| Fusion energy with less pollution has been considered as the key solution to the world energy problem. Tokamak, which is a controlled fusion device, is important for researching the phenomenon during the fusion reaction and utilizing the fusion energy. However, by the reason of the harsh environments of the tokamak device, the components in the vacuum vessel(VV) may be damaged during fusion experiment. Besides, because of the numerous device, the complex pipes, the limited operation space and the situation that the in-vessel components likely to be polluted, the manual operation is forbidden even when the maintenance is needed. As a consequence, it’s important and essential to design and develop a remote robot system which can perform the observation task, the inspection task, the assembly and disassembly task, the recycle task, the transport task and the maintenance task by the long reach manipulator outside the W. For the background mentioned above, the prototype of the remote multi-joint manipulator, which is dedicated for the fusion device, with the objective of establishing the basis of the high-quality remote robot system and accelerating the speed of utilizing the fusion energy is presented in this paper.The main conclusion and innovation is mentioned below:Firstly, considering the special and specific requirements of the robot system used for the fusion device, the whole design of the robot with sufficient degrees of freedoms(DOFs) and long cantilever structure is determined. The configuration of the manipulator is researched based on the overall design of the system. Considering the results of the structural mechanics analysis, the gravity compensation module is designed for compensating the deformation caused by the gravity. On account of the large bending radius of the radiation-resistant fiber, the fiber deployment system is designed and developed.Then, from the perspective of the structural features of the robot and the demands for the inspection task, the inspection procedure can be separated into three parts:move in/out the W, the large-scale inspection and the free inspection. The kinematics conrtrol problem for the long reach multi-joint manipulator is researched.. The kinematic model is established based on the standard D-H method and the modified D-H method. The inverse kinematics problem is resolved when the working process is taken into consideration. The workspace of the multi-joint manipulator is acquired by the numerical analysis method. The kinematics simulation is given based on the Matlab software.Then, the statics problem and dynamics problem of the multi-joint manipulator, including the mathematical model and the simulation, is researched. The internal force and torque applied on the joints and the links is acquired. Then, the statics model is given. The statics simulation and the modal analysis and simulation is given by the method of the finite-element analysis, which can provide the basis for the vibration control and the optimal design. The single module dynamics model and the system dynamic model is given based on the Lagrange method. The trajectory planning is presented. The dynamic simulation under the typical working path is finished using the Adams software.Finally, the flexible model of the multi-joint manipulator is presented. The whole system can be divided into different parts by the reason of the structure and the properties of the applied force. The flexible model of the system is given based on the analysis of the deformation of the links and the joints. The transfer matrix on account of the deformation is proposed. The simulation result indicated that the flexible model can improve the position precision of the long reach multi-joint manipulator efficiently.For validating the availability of the research, the prototype of the long reach multi-joint robot is designed and developed. The experimental results indicated that the robot with good statics property, excellent kinematic and dynamic performance can satisfy the requirements of the functions.
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