Type Synthesis And Research On Design Technology Of Fault-tolerant Six-axis Force Sensor

Six-axis force sensor that applied in occasions like space robot, spacecraft docking, precision assembly and ocean operation, is restricted by complex and harsh environment. The share idea and fault tolerance theory were introduced in six dimensional force sensor structure design and researching. Studying on configuration synthesis, reliability analysis, performance index, optimization design and calibration experiment, creates a new branch for the application of redundant mechanism, where are major industrial application prospect. The main contents are as follow:Firstly, based on the requirement of high reliability, the mechanism choice and design criteria for parallel six-axis force sensor with fault tolerance was researched. Based on the type synthesis of parallel mechanism which can measure six-axis force, we can choose the basic geometries that fit the fault tolerance. Based on the theory of reliability, reliability and redundancy optimization model of the sensor system and the reasonably allocate of redundant branch number was established. We have researched the force measuring platform, the load platform and measuring branches.Secondly, laid a foundation for analytical performance analysis, the equivalent mathematical model of the sensor was established, and the force mapping matrix was constructed. Performance index of six-axis force sensor were introduced, and to simplify the model we have selected part size parameters and studied the effect of variable parameters on the sensitivity. Based on performance indicators, optimization analysis was done by optimization module of ANSYS Workbench. A small range six-axis force sensor with high resolution was designed, and manufacturing the prototype.Then, we introduced the materials parameter of prototype, manufacture, sensor patch, group the bridge and the material and size of lower plate and top plate and their function. By finite element analysis software, the sensor range and inearity error and calibration matrix are obtained, finishing Virtual Calibration. Meanwhile, the modal analysis of the prototype and the vibration mode and natural frequency by finite element software was done.Lastly, based on the existing hardware and software, parameters and the function of each part was introduced, and based on the prototype which contains common composite hinge we have carried out the static calibration experiment to prove the feasibility of the sensor system.