轻量化机器人复合材料的设计与制造

工业机器人是当前工业生产领域中的高技术装备，它集成了机械设计，材料设计，自动化控制系统等多个方面的关键技术。随着人类社会的发展，目前，工业机器人已被广泛应用于人类社会生产的各个领域当中。传统工业机器人由于具有相对笨重的结构，能耗高，效率低，难以满足当今社会日益凸显的能源和环保问题。为了提高工业机器人的精度和速度等，降低能耗，进一步扩大其应用范围，以解决人口老龄化带来的劳动力不足等问题，如何对工业机器人进行轻量化设计成为当前该领域的研究重点。 传统工业机器人通常选用钢、铝合金等金属材料，相比于碳纤维复合材料，其模量低，强度低，密度高，这是导致工业机器人自重过高的一个重要因素。而碳纤维复合材料在具有超高模量、超高强度和超低密度的前提下，同时还具备可设计性强，应用潜力大等优点。为了实现工业机器人的轻量化，本文选择碳纤维复合材料替代传统的金属材料作为机械臂结构件的选用材料。在分析工业机器人机械臂工作情况，基于其载荷和运动特点，提出碳纤维轻量化机械臂的设计方案。在原有轻量化碳纤维机械臂的基础之上，进一步优化结构和替换材料。为建立材料参数到最终机器人整体结构刚度矩阵的计算路线，采用经典层合板理论，悬臂梁模型，以及机器人结构刚度矩阵计算理论等模型，计算理论结果，并通过仿真验证理论结算结果的正确性。为验证设计方案可行性，选择合适的加工工艺加工所设计的轻量化机械臂。通过试验，测试所加工的机械臂是否满足设计要求。所涉及的试验包括宏观层面的机械臂整体性能测试和微观层面的材料微观性能分析等。

Industrial robots are hightech equipment in the current industrial production field. It integrates several key technologies such as mechanical design, material design, and automation control system. With the development of human society, industrial robots have been widely used in various fields of human social production. Due to the relatively heavy structure, high energy consumption, and low efficiency of traditional industrial robots, it is difficult to meet the increasingly prominent energy and environmental issues in today’s society. To improve the accuracy and speed of industrial robots, reduce energy consumption, and at the same time further expand its application range, how to carry out the lightweight design of industrial robots has become the current research focus in this field. Compare with the Carbon Fiber Reinforced Plastics (CFRP), metal materials, usually used in traditional industrial robots, have several disadvantages such as low modulus and low strength, but high density, which makes the traditional industrial robots too weight. Meanwhile, because of it’s strong designability, CFRP has a widely application potential. To realize the lightweight of industrial robots, CFRP has been chosen to replace traditional metal materials as the structure material of the mechanical arm. The specific research content is as follows: We analyzed the working conditions of the industrial robot manipulator. Based on its load and movement characteristics, we proposed a design plan for the carbon fiber lightweight manipulator. Based on the original lightweight carbon fiber manipulator, the structure is further optimized and materials are replaced. We established a calculation route from material parameters to the final stiffness matrix of the overall robot structure. Classical laminate theory, cantilever beam model, and robot structure stiffness matrix calculation theory are used to calculate the theoretical results of the robot structure stiffness matrix. And the results are verified by the Finite Element Analysis. To verify the feasibility of the design scheme，we selected the appropriate processing technology to manufacture the designed lightweight robotic arm and verified whether the robotic arm meets the design requirements through experiments.