Research Of Hole Making System For Carbon Skin Structural Components Based On Robot Technology

In recent years, there has been very high demand for composite materials which process high strength and low density in aerospace industry, and the issues associating with composite materials have been attracted more and more attentions. Because of the interrupted cutting problems, holes on composite materials such as carbon skin structural components are very difficult to drill with traditional machining technique. Therefore, It is required to develop a special hole making system with smaller axial cutting force in the processing of drilling. And the special machining system owns a satisfactory space in chip and heat transfer bulk. The special carbon skin hole making system designed in this paper can effectively reduce the hierarchical phenomenon and export defects which are caused by overloaded cutting force during the machining process. In this thesis, a carbon skin hole making system is developed, and the following aspects of research have been considered.In this paper, an industry robot with six degrees of freedom is used in the carbon skin hole making system as the carrier of the power head for drilling. The drilling tools can be placed on the hole-based position by using the industry robot. the tools which are settled on the manipulators possess some advantages in quickly moving, high precision and the large space of movement. This system uses machining visional technology for setting tools. the relationship between the tool coordinates and robot coordinate can be simulated to realize fast and high precision in setting tools.The innovative part is connected with a conducting slip ring to power up the motion. The solution for motion control is realized by using a servo motor to drive the ball screw for the axial motion and radial displacement. A complete virtual prototype designed in Solidworks possesses the characteristics of virtual assembly, interference checking and simulation analysis of movement. A finite element analysis was carried out on the virtual prototype developed to simulate the stress in the real environment and complete the statics record. A Dynamics analysis of virtual prototype is also introduced to improve the system of weak parts in order to achieve the design requirements.The hole making system for carbon skin structural components developed in this thesis uses industry computer as the main controller, and the data communica tion with the power head and other parts is performed via an interface board. The industry robot is controlled by the industry computer via an Ethernet interface, and the machine vision is realized with a USB camera.Finally, the hole making system is assembled and tested fully before it can be launched to market. The machine physical prototype is also analyzed in finite element software, and based on the real world testing of the physical prototype experiments. The results of the test have been analyzed in order to improve the prototype.