and a new type of machine called the reconfigurable machine （RM） on its production line.Typically, a dedicated machine used in a DMS is designed around a specific part that is mass produced. It is designed to perform a single operation with high reliability and repeatability, and high productivity and therefore is relatively simple and less expensive. Machines that are used in an FMS are designed to perform most operations in a flexible manner. These flexible machines are computer numerical controlled（CNC） and can produce many different parts by changing their computer programs. Since reliability, repeatability and high productivity arerequired for mass production lines, flexible machines designed for high volume production are relatively expensive. In contrast, the RM is designed for customized flexibility, i.e., the flexibility needed to produce a particular part familyL7. The RM can perform a pre-designed set of requiredoperations as specified for the specific part family with high reliability, repeatability and high productivity. The limited, customized flexibility allows reduction of investment costs on the one hand and fast response when a product changes on the other, both representing economicalbenefits.The innovativeidea of RMS and its six core characteristics was originally developed for“systems”, namely, mass production lines. Development of new design principles based on RMS philosophy was required in order to design RMs. These machines are to be used on RMS lines, thereby extending the RMS concept from a system level to the machine level.In the literature, several general principles of machine design have been proposed and discussed. For example, Doubbel describes principles of embodiment design such as: principle of division of tasks, force and energy transmission, as well as safety and reliability principlesL8. Norton defines engineering design as “ The process of applying the various techniques and scientific principles for the purpose of defining a device, a process or a system in sufficient detail to permit its realization” and alsodescribes the phases of the design processL9. Suh presents a thorough discussion of the design process in engineering using mathematical tools and shows examples of machine designLl0. He presents the design equation that relates the functional requirements vector FR to the design parameters DP vector using the design matrix LA. Using this approach, he studies different cases of coupled design, redundant design and ideal design. Other researchers focus on design principles of machines which are used primarily for manufacturing. Altintas presents fundamental principles of designing CNC machine toolsLll. It includes sizing and selecting drive motors, configuration of physical structure and modeling of servo control. Design principles of CNC machine tools were also presented in detail by orenLl2. Design principles of machining systems as well as an upgradeable multi spindle RM are discussed inLl3. RM design concepts are studied inLl4 with the goal of developing“modular reconfigurable machine”. As stated there, the key characteristics ofmodular machine design were focused on decomposition, standardizationand exchangeability. According toLl5, the design of RMS is based on a construction20kit principle that enables it to adjust to new production requirements by substitution, addition or removal of machine systems. A synthesis methodology for designing reconfigurable machine tools （RMT）Ll6,l7 takes a set of functional requirements and a set of process plans as the input and generates a set of kinematically viable RMTs to meet the given specifications. A thorough study of machine tools scalability in the context of RMS is presented and discussed inLl8. Current studies are focused onimproving dynamic design capabilities of RMTsLl9 and on a modular approach forRMT servo axis modelingL20. The derived machine tool models can be used for design and control of RMT servo axes. When high volumes of parts are produced, there is a need for rapid and low cost inspection equipment for measuring geometrical and dimensional tolerances as well as surface quality. Typically, dedicated gages that are designed for high precision and high repeatability are expensive and are not flexible to product changesL2l. Therefore, manufacturers prefer using flexible coordinate measuring machines （CMM） that can measure many different parts or featuresL22. An interesting application of the general design principles proposed by SuhLl0 demonstrates a methodology for selecting a measuring system for inspection of mechanical partsL23. Utilizing this methodology, the authors selected a flexible CMMbased system for completing their task.The goal of this paper is to introduce and explain the design principles of RMs. These design principles follow the concepts and vision of the RMS philosophy presented inL6, 7 and introduce a complete set of practical design principles. Based on these design principles, several RMs were designed. The paper presents three examples of such machines designed for machining, inspection and assembly operations. We explain how the design principles are reflected in the actual design of each machine. Metal cutting, metrology and assembly represent different manufacturing operations； however, similar design principles have been used to design RMs for each of these operations. Two full-scale prototypes of RMs were built（Sections 3 and 4）. These RMs were experimentally tested to evaluate their reconfigurability features as well as their functional performance. The paper briefly describes some of these studies and refers the readers to more complete2ldocumentation of our research efforts.Section 2 presents and explains the design principles of RMs. Sections 3, 4 and 5 describe each RM that was designed based on the design principles discussed in Section 2. First a brief description of the machine is provided. Then, the application of the design principles during the design phase as well as the studies and validation performed for each machine is discussed. Section 6 summarizes the paper and presents concluding remarks.2 Design principlesAn RM is a machine that is specifically designed to handle product variants within a specific part family. A good design of an RM is a design that makes it proficient in handling changes and simplifies the changeover procedure.The design principles of RMs follow the philosophy of reconfigurable manufacturing systems. RMs are designed mainly for mass production applications. RMs are designed to allow customized flexibility and a cost-effective production and inspection of a family of parts.A machine is classified as an RM if its design follows the necessary principle and several of the primary principles stated below.Necessary principle:l. A reconfigurable machine is designed around a specific part family of products. Primary principles:5. A reconfigurable machine is designed for customized flexibility only.6. A reconfigurable machine is designed for easy and rapid convertibility.7. A reconfigurable machine is designed for scalability: allows addition or removal of elements that increase productivity or efficiency of operation.8. A reconfigurable machine is designed to allow reconfiguration of the machine to operate at several locations along the production line performing different tasks at different locations, using the same basic structure.9. A reconfigurable machine should be designed applying modularity concepts,3namely, using common “building blocks” and common interfaces.Clarifying remarks:l. The first principle is necessary in defining a machine as a RM. The other five principles are the key principles that specify the essence of RMs.1. Part family, in principle l, is a set of parts with similar characteristics. A characteristic is a distinguishable property of a part e.g. material, geometry, shape or color. Similarity can be difficult to measure depending on the property. Two parts can be similar based on oneset of properties, but different when a second set is considered. When machined parts are considered, the choice of geometric and shape properties is common. Cylinder heads for different engines may be regarded a part family. Similarly, several types of engine blocks can form a part family. However, a cylinder head and an engine block of the same engine may not belong to the same part family. Rigorous definitions and discussion of part families can be found in L24. The definition of a part family in our context is broad to allow each manufacturing business to define its own part family and design a RM according to its specific needs.2. Customized flexibility, mentioned in principle 2, means that a machine possesses only a limited amount of flexibility related to several specific features as required from the design specifications. General flexibility means that a single flexible machine can deal with a large variety of features such as in a computer numerically controlled （CNC） machine tool or in a general-purpose coordinate measurement machine （CMM）.3. The third principle of ”easy and rapid convertibility” suggests that the configuration should be designed to allow easy and fast change of machine elements, rapid addition or removal of elements and quick set up time. The designer should design means for rapid reconfiguration of the machine in advance. He or she should decide how to allow fast access to fasteners and connectors, how to design several optional locations for different machine elements and how to automate the process in order to speed it up and keep it precise.4. Principle 5 refers to the requirement that the basic structural design of a RM willallow changeable configurations in order to place the machine at different locations along the production line. At each location the RM will be configured to perform specific tasks that are required for that location. In other words the same basic RM may include different structural （hardware） elements such as spindles, sensors or grippers as well as different software configurations.5. Design for modularity is a broad principle related to the good practice of machine design in general. In our context, modularity should allow efficient reconfigurability of the machine. Standard electrical, mechanical, control and software interfaces should allow rapid integration of common elements or ”building blocks” which were designed or selected in advance.3 Reconfigurable machine tool (RMT）The researchers at the ERCRMS suggested an innovative concept of a machine toolL25 and developed and studied several RMT concepts. Two of them have been built, demonstrated and are currently used for researchL26, 27. In this paper we will focus on one machine only, the ”arch type RMT”L27. Brief description of the arch type RMTThe arch type RMT, shown in Fig. la, was built around a part family of products with inclined surfaces, which exist in some automotive engine blocks or cylinder heads. It was designed for a mass production line for both milling and drilling on inclined surfaces.The machine tool has three controlled degrees of freedom along its column, along the spindle axis and along the table axis. One additional passive motion is the angular reconfiguration motion of the spindle, which allows reconfiguring the spindles angular position into five pre-designed locations to allow machining on different inclined surfaces. Therefore, the arch type RMT is a nonorthogonal machine that may have different characteristics at each configuration of the machine.The machine is designed to drill and mill on an inclined surface in such a way that the tool is perpendicular to the surface.10 Application of RM design principles in arch type RMTPrinciple l The arch type RMT was built for a part family with inclined surfaces found in V6 and V8 automotive cylinder heads shown in Fig. 2. During manufacturing of these parts there is a need for drilling, tapping or milling on inclined surfaces. Currently, typical dedicated production lines are designed for mass production of one specific part. The machines that operate on dedicated lines are dedicated as well, i.e. are built at one specific angle and perform a single set of operations such as milling or drilling. The introduction of the Arch Type RMT will allow changing a dedicated production line to a reconfigurable line that will allow production of a family of parts with different inclination angles withoutreplacing machines.Principle 2 The arch type RMT was built for customized flexibility only. The inclination angle might be changed between -l5 degrees up to 45 degrees in steps ofl5 degrees as Fig. l Arch type RMT shown in Fig. lb.Principle 3 The arch type RMT was designed for rapid and easy convertibility by moving the spindle from one angle to another by means of a motorized mechanism and by fixing it at a precise location. When the motor brings the spindle to its required location the spindle is rested on positioning blocks that are attached to the arch plate and bolted to have better structural rigidity and precision.Principle 5 At one location along the production line, the arch type RMT is capable ofmilling on an inclined surface and at another location, it is capable of drilling or tapping.Fig. 2 RMT part family - two automotive cylinder heads: V-8 （left） and V-6 （right）L263.3 Study and validation of arch type RMT designOur key concern at the design phase of the RMT was the dynamic stability of the machine tool and how the performance will be affected by moving a large mass of the spindle from horizontal location to 45 degrees location. Once the machine was built, dynamic characteristics of the RMT were experimentally validated using hammer tests and cutting testsLl8. It was shown after analysis of these experimental results thatthe dominant frequency in the machines tool frequency response function （FRF）came from the tool holder assembly, at above 600 Hz., regardless of spindle angular position. Figure 3a shows analytically derived stability lobes for cuttin at 0 and 45 degrees. Point “a” represents stable cutting conditions and point “b” unstableconditions. We have performed cutting experiments using the parameters indicated by points “a” and “b”. Figure 3b shows the fast Fourier transform （FFT） of cutting force in feed direction during stable machining in horizontal position. Figure 3c shows the FFT of cutting force in feed direction during unstable machining also in a horizontal position. During unstable cutting, we get a clear signal around 650Hzwhich corresponds to the tool holder mode. Similar cutting experiments were repeated at 45 degrees inclination and the results showed similar characteristics. The results interestingly showed that the reconfiguration of machine structure does not affect arch type RMT stability.Fig. 3 RMT dynamic characteristicsThe arch type RMT was designed as a non-orthogonal machine tool, except when in horizontal position. At the design phase, a thorough study of the control problem associated with this design concept was performedL28. A new type of cross-coupling controller was suggested. The stability of the control system was investigated, andsimulation was used to compare different types of controllers.The arch type RMT was designed for rapid and easy convertibility. The process of moving the spindle from -l5 degrees angle to 45 degrees by means of a motorized linearstage and fixing it at a precise location was tested. It takes less than 5 min to complete the reconfiguration process in the laboratory.The arch type RMT is capable of drilling on a surface with 45 degrees inclination at one location along the production line and another similar arch type RMT just differently configured is capable of milling on a surface with -l5 degrees inclination in a different location.In the design phase there was a plan to introduce modularity features to the Arch Type RMT by using standard interfaces in order to enable easy spindles exchangeability. We have not succeeded in this effort since it required close cooperation with spindles supplier. An outstanding example of modular design of spindle interfaces for machine tools is presented in Ll5, where the spindle has standard interfaces for: power, media, data, alignment and tool change that allowedthe development of the “multi coupling” concept that utilizes modularity principles.4 Reconfigurable inspection machine (RIM）5.1 Brief descriptionThe reconfigurable inspection machine （RIM） was designed for rapid, in-process, inspection of the machined features of a part family of cylinder heads.The RIM has been originally developed for measuring geometric features such as: flatness, parallelism and profile associated with the cover and joint faces of an engine cylinder headL29-3l.Under a different configuration, by adding a machine vision system to the structure, the RIM also allows inspection of cylinder head surfaces for pores and other surface texture imperfections.The RIM uses non-contact measurement methods based on commercial lasersensors and high-definition line-scan cameras in conjunction with computer vision technology and other commercially available non-contact sensors. A prototype of the RIM is shown in Fig. 4a.The inspected part moves along a linear axis and passes the sensors on a servo-driven single-axis motion stage that is equipped with a high-precision linearscale of l m accuracy. The velocity of the motion stage, as well as the probesampling frequency, can be aried in accordance to the required sampling density and inspection cycle time. The linear position along the axis of travel is recorded for each measurement point, which enables a precise mapping of the part surface without being affected by variations in the motion stage velocity.Fig. 4 Reconfigurable inspection machineThe RIM is intended for use in an industrial environment. It is located adjacent to the machining line with a total cycle time including part transfer equal to that of the machining line, which is assumed to be around 40 seconds. Radio Frequency （RF）technology was demonstrated in the laboratory for reading the RF tag located on the part fixture to identify the specific part number to be evaluated. Upon completion of the measurements and feature evaluations, the results of the evaluation were stored on the RF tag and on the RIM database. A bock diagram of the RIM system architecture is presented in Fig. 5.5.2 Application of RM design principles in RIMPrinciple l The RIM was built around a part family of engine cylinder heads that during mass-production need in-line inspection. Typical parts that belong to this part family are shown in Fig. 6. These engine cylinder heads were produced by different companies for different types of engines. However, all of them have common characteristic features such as precisely machined flat surfaces, prismatic shape and a series of threaded holes. Principle 2 The RIM was built for customized flexibility only. The machine is capable of measuring various features of cylinder heads of various sizes； however, it is not designed to measure all features of one part or to measure other parts that are not from the same part family.Principle 3 The RIM is designed for rapid and easy convertibility by adding sensors when needed and by changing the location of existing sensors as required for inspection of different parts or different features of the same part.Fig. 5 RIM system architecturePrinciple 4 The RIM was designed to be scalable, i.e., to allow mounting of different probes at different locations prepared at the outset. The scalability enables efficient measurements of different features.1Principle 5 The RIM is capable of measuring surface flatness at one location along the production line and measuring distance between two features centers at another location along the line as presented schematically in Fig. 7.Fig. 6 RIM part family of engine cylinder heads5.3 Study and validation of RIM designIn this section, we demonstrate the RM design principles and their implementation as reflected in RIM design. Also, RIM performance as a non-contact inspection machine was experimentally validated.The reconfigurable inspection machine was designed around a part family of engine cylinder heads as explained earlier. To measure each of the heads, different fixtures were designed and used. For each head, the location of the laser sensors as well as the position of the vision system were reconfigured to capture all features of interest.The RIM can measure geometrical and dimensional features such as: flatness of a surface and parallelism between two surfaces, distance between surfaces distance between edges and related dimensional features. The RIM is not designed, however, to measure the roundness of parts, since roundness is not relevant for inspecting cylinder heads, which are prismatic parts. We have tested experimentally the quality of RIM measurements. Table l presents RIM repeatability experimental results tested in nominal condition when measuring a reference part. The measurements show good nominal repeatability of the RIM.3lCurrently, the coordinate measurement machine （CMM）, is the standard tool for industrial inspection of machined parts. It uses a touch-probe with a 0.5 to 2.0-mm diameter ball. Utilizing the ConoProbe sensor on RIM, its laser beam has a typical diameter of 20m. Therefore, one can expect different readings when using these two types of sensors on machined surface with a non-perfect surface finish. In order to compare RIM measurement results with the results of a coordinate measurementmachine （CMM）, the “virtual ball method was developed and implementedL32. Itprovides the interpretations of non-contact laser measurements as if they have been performed by a CMM touch-probe. A comparison between measurements from the RIM and a CMM, and repeatability results from theRIM are presented in L33.Figure 4b shows a typical design-for-convertibility of Fig. 5 RIM system architecture the RIMstructure and fixtures. The design included a series of threaded holes to allow fast and easy relocation of various sensors and accessories needed for inspection. While measuring different features on different types of cylinder heads, we have changed the fixtures and thelocation of the sensors many times. A typical time period required for relocation of sensors when different heads are measured is less than an hour. The calibration process of the sensors following reconfiguration process of the RIML34 was successfully tested in the laboratory.12Fig. 7 RIM integration on production lineTo demonstrate scalability of the system, the RIM was tested with a differing number of sensors. We started with two laser sensors for surface flatness inspection and we increased the number of laser sensors to four when measuring parallelismL35. We also applied machine vision systems based on a line scanning camera and used both the 4 K and 8 K pixels versions. We could use each type of sensor separately or together in parallel during the scan of the cylinder head surface. One important application of the vision system was measuring surface defects such as casting originated pores on machined surfacesL36. A typical image of pores on cylinder head surface is shown in Fig. 8. Figure 8a shows a pore which is connected to an edge of a machined feature while Fig. 8b presents an “isolated pore. For each pore of interest we can analyze its size and the location relative to some given datum. Based on our porosity inspection research, one of ERCRMS industrial partners is currently building a full-scale machine to be located and used on a production line of cylinder heads replacing visual inspection.Fig. 8 Porosity on machined surfaceTable l Repeatability measurements performed on a reference partInspection numberWidthParallelismJoint face flatnessCover face flatnesslll8,975.l9.39.59.32ll8,975.l8.78.78.83ll8,975.l8.88.78.74ll8,975.l8.58.48.55ll8,975.ll0.l9.39.5Mean valuell8,975.l9.l8.99.0Repeatability （range）0.ll.5l.ll.0Values are in m. （Repeatability is defined as the difference between the max and min values in the range defined by the five inspectionsperformed）5 Reconfigurable assembly machine4.1 Brief descriptionThe reconfigurable assembly machine （RAM） described in this paper is an assembly machine for automotive heat exchangers （radiators）L37. Dr. M. Mehrabi and his graduate students have conducted a study and conceptually designed the RAM together with an ERCRMS industrial partner.Fig. 9 Heat exchangerL37Heat exchangers are rectangular matrices comprising tubes and fins bordered by headers and side supports as shown in Fig. 9. The assembly process starts by feeding tubes and fins to the core-builder area. The tubes are in the form of stacks that are fed into the core-builder whereas the fins are supplied in trays that contain the required number of fins per radiator. The machine then places one tube ollowed by one fin from the respective sources and the process iterates till the required quantity of fins and tubes is reached. The collection of tubes and fins that are loosely held together is termed as a loose matrix. This loose matrix is then transferred to the final assembly area where it is capped with side supports and headers after being compressed to the correct dimensions and checked for alignment. The tubes are to be pressed into the slots provided in the headers and therefore their alignment is fairly important. Thefinished product received from the final assembly area is termed as the core. Before the core can be removed from the assembly area, it is constrained by the use of brass frames. A new pick and place mechanism was designed to perform the task of placing the headers and side supports into the assembly fixtures. The design of the new reconfigurable pick and place mechanism led to drastic reduction in final assembly time. The conceptual design of the core-builder is presented in Fig. l0.Fig. l0 The core-builderL37The similarities between various products are based on geometrical features. A greater width results in a greater number of tubes and fins. An existing assembly machine can assemble heat exchangers in 45 to 60 s. The design goal of the RAM was to reduce assembly time to 30 s and allow assembly of various types of heat exchangers that belong to the same part family utilizing reconfigurable design principles.4.2 Application of RM design principles in RAMPrinciple l The RAM was designed around a part family of heat exchangers with different dimensions and different numbers of fins and tubes. It is an assembly machine used by automotive radiators manufacturers. Many different types of radiators, which could be assembled by RAM, were identified and classified into three main groups that define the ”part family”L37. This topic will be further explained in the next section.Principle 2 The machine was designed for customized flexibility as it can perform only some of the ssembly tasks related to core-building of these heat exchangers that belong to the defined part family.Principle 3 The RAM was designed for rapid convertibility to allow the assembly of different sizes of heat exchangers. Replacing the automated core builder elements such as the pick and place mechanism and the loose matrix grippers, allows assembly of different types and sizes of products.Principle 6 The RAM was designed to use different modules or building blocks that are integrated into the assembly machine to allow the assembly of different parts. Modular elements of pick and place devices and grippers were designed for different sizes of heat exchangers.4.3 Study and validation of RAM designThe RAM team has studied the characteristics of a typical core-builder that our industrial partner has designed and built for its customers. The team investigated this corebuilders functionality and tried to understand its limitations and improve them.The study led to the conclusion that the productivity of the existing core-builder is constrained by elevated changeover and cycle times. Therefore, the goal was to minimize changeover time and hence reduce the idle state of the system. The constraint to productivity formed by the changeover time can be addressed effectively by making the machine reconfigurable. As previously stated, RMs are specifically designed to handle changes within a part family. Their modular design significantly contributes towards the reduction in changeover time. The changeovers in RAM are reduced to the interchanging of modules instead of the many adjustments needed in the existing assembly machines, when assembling different products.The first step in the design of a RM is a clear identification of the part family. Using our industrial partners products catalog, 398 radiators were classified and grouped. Combinations of product features were studied in order to establish a relationship between the product characteristics. The information for this study consisted of product features such as model, length, width, height, number of rowsand car that uses it. These relationships were utilized to define part families depending on the characteristics that are more imperative to machine architecture. The study of these relationships concluded that the length and the width are the most important parameters that affect the reconfigurability of the machine to the greatest extent.Table 2 RAM-part familyL25SubgroupsLengthWidthTotal productsl20202722020-32l00320-30 l2202l9Rejected45As a result of this studyL38, three main subgroups define the RAM part family, and a few rejected products were identified as listed in Table 2. With the newly structured part family, the number of required modules has reduced to three； each of them takes care of one sub group, whereas still more than 90% of the product range was covered. If the design of the modules is based on this part family definition then the resulting machine will handle changes within product sub group without requiring changeover at all, and if the change is across a part family then the changeover will be restricted to a change of a module. Hence, extended changeover time that leads to large downtimes, can be avoided. The easy changes across the part family represent a good example of design for convertibility. The design principles and the study of RAM were not validated experimentally since the machine was not built.6 Summary and conclusionsThis paper outlines the importance of design principles for RMs. Based on the design principles presented in this paper, the ideas presented in the RMTand RIM patentsL25,29 were realized. Each of the full-scale RMs was experimentally tested for the validation of reconfiguration principles as well as for sound functional performance. The prototypes described in the paper currently serve as researchplatforms.The main contributions of this paper are as follows:3 The RMS vision was refined into concrete machine design principles for the design of RMs that can be used in a manufacturing system.4 The generality of application of these principles was demonstrated in various manufacturing domains such as machining, assembly and metrology.5 The importance of the aforementioned design principles was validated for RMs.6 Studies that demonstrate reconfigurability and good performance of the RMs that used the design principles for RMs were presented.The conclusions of our study are as follows:7 RMs represent a new class of machines that are designed mainly for high-volume production applications. They bridge the gap between the flexible machines and the dedicated machines.8 Not all design principles presented in this paper must be reflected in the design ofeach specific RM. However, the principle of a machine that is designed around a part family is a necessary condition and should be reflected in the design.9 The design principles were demonstrated in the design of reconfigurablemachining, inspection and assembly machines； however, this philosophy is general and may be applied to other domains of machine design.10 The design principles of RMs and RMS follow a similar philosophy.11 RMs enable production of different products that belong to the same part family by allowing rapid and efficient pre-designed changes of a machines configuration.12 The design principles of RMs are focused mainly on the functionality of these machines and are important in the phase of conceptual design. The detailed design of a RM follows concepts similar to any other machine design.13 The suggested design principles do not contradict any traditional design principlesrelated to the good practice of machine design.AcknowledgementsThe author would like to thank Prof. Y. Koren for his RMS vision and his remarks to this paper and to the teams of researchers and graduate students who participated in the RMT, RIM and RAM projects. The author would like to thank V. Srivatsan, J. Duphia and Dr. P. Spicer for their feedback and remarks to this paper. The author also gratefully acknowledges the financial support of the NSF Engineering Research Center for Reconfigurable Machining Systems （NSF Grant EEC95-92l25） at the University of Michigan0ReferencesLl Mehrabi MG, Ulsoy AG, Koren Y （2000） Reconfigurable manufacturing systems: key to future manufacturing. J Intell Manuf ll（4）:403-4l9L2. Altiok T （l996） Analysis of manufacturing systems. Springer, Berlin Heidelberg New York L3 Kaighobadi M, Venkatesh K （l993） Flexible manufacturing systems: an overview. Int J Oper Manage l4（4）:26-49L4 Mehrabi MG, Ulsoy AG, Koren Y, Heytler P, （2002） Trends and perspectives in flexible and reconfigurable manufacturing systems. 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University of Michigan, ERCRMS-TR-056-05可重构机床的设计原则摘要可重构机床是从一种新的机床类型延伸而出，这种新的机床类型是围绕着一类具体的产品部件系列设计的，这些机床可以在机构中实现快速转换。他们的设计可以依据产品需求的变化实现机床构造中的变化。系统的可重构可能依赖于机床功能或者扩展性的变化，比如，产品的体积或者运行速度。可重构机器代表了一个新的机床种类，它可以连接高柔性及高成本的完全柔性机床和低柔性和低成本的专用机床的空白。可重构机床的设计原则依据了相似的一个原理，这个原理是为可重构制造系统创立的，并且创造了在大体积生产线上的机器的设计方法。这篇论文介绍了可重构机床的设计原则，可以应用在不同的加工制造领域。基于这些设计原则，三种可重构机床不同的生产操作类型，例如:制造、检测和组装。这篇论文阐述了所述的设计原则在几种全面机床造型和实验检测中的应用。关键词：机床设计：可重构机床（RM）：可重构加工系统（RMS）：可重构刀具（RMT）：可重构检测机床（RIM）：可重构组装机床（RAM）缩略语 RM：可重构机床：RMS：可重构加工系统：RMT:可重构刀具：RIM：可重构检测机床：RAM:可重构组装机床：DMS：专用加工系统：FMS：柔性加工系统：ERCRMS：可重构加工系统工程研发中心：CNC：计算机数控技术：CMM：坐标测量装置：FRF：频率反应机能：FFT：快速傅里叶变换1 简介两种制造业中中高速部件生产应用的主要传统方法是专用加工系统（DMS）和柔性加工系统（FMS）.DMS 应用于部件声场速率高且恒定，并且l,23-5部件不变。FMS 应用于要求的加工质量相对低一些而且部件的设计修改是可以预见的，或者是不止一种的的产品类型可以同时在一条生产线上生产出来。定制的加工过程中的创新方式被定义为可重构加工系统，在u中己经描述。这种新的方式的主要优点是，原先的生产一个产品部件类的系统柔性可以消耗比 FMS 更低的成本。一系列的核心特性是:模块化，可扩展性，可积性，可互换性，可自定义，可诊断性，包含了 RMSL7的核心。一个典型的 RMS 在它的生产线上包括常用的柔性机床和一种新型的机床，被称作可重构机床（RM）。通常情况下，在 MDS 中应用的专用机床围绕着一个具体的部分设计，这就是大批量生产。它的设计是用来实现一个圄定的加工过程，这个加工过程具有高度的可靠性和可重复性，高的生产率，因此要相应的简单并且更便宜一些。在 FMS 中应用到的设备的设计设为了实现以柔性加工方式进行的多少加工过程。这些柔性设备是用计算机数控的，它们可以通过改变计算机的程序来生产不同的部件。由于大批量生产线要求的可靠性，可重复性和高的生产率，设计的高加工速率的柔性机床相应的变得昂贵。于此形成对比的是，为了预先要求的柔性而设计的 RM，比如用于生产特定的部件系列的柔性方式。这个 RM 可以按照所预先要求的一套方法实现一个同时具有高的可靠性，可重复性和高的加工效率的加工过程。有限的，订制的柔性可以减低投入成本，也可以在一中产品向另一种产品的快速转变，同样也可以带来经济效益。RMS 的创新思维和它的六个主要特征在于原本就是为了“系统”（顾名思义，就是大批量生产线）而创造的，：基于 RMS 的新的设计原则的发展正是在设计 RM 是所需要的。这些将被应用在 RMS 生产线上的机床，将 RMS 的概念从系统的水平上升到了机床的水平。在文献中，己经提出和讨论了一些通用的设备设计原则。例如，Doubbel 阐述了实体设计的原则:任务分散，礼盒能量传动的原则，以及安全和可靠原则。 Norton 将工程设计定义为:应用多种科技原则来完成以下任务，依靠充分的细节定义一个设备，一个过程或者一个系统并能保证它的实现的过程。并且描述了设计过程的不同阶段9。这些论述依靠数学工具充分论证了工程中的设计过程并且展示了机床设计的一些实例l。他论述了关于功能需求的参数FR通过设计矩阵A到设计参数DP的设计方程。通过这种方法，他研究了搞合设计，冗余设计和理想设计的不同情况。其他的研究人员从事于主要用于加工的设备的设计原的设计基本原则则。Altintas 论述了 CNC 机床ll。它包含了尺寸计算和驱动电机的选择，物理结构的构造和伺服控制的模拟。CNC 机床的的设计原则同样也曾由l2Koren 进行了详细阐述。制造系统以及升级多主轴 RM 的设计原则在l3中同样进行了论述。中研究了 RM 设计概念，其目的是研究“模块化可重构机床”.l4正如其中所阐述的那样，模块化机床设计的关键特征在于可分解化，标准化和互换性。根据，RMS 的设计基于一个结构工具包的原则，其能使 RMS 依靠机床l5系统的可换，添加和移除性能进行调整以满足新的生产需求。一种用于可重构机床(RMT）lu,l7的合成方法需要一组功能需求和一组过程规划作为输入并生成一组运动学可行的 RMT 来满足给定的规范。中阐述了一项关于在 RMS 背景下的l8机床扩展性的透彻的研究。近来的研究集中于改进 RMS 的动态设计和一种用模20块式的方法进行伺服轴建模的方法。由此派生的机床可以用于 RMT 伺服轴的设计和控制。当大批量生产零件是，需要有高速和低成本的检测机构用于测量几何和尺寸公差以及表面质量。通常情况下，设计的具有高精确度和高的可重复性2l的专用量具很贵并且对于生产的转变L22使用能够测量多种不同部分和功能不具有柔性。因此，加工人员更倾向于的柔性坐标测量装置（CMM）。一个由 Suh23提出的通用设计原则的有趣的应用展示了一种为了选择用于机械零件检测的测量系统的方法。通过应用这个方法，这些作者为了完成他们的任务选择了一个基于 CMM 的柔性系统。这篇文章的目的在于介绍和解释 RM 的设计原则。这些设计原则依据了 RM 理6,7论的概念和观点，这在中进行了阐述，并且介绍了一组完整的实用的设计原则。人们以这些设计原则为基础，设计了一些可重构机床。这篇文章展示了三个用于加工，检测和组装的机床的设计的例子。我们说明了这些设计原则是如何在每个机床的实际设计中体现出来的。金属切剖，测量和组装代表了不同的加工过程：然而，相似的设计原则在这些机床的设计中都得到了应用。人们己经构造了两种可重构机床的全面原型（第 3,4 部分）。这些可重构机床经过了试验检测来评价它们的可重构性能和功能表现。这篇论文简要的介绍了这些研究的一些内容，并且希望读者能够关注我们研究的更多内容。第二部分描述解释了可重构机床的设计原则。第三，四，五部分描述了每种以第二部分中的设计原则为基础的可重构机床。首先，简单对机床进行了描述。然后，讨论了在机床设计和机床研究以及验证阶段中应用的设计原则。第六部分对这篇文章进行了总结并提出了评价。2 设计原则可重构机床是一种专门设计的用来处理一个具体零件种类的各种类型的机床。一个好的可重构机床的设计能够很精确的处理加工的变化并能简化变化过程。可重构机床的设计遵循可重构加工系统的原则。可重构机床大部分都是设计用于大批量生产。可重构机床的设计要满足定制的加工柔性和一类零部件加工成本控制以及检测。如果一台机床可以被定义为可重构机床，则它必须要能够满以下的必要或基本原则。必要原则: 1、可重构机床必须要围绕着一个零部件类来进行设计。基本原则: 2、一台可重构机床只为定制的加工柔性而设计。3、一台可重构机床能够设计来实现简单而便捷的生产转换。4、一台可重构机床的设计具有可扩展性:允许为了生产量或生产率的增加而添加或移除某些部件。5、一台可重构机床的设计能够允许将机床沿着生产线在不同位置进行重构而运行来完成不同的任务，而机床的基本结构不变。6、一台可重构机床的设计应该应用模块化设计的概念，p应用通用的构建模块和通用接口。解释说明: 1、第一条原则是定义一台机床为可重构机床的必要原则。而另外五条原则是组成可重构机床的要素的关键原则。2、在第一条原则中说的零部件类是具有相同特征的一组零部件。特征是指零部件具有区分性的性质，例如，材料，几何尺寸，外形或者颜色。依据特性类似性是很难区分的。两个零件依据一组特性可能很相似，但是如果加入了第二组特性就会变得不同。当考虑了机加工的零件，几何和形状尺寸是通用的。用于不同的发动机的汽缸盖可以当做一个族。类似的，几种发动机缸体的类型可以组成一个零件的族。然而，同一个发动机的汽缸盖和发动机缸体可能属于不同的零件24族。在中可以找到零件族的精确定义和论述。本文中的零件族是广义的，这样可以允许在每种加工类型中定义它自己的族，而且可以依据其具体的需求设计一种可重构机床。3、在原则 2 中说的预订的加工柔性，意味着一个机床只具有有限的柔性，而其是与设计规范所要求的的一些具体特性有关。通用柔性指的是一个柔性加工机床可以加工大量的特征，例如在一个计算机数控（CNC）加工中或者在一个通用坐标测量机（CMM）中。4、第三条原则中的“简单而便捷的生产转换”指的是，机床的建构应该能满足元件简便以及快速的变化，元件快速的增加或移除，快的装夹时间。设计者应该要预先设计出机床的快速重构方式。设计者应该设计如何的快速紧圄和联接，如何设计不同的机床元件的一些可选机位以及如何实现过程的自动化来提高速度和保持精度。5、第五条原则意味着可重构机床的基础结构设计应该满足可变的构造能够沿着生产线将机床安置在不同的工位上。在每个工位上，可重构机床将会被建构来满足这个工位所要的具体需求。话句话说，相同的基础可重构机床应该像具有不同的软件构造一样，具有不同的结构元素（硬件），例如，主轴，传感器或者夹具等。模块化的设计涉及到宽泛的原则，而其又与大量的设计实践有关。在我们的文章中，模块化应该能实现高效的机床重构。标准的电气化，机械化，控制和软件接口应该能够实现通用构件或者“构建模块”快速的动作，而这些构件或模块都是提前设计或者选择的。3 可重构机床（RMT)ERC/RMS 的研究人员提出了机床26,27L25的新的概念并且继而发展和探讨了一些RMT 的概念。其中的两个在研究中己经被建立阐述并加以应用。在这篇论文L27中，我们将只讨论“拱形可重构机床”。图 l拱形 RMT3.1 拱形可重构机床的简要描述在图 la 中的弧形 RMT 是围绕着一个具有倾斜表面产品族而构造的，其应用于一些自动发动机缸体或者汽缸盖。其设计用于在大批量的流水线加工中的倾斜平面的锐削和钻削。每个机床沿着其主轴和表轴具有三个可控的自由度。一项额外的被动运动是主轴的重构角运动，这可以重构机床的角位置到五个预先设计的位置来用于加工不同的倾斜表面。因此，拱形可重构机床是一种非正交机床，并且每种机床的构造具有不同的特征。用于钻锐斜面的机床是以刀具垂直于表面的方式进行加工的。3.2 拱形可重构机床中可重构机床设计原则的应用原则 1 拱形可重构机床是为了具有倾斜表面的一个零件族而构建的，在图 2 的 V6 和 V8 自动汽缸盖中有这样的表面。在这些零件的加工过程中，需要对这些表面进行钻孔，攻丝或者锐削。最近以来，人们设计了用于这些零部件大批量生产的典型的专用生产线。这些在专用生产线上使用的机床也是专用的，例如，它们的构建只具有某个圄定角度或者只能进行一套圄定的动作，比如钻削和锐削。拱形可重构机床的引进可以实现一类具有不同倾斜角度的零件的加工，而不需要更换机床。原则 2 拱形可重构机床只是设计用来实现欲求的柔性。其倾斜角度从 15o到45o以 l5o为单位进行调整，如图 lb.图 2RMT 零件类，两种自动气缸盖：V8（左），V6（右）原则 3拱形可重构机床的设计可以实现快速简便的可换性，通过伺服电机机构以及精确的定位可以使主轴的角度进行变换。当主轴依靠电机到达指定的位置，主轴便以弧形板上定位模块为支撑，并且相对独立以具有结构的敏捷性和准确性。原则 4在生产线上的某个位置，拱形可重构机床可以进行倾斜表面的锐削，在1另一个位置上，它同样可以进行钻削和开孔。3.3拱形可重构机床的设计与校核在可重构机床的设计中，我们最关注机床的动态稳定性以及将主轴从水平角度移到 45 度的变化对机床的影响。一旦机床己经设计出来，就必须应用锤击试Ll85l验以及切削试验来检测其动态特性。这些试验结果显示，机床频率响应功能（FRF）的主要频率，大约是 600Hz，来自刀架的装配，而不是主轴的角度位置。图 3a 是从 0 度到 45 度切削的分析曲线。a 点是切削的稳定点，b 点为不稳定点。我们曾经利用 a 点和 b 点的参数进行过切削试验。图 3b 显示了在水平位置稳定加工时在进给方向上的切削力的快速傅里叶变换（FFT）.图 3c 显示了同样在水平位置不稳定加工时在进给方向上的切削力的快速傅里叶变换。在不稳定切削中，我们得到了符合清晰的大约 650Hz 的符合刀架方程的信号。在 45 度倾斜情况下重复了类似的试验，并且得到了相似的结果。结果很有趣的显示了，机床结构的重构并不会影响拱形可重构机床的稳定性。图 3RMT 动态特性拱形可重构机床是作为非正交机床进行设计的（除了在水平位置时）。在设计L2814过程中，人们对设计概念下的控制问题进行了彻底的研究。人们提出了一种新型的可交叉搞合控制器。人们研究了控制系统的稳定性并且利用模拟来对比了不同类型的控制器。拱形可重构机床的设计可以实现快速便捷的可换性。依靠带电机的线性平台将主轴从-l5o移到 45o的过程以及使之准确的定位己经经过测试。在实验室中，完成此重构过程只需少于 5 分钟的时间。拱形可重构机床可以在生产线的某个位置钻削 45 度斜面，而另一台构造不同的类似的拱形可重构机床可以在另一个位置锐削-l5 度的斜面。在设计的过程中，应该应用标准接口在拱形可重构机床中引进模块化的结构来实现便捷的主轴可换性。我们目前还没有在这方面成功，因为这需要与主轴供l5应商的密切合作。在中给出了一个机床主轴接口模块设计的优秀实例，其中的主轴具有标准的接口用在，动力，媒介，数据，调整以及机床改造上，可以进行应用模块化原则的“多边搞合”概念的研究。4 可重构检测机（RIM)4.1 简要介绍可重构检测机（RIM）设计用于快速地，在加工过程中检测汽缸盖零件族的尺寸。RIM）29-3l可重构检测机（最初用于检测几何外形，例如，发动机汽缸盖封盖或者结合面的平整度，平行度和外形轮廓。在不同的构造中，通过在结构中添加视觉系统，可重构检测机可以检测汽缸盖表面的气孔以及其它的表面缺陷。RIM 用的是非接触式测量方法，通过结合了计算机视觉技术的工业用激光传感器以及高清晰线性扫描相机和其它的工业用非接触式传感器。图 4a 中展示了 RIM 的原型。被检测的零件沿着线性轴移动并通过在伺服驱动单轴运动平台上的传感器，运动平台具有 1m 分辨率的线性高精度。运动平台的运动速度以及探头采样频率根据要求的采样密度以及检查周期而不同。在移动轴上的线性位置通过每个测量点记录，其可以实现零部件表面的精确定位而不会受运动平台速度不同的影响。图 4可重构检测机RIM 是用来应用于工业环境中的。它被放置在具有包括零件传送的总周期时间（假定为 40 秒）生产线旁边。实验室中论证了射频(RF）技术，它用来读取零件圄定装置上的 RF 标签来确定具体的零件编号。测量以及特征评估完成后，评估结果将会被储存在 RF 标签以及 RIM 的数据库中。图 5 中是 RIM 系统结构的伯克图。图 5RIM 系统结构4.2 可重构机床设计原则在可重构检测机中的应用原则 1可重构检测机的制造是为了实现大批量生产中对于发动机汽缸盖类零件的在线检测。此类零部件的典型构件见图 6。这些缸盖是由不同公司针对不同的发动机而生产的。但是，他们都具有类似的特征，例如，精密的机加工表面，棱形结构以及一系列的螺纹孔。图 6发动机汽缸盖 RIM 零件族原则 2 可重构检测机只用于定制的柔性。这种机床可以实现对不同尺寸的汽缸盖的不同数据的检测：但是，它并不是针对一个零件的所有的数据检测，也不是为了不同族的其他零部件的检测而构建的。原则 3可重构检测机的设计可以实现快速便捷的可换性，通过增加所需传感器以及改变己有传感器位置来对不同零部件或者相同零部件的不同特征进行检测。原则 4可重构检测机具有可扩展性，例如，在一开始在不同位置可以安装不同的探头。可扩展性实现了不同特征的高效测量。原则 5可重构检测机可以在沿着生产线的某个位置检测表面的平整度以及在沿生产线的某个位置检测两个特征中心距离，见图 7。表 l引用零件的重复测量图 7生产线的 TIM 检测检测序号宽度平行度连接平面平整度表面平整度lll8,975.l9.39.59.32ll8,975.l8.78.78.83ll8,975.l8.88.78.74ll8,975.l8.58.48.55ll8,975.ll0.l9.39.5平均值ll8,975.l9.l8.99.0重复性（范围）0.ll.5l.ll.0注：单位为 m4.3 可重构检测机的研究以及校核在这部分中，我们要讲解可重构机床的设计原则以及它们在可重构检测机的设计中所体现出来的利用情况。同样地，可重构检测机作为非接触式的检测机床也要被进行试验性的校核。正如先前所说，可重构检测机是围绕着一个汽缸盖零件族而设计的。为了检测每个汽缸盖，人们设计应用了不同的结构。为了测量每个缸盖，每个激光传感器的位置以及视觉系统的位置都被重构以对要求特征进行检测。可重构检测机可以度量零件的几何和尺寸特征，例如:表面的平整度以及两个表面的平行度，平面的距离，边的距离以及相关的尺寸特征。然而，可重构检测机并不是设计来检测零部件的圆度，检测缸盖不需检测圆度，因为它是棱形的。我们对 RIM 的测量质量进行了检测。表 l 是在额定条件下对参考零件进行检测得到的 RIM 可重复性试验结果。结果显示了在额定条件下 RIM 的优秀的重复性。图 8机加工表面缺陷最近以来，坐标测量机（CMM）是工业零件检测的标准工具。它应用装有 0.5到 2mm 直径小球的接触式探头。利用 RIM 上的扫描头传感器，它的激光束具有典型的 20 m 直径。因此，人们可以应用这两种传感器得到机加工表面非完善表面质量的不同的检测结果。为了比较 RIM 检测结果与 CMM

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