冲床上料机械手设计
摘　　要
机械手是模仿着人手的部分动作，按给定程序、轨迹实现自动抓取、搬运和操作的自动机械装置。在工业生产中应用的机械手被称为“工业机械手”。本次设计的60吨冲床上料机械手根据规定的动作顺序，完成对机械手的设计，对机械手的工作原理，结构使用范围，特点参数选择等方面进行了阐述。此60吨冲床上料机械手主要是给冲床进行上料和从储料框中取料；机械手的抓重1Kg；1个自由度三个具体动作，自由度为腰座的转动,采用圆柱坐标；其余两个动作为机械手的升降和伸缩，采用螺母和螺栓调节，可根据生产的需要改变机械手手臂的高度和长度以及更换吸盘。回转角度：60度；送料频率：50-60次/分；驱动方式为气压传动；机械手的腰座回转采用气缸带动齿条齿轮驱动；本设计主要对手部进行了设计和计算，腰座回转采用回转气缸。

关键词：上料机械手；冲床上料；气压传动

Design for the punch manipulator
Abstract
Manipulator is imitate the part of the hand, according to the given program, track and for automatic mechanical device to realize the acquirement, handling and operation of the. The manipulator used in the industrial production is called "industrial manipulator". 60 tons punch the design of the manipulator according to the provisions of the action sequence, complete the design of manipulator, the working principle of the manipulator, the use range structure, gives the characteristic parameters. This 60 tons punch manipulator is mainly to press for feeding and from the material storage box material; mechanical hand catch weight 1Kg; 1 degrees of freedom three specific actions, degrees of freedom for rotation waist seat, using cylindrical coordinates; the remaining two of the mechanical hand movements and the expansion, the nut and bolt adjustment, according to production needs to change the mechanical arm height and length and replacing chuck. Because the rotary angle: 60 degrees; the feeding frequency: 50-60 times / points; drive mode for pneumatic drive; waist seat rotary manipulator cylinder is used to drive a rack gear drive; the design of the main part of the design and calculation, waist, rotating the rotary cylinder.

KeyWords：feeding manipulator；punch feeding；pneumatic transmission
目录

1 绪论 1
1.1 机械手简介 1
1.2 机械手发展现状及应用 1
1.2.1国内外发展现状 1
1.2.2机械手的应用 4
2 机械手的总体设计 7
2.1 机械手的总体结构 7
2.1.1 机械手组成 7
2.1.2 机械手坐标形式的确定 9
2.1.3上料机械手的组成及工作原理 9
2.2 机械手腰座结构的设计 11
2.1.1 机械手的驱动系统的确定 12
2.1.2 机械手的机械传动机构的确定 15
2.3 机械手手臂的结构设计 18
2.4 机械手手部的结构设计 19
3 机械手理论分析和设计计算 21
3.1 系统设计计算 21
3.1.1 确定气压系统基本方案 21
3.1.2 气压缸的总机械载荷的计算 22
3.1.3 气缸强度的计算及校核 23
3.1.4 计算和选择气缸元件 25
3.2 吸盘的选择和计算 25
总结 29
参考文献 30
致谢 31
毕业设计（论文）知识产权声明 32
毕业设计（论文）独创性声明 33

1 绪论
1.1 机械手简介
工机械手是模仿着人手的部分动作，按给定程序、轨迹和要求实现自动抓取、搬运或操作的自动机械装置。在工业生产中应用的机械手被称为“工业机械手”。生产中应用机械手可以提高生产的自动化水平和劳动生产率:可以减轻劳动强度、保证产品质量、实现安全生产；尤其在高温、高压、低温、低压、粉尘、易爆、有毒气体和放射性等恶劣的环境中，它代替人进行正常的工作，意义更为重大。因此，在机械加工、冲压、铸、锻、焊接、热处理、电镀、喷漆、装配以及轻工业、交通运输业等方面得到越来越广泛的引用。
机械手的结构形式开始比较简单，专用性较强，仅为某台机床的上下料装置，是附属于该机床的专用机械手。随着工业技术的发展，制成了能够独立的按程序控制实现重复操作，适用范围比较广

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内容简介：: 毕业设计（论文）中期报告毕业设计（论文）中期报告题目：题目：冲床上料机械手设计冲床上料机械手设计系别机电信息系专业机械设计制造及其自动化班级姓名学号导师 2013年 3 月 19 日 21234n DpKKKp=贩 1.设计（论文）进展状况设计（论文）进展状况1.11.1 机械手的总体设计的框架设计以及部分的详细完善机械手的总体设计的框架设计以及部分的详细完善1.1.1 机械手的总体结构机械手的总体结构 1）机械手总体结构的类型 2）设计具体采用方案1.1.2 机械手腰座结构的设计机械手腰座结构的设计腰座是机器人的第一个回转关节，对机械手的最终精度影响大，故采用气压驱动来实现腰部的回转运动。1）气缸选择单活塞杆的双作用气缸，他是气缸中应用最广泛的一种。活塞杆上的驱动推力，驱动拉力和活塞直径的计算：驱动推力： P推=D2p4 驱动拉力：P拉=（D2-d2）p4 2）确定气压系统的主要参数计算气压缸的总机械载荷根据机构的工作情况气压缸所受的总机械载荷为 3）气缸主要参数的确定缸筒壁厚的较核当 D/时，气压缸壁厚的较核公式如下：活塞杆直径的较核活塞杆直径的较核公式为: 4）计算和选择气缸元件气动马达的计算确定气动马达的实际工作压力确定气动马达的气流量1.1.3 机械手手臂的结构设计机械手的垂直手臂（大臂）升降和水平手臂（小臂）的伸缩运动都为直线运动。bfsfmwFFFFFF10) 13 . 14 . 0(2yyPPD4Fdpp11ppppmaxqKqp注：1. 正文：宋体小四号字，行距22磅；标题：加粗宋体四号字。? Journal of Mechanical Science and Technology 21 (2007) 10181027 Journal of MechanicalScience andTechnology Control of Two-Axis Pneumatic Artificial Muscle Manipulator with a New Phase Plane Switching Control Method TU Diep Cong Thanhb, Kyoung Kwan AHNa,* a School of Mechanical and Automotive Engineering, University of Ulsan, Korea b Mechatronics Department, Ho Chi Minh City University of Technology, Viet Nam (Manuscript Received September 25, 2006; Revised April 24, 2007; Accepted April 24 2007) - Abstract The use of robots in rehabilitation has become an issue of increasing importance because of the requirement of functional recovery therapy for limbs. A novel pneumatic artificial muscle (PAM) actuator which has achieved increased popularity for providing safety and mobility assistance to humans performing tasks, as well as providing another advantages such as high strength and power/weight ratio, low cost, compactness, ease of maintenance, cleanliness, readily available, cheap power source, and so on has been considered during the recent decades for use in a therapy robot, which in particular requires a high level of safety. However, some limitations still exist, such as air compressibility and the lack of damping ability of the actuator to bring the dynamic delay of the pressure response and cause the oscillatory motion. In addition, to aid rehabilitation more efficiently, the robot should adjust its impedance parameters according to the physical condition of the patient. For this purpose, the manipulator join is equipped with a Magneto-Rheological Brake (MRB). A new phase plane switching control method using MRB is proposed for tracking sinusoidal waveforms. The effectiveness of the proposed algorithm is demonstrated through an experiment using a fabricated two-axis PAM manipulator. The experiment proves that the stability of the manipulator could be greatly improved using a high gain control without regard to the change of the frequencies of the reference input and the external load condition, and without decreasing the response speed or lowering the stiffness of PAM manipulator.? Keywords: Pneumatic artificial muscle; Phase plane switching control; Manipulator; Magneto-rheological brake - 1. Introduction The number of people requiring rehabilitation due to bone fracture or joint disease caused by traffic accidents and cerebral apoplexy, and for functional motor problems due to advanced age, numbers several hundreds of thousands worldwide. The application of robotics to rehabilitation is thus of great concern. Functional recovery therapy is normally carried out by medical therapists on a person-to-person basis, but automatic equipment has been put to practical use in physical therapy programs that repeat relatively simple operations, such as a continuous passive motion machine, a walking training device, and a torque machine used for a single axis (Doi, 1993; Fujie et al., 1994; Fujie et al., 1995). This research deals with functional recovery therapy, one important aspect of physical rehabilitation. Single-joint therapy machines have already been created (Ahn and Thanh, 2004; 2005a; 2005b). However, multi-joint robots are necessary to achieve more realistic motion patterns, and hence are necessary for more efficient therapy. This kind of robot must have a high level of safety for human use. The PAM mani-pulator has been used to construct a therapy robot with two degrees of freedom (DOF). A 2-DOF robot for functional recovery therapy driven by pneumatic *Corresponding author. Tel.: +82 52 259 2282, Fax.: +82 52 259 1680E-mail address: kkahnulsan.ac.kr TU Diep Cong Thanh and Kyoung Kwan AHN / Journal of Mechanical Science and Technology 21(2007) 10181027 1019 muscle was developed by Zobel (Zobel et al., 1999) and Raparelli (Raparelli et al., 2001; 2003) artificial muscle actuators for biorobotic systems by Klute (Klute et al., 1999; 2000; 2002; 2003) a pneumatic muscle hand therapy device by Koeneman (Koene-man et al., 2004) and a human-friendly therapy robot (Thanh and Ahn, 2006a). However, some limitations still exist, such as the air compressibility and the lack of damping ability of the actuator to bring the dynamic delay of the pressure response, causing oscillatory motion. In addition, to execute reha-bilitation more efficiently, the robot must adjust its impedance parameters according to the physical condition of the patient. For this purpose, a new technology, an electro-rheological fluid damper (ER Damper), has been applied to the PAM manipulator. Noritsugu and his team used an ER damper to improve the control performance of the PAM manipulator with a PI controller and pulse code-modulated on-off valves (Noritsugu et al., 1994). By separating the region where the damper produces a damping torque to reconcile both damping and response speed under high gain control, the results show that the ER damper is an effective method for use in a practically available, human-friendly robot using the PAM manipulator. Moreover, position control is improved without a decrease in response speed. However, some limitations hamper the technology, since ER Fluid (ERF) requires extremely high control voltage (kV), which is problematic, and in particular, potentially dangerous, only operates in a narrow temperature range (and one unsuitable for PAM manipulators), and exhibits nonlinear charac-teristics. Because ERF has many unacceptable dis-advantages, magneto-rheological fluid (MRF) has been considered an attractive alternative for the advantages listed in Table 1, and has been recently used in human-friendly therapy robots (Thanh and Ahn, 2006b). Though these systems were successful in addressing smooth actuator motion response to step inputs, assuming that two axes PAM manipulator is utilized in therapy robot in the future, which is the final goal of our research, it is necessary to realize fast response, even if the external inertia load changes severely with sinusoidal response without regard to the various frequencies. Therefore, to realize satisfactory control perfor-mance, a MRB is equipped to the joint of the mani-pulator. A phase plane switching control method using a MRB is proposed for the case of tracking sinusoidal waveforms, and the effectiveness of the proposed algorithm will be demonstrated through the experi-ments involving a two-axis PAM manipulator. The experiments show that the stability of the manipulator could be greatly improved under a high gain control without regard to variations of the frequencies re-ference and external load conditions, and without decreasing the response speed and low stiffness of the two-axis PAM manipulator. 2. Experimental setup 2.1 Experimental apparatus The schematic diagram of the two-axis pneumatic artificial muscle manipulator is shown in Fig. 1. The Table 1. Comparison of rheological fluids. Magneto-Rheological Fluid Electro-Rheological Fluid Max. Yield Stress50 100 kPa 2 5 kPa Viscosity 0.1 1.0 Pa-s 0.1 1.0 Pa-s Operable Temp. Range -40 to + 150 oC +10 to + 90 oC (ionic, DC) -25 to + 125 oC (non-ionic, AC) Stability Unaffected by most impurities Cannot tolerate impurities Response Time milliseconds milliseconds Density 3 4 g/cm3 1 2 g/cm3 Max. Energy Density 0.1 Joule/cm3 0.001 Joule/cm3 Power Supply2 25 V 1 2 A (2 50 watts) 2 25 KV 1 10 mA(2 50 watts) Fig. 1. Schematic diagram of two axes pneumatic artificial muscle manipulator. 1020 TU Diep Cong Thanh and Kyoung Kwan AHN / Journal of Mechanical Science and Technology 21(2007) 10181027 Fig. 2. Working principle of the pneumatic artificial muscle manipulator. Fig. 3. Photograph of the experimental apparatus. Fig. 4. Construction of MRB. the pressure difference between the antagonistic artificial muscles and the external load is rotated as a (a) (b) Fig. 5. Characteristics of MRB. Table 2. Experimental hardware. No.Name Model name Company 1Proportional valveMPYE-5-1/8HF- 710 B Festo 2Magneto-Rheological Rotary Brake MRB-2107-3 Rotary Brake Lord 3Pneumatic artificial muscle MAS-10-N-220-AA-MCFK Festo 4D/A board PCI 1720 Advantech 5Wonder Box Device Controller Kit RD-3002-03 Lord 6Rotary encoder H40-8-3600ZO Metronix 724-bit digital counter board PCL 833 Advantech result in Fig. 2. The joint angles, 1 and 2, were measured with a rotary encoder (METRONIX, S48-8-3600ZO) and fed back to the computer through a 24-bit digital counter board (Advantech, PCL 833). The external inertia load could be varied from 20 kgfcm2 to 40 kgfcm2, a 200 % change with respect to the minimum inertia load condition; various frequencies of reference input (sinusoidal) waveform are considered. The experiments are TU Diep Cong Thanh and Kyoung Kwan AHN / Journal of Mechanical Science and Technology 21(2007) 10181027 1021 conducted under an ambient pressure of 0.4 MPa and all control software is coded in C program language. A photograph of the experimental apparatus is shown in Fig. 3. 2.2 Characteristics of MRB The design of the MRB is shown in Fig. 4. The rotor is fixed to the shaft, which can rotate relative to the housing. The gap between the rotor and housing is filled with MRF. The braking torque of the MRB can be controlled by the electric current in its coil. The apparent viscosity of the MRF is changed within a few milliseconds of the application of a magnetic field, and returns to its normal viscosity in the absence of a magnetic field. The following experiments are performed to investigate the characteristics of MRB; measurement data is reported in Fig. 5 and Table 3. The MRB is connected with a torque transducer and a servomotor in series. In the experiments, the rotational speed is varied from 100 rpm to 1000 rpm and the applied current from 0 A to 1 A. These ranges are used because the response of the system does not reach 1000 rpm and the maximum current applied for MRB is 1 A. Figure 5 shows the damping torque with respect to the change of the input current (a) and rotational speed (b) of MR Brake. From Fig. 5, it is clear that the damping torque of MRB is independent of rotational speed and almost proportional to input current. Thus, Eq. (1) for inputs current I and dam-ping torque Tb Table 3. Measurement data of MRB. W / I 0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.80.91 100 0.28 0.81 1.33 1.87 2.44 2.93 3.51 4.03 4.5 5.11 5.57200 0.31 0.82 1.33 1.92 2.4 2.96 3.57 3.99 4.54 5.12 5.67300 0.3 0.81 1.36 1.89 2.48 2.99 3.54 4.03 4.55 5.13 5.58400 0.31 0.82 1.35 1.94 2.46 2.98 3.55 4.05 4.59 5.05 5.62500 0.31 0.83 1.37 1.87 2.4 2.99 3.55 4.08 4.61 5.06 5.58600 0.3 0.83 1.36 1.87 2.48 3 3.53 4.05 4.54 5.06 5.55700 0.28 0.86 1.37 1.9 2.46 3.01 3.54 4.03 4.55 5.04 5.55800 0.29 0.86 1.37 1.9 2.44 3.05 3.54 4.08 4.59 5.04 5.58900 0.29 0.89 1.41 1.92 2.53 3.05 3.57 4.11 4.58 5.01 5.611000 0.29 0.89 1.44 1.93 2.53 3.04 3.57 4.14 4.61 5.03 5.59W: Rotational Speed rpm I: Current Applied A ( )bTf IabI=+ (1) Here, a and b are constants determined using characteristic MRB response curve. 3. Control system 3.1 Position control system To control this PAM manipulator, a conventional PID control algorithm is used as the basic controller in this research. The controller output can be expressed in the time domain as follows: 0( )( )( )( )tpppdiKde tu tK e te t dtK TTdt=+? (2) Taking the Laplace transform of (2) yields ( )( )( )( )pppdiKU sK E sE sK T sE sTs=+ (3) The resulting transfer function of the PID controller is: ( )11( )pdiU sKT sE sTs?=+? (4) A typical real-time implementation at sampling sequence k can be expressed as follows: ( )( )(1)( )( )(1)ppipdK Tu kK e ku ke kTe ke kK TT=+ (5) where u(k) and e(k) are the control input to the control valve and the error between the desired set point and the output of joint, respectively. In addition, using an MRB is an effective way to improve the control performance of the PAM manipulator by reconciling both the damping and response speed (because it works in only the regions where the acceleration or deceleration is too high). Here, s is Laplace variable, Ta is the torque produced by the manipulator, Tc is constant torque, KED determines the gain for the torque proportional to the angular speed ?, and Vc is a control voltage of source calculated from Eq. (1) to produce Tc. The 1022 TU Diep Cong Thanh and Kyoung Kwan AHN / Journal of Mechanical Science and Technology 21(2007) 10181027 direction of the damping torque is opposite to the direction of rotation of the arm. Therefore, Eq. (6) below indicates that the damper produces a damping torque Tb. ()( )bEDcTKTsign=+? (6) The structure of the proposed phase plane switching control method is shown in Fig. 6. 3.2 Conventional phase plane switching control method Figure 7 shows the conventional phase plane switching control method. In the region in which the joint angle of the arm approaches to the desired angle, ab, cd, in Fig. 7(a), the current is not applied, whereas in the region (the diagonally shaded areas) bc, de, the current is applied to improve the damping performance for faster convergence to the desired angle. Though the system successfully responds smoothly to step inputs, its quality degrades (and response lengthens) due to sinusoidal waveform reference input of uncontrollable points (c, e and so on). In addition, assuming that two-axis PAM mani-pulators are utilized in future therapy robots (the final goal of our research), it is necessary to realize a fast response, even if the external inertia load changes severely with sinusoidal response, and one that is independent of frequency over the occurring fre-quency range. 3.3 Proposition of new concept of phase plane switching control algorithm The damping torque bT, which is shown in Eq. 1, improves the damping performance of the mani-pulator. Since the damping torque acts in the direction opposite the rotational motion of the manipulator, its acceleration performance is degraded. In the region where the joint angle of the arm approaches to the desired angle, , , ,oa bc de fg, in Fig. 8(a), the current is not applied since a high response speed is required. In the region where the arm passes through the desired angle, i.e. the diagonally shaded areas of , , ,ab cd ef ghin Fig. 8(a), a current is applied to improve the damping per-formance, so that the arm converges to the desired angle more quickly. To determine whether the magnetic field should be applied, the phase plane Fig. 6. Block diagram of new concept of phase plane switching control. (a) (b) Fig. 7. A conventional phase plane switching control method. shown in Fig. 8(b) is used. The horizontal axis in the phase plane corresponds to joint angle deviation e between the desired angle rand the joint angle , and the vertical axis corresponds to the time derivative of the deviation, deedt= ?. Each point ahon the phase plane corresponds to the likewise lettered point in Fig. 8(a). Here, the region with the application of current are controlled by 1112(),()hshs, the gradient of the TU Diep Cong Thanh and Kyoung Kwan AHN / Journal of Mechanical Science and Technology 21(2007) 10181027 1023 (a) (b) Fig. 8. A new concept of phase plane switching control method. line shown in Fig. 8(b). The region under the application of the damping torque is controlled as 1hand 2h. The advantage of controlling the region in which MRB is applied is needed to without de-creasing response speed. The effectiveness of pro-posed controller will be experimentally investigated. 4. Experimental results In this study, a controller for a two-axis PAM manipulator using the new concept of a phase plane switching controller is fabricated, and experiments are carried out using a sinusoidal waveform as a reference input at two different frequencies (f=0.3 Hz and 0.5 Hz). Two external inertial load conditions (Load 1 = 20 kgfcm2; Load 2 = 40 kgfcm2) are also tested (the loads are attached to the end of Arm 2). In addition, the conventional PID controller and the proposed controller are compared. Firstly, the experiments are carried out to verify the effectiveness of the proposed controller at various reference input frequencies (of Joint 1). Figure 9 shows the comparison between the conventional PID controller and the proposed controller of experimental result of Joint 1 and the effectiveness of proposed controlled is shown in detail in Fig. 10 with respect to (a) f=0.3 Hz (b) f=0.5 Hz Fig. 9. Comparison between conventional PID controller and proposed controller (Joint 1). f=0.3Hz and f=0.5Hz. In the experiment, the initial values of the proposed controller are set to 6190 10pK=,610 10iK=, 6150 10dK=, 0.015EDK=, 120.8,1,2cThh= =. These para-meters were obtained by trial-and-error. These ex-perimental results show that there is a large tracking error and time delay with respect to the increase of the frequency of the reference input; when using PID controller the response becomes worse with fre-quency up to 0.5Hz, whereas the settling time de-creases and the tracking performance is guaranteed by using the proposed controller. The damping torque is not applied for fast response when the manipulator starts to move, and the damping torque is applied by the MRB to the rotational axis of the PAM mani- 1024 TU Diep Cong Thanh and Kyoung Kwan AHN / Journal of Mechanical Science and Technology 21(2007) 10181027 (a) f=0.3 Hz (b) f=0.5 Hz Fig. 10. Experimental results of the proposed controller (Joint 1). pulator to reduce the overshoot and oscillation when the manipulator reaches the desired angle. Next, experiments were carried out to investigate the control performance with respect to the various reference input frequencies (of Joint 2). In addition, the external inertial loads (Load 1 = 20 kgfcm2; Load 2 = 40 kgfcm2) are attached to the end of arm (a) f=0.3 Hz (b) f=0.5 Hz Fig. 11. Comparison between conventional PID controller and proposed controller (Joint 2, load 1). 2, and the control parameters are set to be the same as Joint 1. Figures 11 and 12 show the comparison between the PID controller and the proposed controller for tested reference input frequencies and external initial load conditions. These figures show that there is a large error and time delay and that more oscillation occurs with respect to increasing reference input frequency, as well as to increasing external initial loads. In the experiments, the PAM mani-pulator joint angle agrees well with the reference when using the new phase plane switching controller. The effectiveness of the newly proposed phase plane switching control algorithm is also shown in detail in Figs. 13 and 14. The experimental results show that a good control performance and strong robu-stness are TU Diep Cong Thanh and Kyoung Kwan AHN / Journal of Mechanical Science and Technology 21(2007) 10181027 1025 (a) f=0.3 Hz (b) f=0.5 Hz Fig. 12. Comparison between conventional PID controller and proposed controller (Joint 2, load 2). obtained and do not depend on external initial load when using the proposed control method. These experimental results show that the damping torque is applied and released very frequently according to the approach to the desired angle. It is demonstrated that the proposed algorithm is effective in the case of various external loads and does not depend on reference input frequency. In addition, it is understood that the rotational angle of the PAM manipulator smoothly converges to the desired angle with little oscillation. It is concluded that the newly proposed phase plane switching control algorithm effectively tracks control of a sinusoidal waveform with high gain control, and has good control performance, a fast (a) f=0.3 Hz (b) f=0.5 Hz Fig. 13. Experimental results of the proposed controller (Joint 2, load 1). response, and strong robust stability under varying external inertial loads and reference input frequency. 5. Conclusions In this study, a new concept of phase plane switching control using a magneto-rheological brake is proposed and applied to a two-axis pneumatic artificial muscle manipulator to improve the control performance under various external loads and independently of reference input frequency. 1026 TU Diep Cong Thanh and Kyoung Kwan AHN / Journal of Mechanical Science and Technology 21(2007) 10181027 (a) f=0.3 Hz (b) f=0.5 Hz Fig. 14. Experimental results of the proposed controller (Joint 2, load 2). The experiments showed that the proposed control algorithm was highly effective in the tracking control of a sinusoidal trajectory and had high gain control, good control performance, fast response and strong, robust stability with respect to variation of both external loads and reference input frequency. The results also suggest that the proposed phase plane switching control using MRB is one of the most effective methods for developing a practically available, human-friendly robot by using a PAM manipulator. Acknowledgement This work was supported by University of Ulsan, Korea. References Ahn, K. K. and Thanh, T. D. C., 2004, “ Improvement of the Control Performance of Pneumatic Artificial Muscle Manipulators Using an Intelligent Switching Control Method,” in KSME, Int., Jour., Vol. 8, No. 8, pp. 13881400. Ahn, K. K. and Thanh, T. D. 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