An integrated management and control system for dual-robot intelligent drilling and riveting of complex aircraft components

Abstract

The present invention discloses an integrated management and control system for dual-robot intelligent drilling and riveting of complex aircraft components. The system comprises a master control system and several subsystems. The master control system includes an NC master control module, a measurement unit module, a system management module, a robot control module, an end effector module, and a tooling management module. The NC master control module is used to process, parse, and run NC files, importing and executing generated NC numerical control code. The measurement unit module is used to monitor the status of all measurement modules in the system and debug their functions. The robot control module is used to control the Kuka robot and its internal parallel robot. The end effector module is used to control the three end effectors: hammer riveting, pull riveting, and top riveting. The tooling management module is used to control and monitor the digital tooling system. The present invention can achieve hardware and software integration of the intelligent drilling and riveting system, realizing intelligent robotic drilling and riveting.

Description

Technical Field

[0001] The present invention belongs to the technical field of aircraft intelligent drilling and riveting systems, and in particular relates to a dual-robot intelligent drilling and riveting integrated management and control system for complex aircraft components. Background Art

[0002] The quality of aircraft structural connections significantly impacts the accuracy and lifespan of the aircraft's aerodynamic shape. This quality struggles to meet the high-performance requirements of new aircraft, making it a weak link in my country's aircraft manufacturing industry. Riveting is the primary method of connection, and the use of robotic hole-making and riveting technology, along with intelligent control systems, is an effective approach to improving aircraft assembly quality.

[0003] In response to the high-quality, high-efficiency drilling and riveting requirements for my country's aircraft products, as well as the urgent need for the application of intelligent drilling and riveting systems in aircraft development and production, and to address the high-quality, efficient drilling and riveting of complex, irregularly shaped and heterogeneous components, it is necessary to focus on the development of multifunctional end-effectors, the design and development of drilling and riveting robots in narrow spaces, dual-robot drilling and riveting equipment, and digital assembly tooling for complex aircraft components. This will enable breakthroughs in key technologies such as the structural optimization and integration of multifunctional end-effectors and the integrated control of robotic intelligent drilling and riveting systems, ultimately forming a robotic intelligent drilling and riveting system. Ultimately, this will enable dual-robot collaborative, efficient, and precise drilling and riveting, thereby establishing the capability to develop dual-robot intelligent drilling and riveting systems for complex aircraft components and improving aircraft assembly quality and efficiency.

[0004] Therefore, the present invention provides an intelligent drilling and riveting system based on countersinking, hammer riveting, blind rivet riveting, and stress wave riveting. This invention also includes a narrow space drilling and riveting robot based on the drilling and riveting needs of aircraft; a dual-robot drilling and riveting system based on dual-robot collaborative control technology; and a digital assembly tooling system based on the characteristics of aircraft's complex and irregular components. Furthermore, the present invention researches information integration technology and develops integrated control software to achieve system integration control, completing the integration of the robot intelligent drilling and riveting system. Summary of the Invention

[0005] The purpose of this invention is to provide an integrated management and control system for dual-robot intelligent drilling and riveting of complex aircraft components, aiming to achieve intelligent drilling and riveting. By addressing the precision requirements for drilling and riveting on irregularly shaped curved surfaces during aircraft component assembly, this invention conducts intelligent drilling and riveting unit design, robot offline programming, and drilling and riveting process test optimization. This results in the development of specifications for robotic intelligent drilling and riveting, and demonstrates its application.

[0006] The present invention is mainly achieved through the following technical solutions:

[0007] An integrated management and control system for dual-robot intelligent drilling and riveting of complex aircraft components includes a master control system and several interacting subsystems. The master control system includes an NC master control module, a measurement unit module, a system management module, a robot control module, an end effector module, and a tooling management module. The NC master control module is used to process, parse, and run NC files, and import and execute the generated NC numerical control code. The measurement unit module is used to monitor the status and debug the functions of all measurement modules in the system. The robot control module is used to control the Kuka robot and the internal parallel robot. The end effector module is used to control the three end effectors of hammer riveting, pull riveting, and top riveting. The tooling management module is used to control and monitor the digital tooling system.

[0008] In order to better realize the present invention, further, the master control system includes a master control system host computer and a master control system slave computer, and several subsystems include a digital tooling system, a dual robot drilling and riveting system, and auxiliary equipment; the master control system host computer interacts with the master control system slave computer through ADS communication or OPC communication, and the master control system slave computer interacts with the digital tooling system, the dual robot drilling and riveting system, and auxiliary equipment through TCP / IP; the dual robot drilling and riveting system includes a hole-making robot system and a parallel robot system; the master control system host computer includes an NC master control module, a measurement unit module, and a system management module, and the master control system slave computer includes a PLC and a robot control module, an end effector module, and a tooling management module respectively connected to the PLC.

[0009] In order to better realize the present invention, further, the digital tooling system includes a drive system, and the drive system includes a motor horizontal unit, a motor rotation unit, and a motor column return unit. The motor horizontal unit, the motor rotation unit, and the motor column return unit are respectively provided with a position feedback unit.

[0010] In order to better realize the present invention, further, the lower computer of the master control system also includes a camera system, an I / O module, a drive system, and an industrial robot connected to the PLC. The camera system is connected to the PLC through a TCP interface, and the I / O module, the drive system, and the industrial robot are respectively connected to the PLC through an industrial bus; the camera system includes a positioning reference unit; the I / O module includes a pressure foot unit, a normal measurement unit, a riveting unit, a nail feeding system, and a nail feeding station; the drive system includes a hole countersinking unit and a workstation conversion unit.

[0011] In order to better realize the present invention, further, the NC master control module includes an NC file generation unit, a coordinate conversion unit, a precision supplement unit, a coordinate correction unit, a file parsing unit, and an NC execution management unit connected in sequence from front to back; the NC file generation unit is used to obtain the NC file based on process knowledge acquisition and predictive reasoning, the coordinate conversion unit is used to convert the coordinates of the processing points in the NC numerical control code into the coordinate values ​​in the robot coordinate system, the coordinate correction unit is used to perform coordinate correction according to the local reference to form an executable NC file, the file parsing unit is used to load the converted NC file into the system and import it into the NC line management unit, the NC execution management unit is used to issue NC instructions and receive execution feedback results, and transmit data through the ADS server as the intermediate management transmission layer.

[0012] In order to better implement the present invention, further, the execution commands contained in the NC file are any one or more of moving the KUKA robot to a specified position, moving the internal parallel robot to a specified position, hole making, hammer riveting, stress wave riveting, setting process parameters, benchmark detection, quality assessment and tooling movement.

[0013] In order to better realize the present invention, further, the measurement unit module includes a normal alignment module, a reference detection module, a state monitoring module and a quality assessment module; the normal alignment module is used to calculate the angular error between the current spindle direction and the normal of the product skin surface, and judge whether the normal is vertical according to the robot reaching a given position. If not, the normal leveling algorithm is called for correction, and the output variable is the robot coordinate after posture adjustment correction; the reference detection module is used to process the input camera scanning pixel point data through the reference detection algorithm and output the reference coordinates in the robot coordinate system; the state monitoring module is used to monitor any one or more process parameters including spindle speed, feed speed, clamping force, tool position and broken tool detection results when the robot is making holes and display them in real time in the form of a waveform graph; the quality assessment module is used to perform detection after the hole making is completed to detect whether any one or more process parameters including hole diameter, hole margin, countersink depth, verticality and flatness are qualified, and display the hole diameter detection, countersink depth detection, verticality measurement, rivet flatness and surface roughness in a graph.

[0014] In order to better realize the present invention, further, the robot control module includes a Kuka robot control unit and an internal parallel robot control unit; the Kuka robot control unit is used to realize any one or more of releasing the robot, retracting the robot, turning on external automatic, putting back and grabbing the hammer rivet end effector, putting back and grabbing the pull rivet end effector, robot safety confirmation, robot motion stop, robot reset, and robot status feedback for the Kuka robot; the internal parallel robot control unit is used to realize any one or more of starting the robot, disconnecting the robot, starting the robot to run, stopping motion, resetting, and motion of the robot to a specified position.

[0015] In order to better implement the present invention, further, the end effector module includes a hammer rivet end effector, a pull rivet end effector, and a top rivet end effector, and the hammer rivet end effector, the pull rivet end effector, and the top rivet end effector are respectively used to realize status monitoring, processing technology debugging and single-point equipment function debugging; any one or more of the hammer rivet end effector, the pull rivet end effector, and the top rivet end effector are integrated to obtain an external hammer rivet unit and an internal top rivet unit.

[0016] In order to better implement the present invention, further, the system management module includes any one or more of a user management unit, a device status monitoring unit, an NC code specification unit, a system log unit and an alarm information unit.

[0017] Based on the structural characteristics of aircraft products and the demand for drilling and riveting functionality and performance, the present invention requires the end effector to perform functions such as hole drilling, riveting, bolt installation, benchmark detection, and normal measurement. It requires a high level of integration, a complex structure, and high precision. Furthermore, the structure, weight, and size of the end effector directly affect the dynamic and static characteristics of the robot, and thus the accuracy and stability of the system. While ensuring functionality and accuracy, the structure and layout of the functional units must be rationally designed, and the structure optimized to achieve miniaturization and lightweighting of the end effector.

[0018] The beneficial effects of the present invention are as follows:

[0019] The present invention includes multiple hardware systems, each with an independent control system. During the drilling and riveting process, integrated control of the digital measurement system and the on-site monitoring system is achieved, forming a complete and reliable control system, ultimately achieving high-quality and efficient drilling and riveting. The present invention establishes a data integration interface to integrate product geometry data and process parameter data with the control system; establishes a measurement data interface to achieve real-time feedback control of dual-robot drilling and riveting equipment and assembly tooling; establishes an integrated control interface, and adopts multi-source data coupling measurement and control to realize real-time detection of drilling and riveting accuracy, comprehensive evaluation of drilling and riveting quality, and real-time mapping and control of drilling and riveting system status. This enables coordinated movement and operation between industrial robots, narrow space drilling and riveting robots, multi-functional end effectors, and assembly tooling.

[0020] This paper studies information integration technology, focusing on the drilling and riveting process and intelligent drilling and riveting characteristics of irregularly shaped and heterogeneous components. This technology defines information interaction variables between each subsystem and the integrated control system, and constructs a control architecture for system information interaction. Furthermore, the present invention studies the characteristics of each subsystem, combines them with the characteristics of multi-system integrated control, proposes a control strategy suitable for robotic intelligent drilling and riveting, designs the system's control structure, develops integrated control software, and manufactures an integrated control system. Ultimately, this system achieves hardware and software integration, forming a complete robotic intelligent drilling and riveting system. BRIEF DESCRIPTION OF THE DRAWINGS

[0021] Figure 1 This is a structural diagram of the mid-fuselage assembly system;

[0022] Figure 2 It is a schematic diagram of the overall structure of the present invention;

[0023] Figure 3 This is the control principle block diagram of the drilling and riveting multifunctional end effector;

[0024] Figure 4 This is a single-cycle workflow diagram for the drilling and riveting multifunctional end effector;

[0025] Figure 5 Schematic diagram of the technical route for developing hammer riveting and top riveting;

[0026] Figure 6 Principle block diagram of the technical route for blind rivet riveting;

[0027] Figure 7 Develop a technical block diagram for stress wave riveting;

[0028] Figure 8 This is the flow chart of robot collaborative control;

[0029] Figure 9 Schematic diagram of the technical route for designing a drilling and riveting robot for narrow spaces;

[0030] Figure 10 It is a structural diagram of the digital tooling system;

[0031] Figure 11 is a topological diagram of the present invention;

[0032] Figure 12 This is a control principle diagram of the present invention.

[0033] Among them: 1-internal guide rail platform; 3-rotational positioning tooling; 4-rear fuselage components; 5-transfer station; 6-zero point positioning system; 7-external guide rail platform; 8-external robot slide; 9-external robot; 10-end effector; 11-moving column. DETAILED DESCRIPTION

[0034] Example 1:

[0035] An integrated management and control system for dual-robot intelligent drilling and riveting of complex aircraft components, such as Figure 2 、 Figure 11 As shown, it includes a master control system host computer and a slave control system, and several subsystems including a digital tooling system, a dual-robot drilling and riveting system, and auxiliary equipment; the master control system host computer interacts with the master control system slave computer through ADS communication or OPC communication, and the master control system slave computer interacts with the digital tooling system, the dual-robot drilling and riveting system, and auxiliary equipment through TCP / IP; the dual-robot drilling and riveting system includes a hole-making robot system and a parallel robot system; the master control system host computer includes an NC master control module, a measurement unit module, and a system management module, and the master control system slave computer includes a PLC and a robot control module, an end effector 10 module, and a tooling management module respectively connected to the PLC.

[0036] The NC master control module is connected to the measurement unit module and the system management module. The NC master control module is used to process, parse, and run NC files, importing and executing the generated NC code. The measurement unit module is used to monitor the status of all measurement modules in the system and debug their functions. The robot control module is used to control the Kuka robot and the internal parallel robot. The end effector 10 module is used to control the three end effectors 10: hammer riveting, pull riveting, and top riveting. The tooling management module is used to control and monitor the digital tooling system.

[0037] Preferably, the NC master control module includes an NC file generation unit, a coordinate conversion unit, a precision supplement unit, a coordinate correction unit, a file parsing unit, and an NC execution management unit connected in sequence from front to back; the NC file generation unit is used to obtain the NC file based on process knowledge acquisition and predictive reasoning, the coordinate conversion unit is used to convert the coordinates of the processing points in the NC numerical control code into coordinate values ​​in the robot coordinate system, the coordinate correction unit is used to perform coordinate correction according to the local reference to form an executable NC file, the file parsing unit is used to load the converted NC file into the system and import it into the NC line management unit, the NC execution management unit is used to issue NC instructions and receive execution feedback results, and transmit data through the ADS server as the intermediate management transmission layer.

[0038] Preferably, the execution commands contained in the NC file are any one or more of moving the KUKA robot to a specified position, moving the internal parallel robot to a specified position, hole making, hammer riveting, stress wave riveting, setting process parameters, benchmark detection, quality assessment and tooling movement.

[0039] Preferably, the measurement unit module includes a normal alignment module, a reference detection module, a status monitoring module and a quality assessment module; the normal alignment module is used to calculate the angular error between the current spindle direction and the normal of the product skin surface, and determine whether the normal is vertical based on the robot reaching a given position. If not, the normal leveling algorithm is called for correction, and the output variable is the robot coordinate after posture adjustment correction; the reference detection module is used to process the input camera scanning pixel point data through the reference detection algorithm, and output the reference coordinates in the robot coordinate system; the status monitoring module is used to monitor any one or more process parameters including spindle speed, feed speed, clamping force, tool position and broken tool detection results when the robot is making holes, and display them in real time in the form of a waveform graph; the quality assessment module is used to perform inspection after the hole making is completed, and detect whether any one or more process parameters including hole diameter, hole margin, countersink depth, verticality and flatness are qualified, and display the hole diameter detection, countersink depth detection, verticality measurement, rivet flatness and surface roughness in a graph.

[0040] Preferably, the robot control module includes a Kuka robot control unit and an internal parallel robot control unit; the Kuka robot control unit is used to realize any one or more of the following functions of releasing the robot, retracting the robot, turning on external automation, putting back and grabbing the hammer rivet end effector 10, putting back and grabbing the pull rivet end effector 10, robot safety confirmation, robot motion stop, robot reset, and robot status feedback for the Kuka robot; the internal parallel robot control unit is used to realize any one or more of the following functions of starting the robot, disconnecting the robot, starting the robot to run, stopping motion, resetting, and movement of the robot to a specified position.

[0041] Preferably, the end effector 10 module includes a hammer rivet end effector 10, a pull rivet end effector 10, and a top rivet end effector 10. The hammer rivet end effector 10, the pull rivet end effector 10, and the top rivet end effector 10 are respectively used to realize status monitoring, processing technology debugging, and single-point equipment function debugging; any one or more of the hammer rivet end effector 10, the pull rivet end effector 10, and the top rivet end effector 10 are integrated to obtain an external hammer rivet unit and an internal top rivet unit.

[0042] Preferably, the system management module includes any one or more of a user management unit, a device status monitoring unit, an NC code specification unit, a system log unit, and an alarm information unit.

[0043] Preferably, the digital tooling system includes a drive system, which includes a motor horizontal unit, a motor rotation unit, and a motor column return unit. The motor horizontal unit, the motor rotation unit, and the motor column return unit are respectively provided with a position feedback unit.

[0044] Preferably, if Figure 3 、 Figure 12 As shown, the master control system lower computer also includes a camera system, an I / O module, a drive system, and an industrial robot connected to the PLC. The camera system is connected to the PLC via a TCP interface, and the I / O module, the drive system, and the industrial robot are respectively connected to the PLC via an industrial bus; the camera system includes a positioning reference unit; the I / O module includes a pressure foot unit, a normal measurement unit, a riveting unit, a nail feeding system, and a nail feeding station; the drive system includes a hole countersinking unit and a workstation conversion unit.

[0045] The present invention includes multiple hardware systems, each with an independent control system. During the drilling and riveting process, integrated control of the digital measurement system and the on-site monitoring system is achieved, forming a complete and reliable control system, ultimately achieving high-quality and efficient drilling and riveting. The present invention establishes a data integration interface to integrate product geometry data and process parameter data with the control system; establishes a measurement data interface to achieve real-time feedback control of dual-robot drilling and riveting equipment and assembly tooling; establishes an integrated control interface, and adopts multi-source data coupling measurement and control to realize real-time detection of drilling and riveting accuracy, comprehensive evaluation of drilling and riveting quality, and real-time mapping and control of drilling and riveting system status, etc., to achieve coordinated movement and operation between industrial robots, narrow space drilling and riveting robots, multi-functional end effectors 10, and assembly tooling.

[0046] Example 2:

[0047] A dual-robot integrated management and control system for intelligent drilling and riveting of complex aircraft components. This system serves as the overall planning arm for the robotic intelligent drilling and riveting system, primarily responsible for task planning, process execution, and on-site monitoring. It integrates multiple functions, including logic control concepts, algorithms, databases, and logging systems, to achieve unified and efficient management of the system. The system primarily comprises an NC master control module, a robot control module, an end effector module (10), a measurement unit module, a system management module, and a tooling management module.

[0048] Preferably, if Figure 2 As shown, the NC master control module handles NC file processing, parsing, and execution, primarily responsible for importing and executing the NC code generated by the offline programming software. Coordinate conversion involves converting the coordinates of machining points in the NC code generated by the offline programming software into the robot coordinate system to drive the robot. File parsing involves loading the converted NC code into the software system.

[0049] During the loading process, the NC code syntax is checked to ensure that the running code is legal and the system runs stably. Syntax check and display mechanism: The NC code in the interface is checked and displayed, and errors are highlighted. Different display mechanisms are used for the running status, comment code, and master code. The system provides two running modes: single-step running and continuous running. Single-step running means running one line of NC instructions at a time, while continuous running means running continuously from the current line until it reaches the instruction code, breakpoint, or the last line that stops running. Add and delete breakpoints to the NC code. When the program moves to the breakpoint, it will be interrupted. After deleting the breakpoint, it can continue running. Control the start of the NC code program. Stop the running NC program, which is only applicable to the continuous motion mode. Reset the NC code to the initial state and point the current running line to the first line. Monitor the real-time status information of key components such as the external robot 9 coordinate values, the internal robot coordinate values, the reference hole scanning results, the quality assessment results, the spindle speed on the end effector 10, and the tool position.

[0050] Preferably, the robot control module controls the Kuka robot and the internal parallel robot. Control of the Kuka robot includes releasing the robot, retracting the robot, enabling external automation, placing and grabbing the hammer rivet end effector 10, placing and grabbing the pull rivet end effector 10, confirming robot safety, stopping robot motion, resetting the robot, and providing robot status feedback. Control of the parallel robot includes starting the robot, disconnecting the robot, starting the robot, stopping motion, resetting the robot, and moving the robot to a specified position.

[0051] Preferably, the end effector 10 module is used to control the three end effectors 10: hammer riveting, pull riveting and top riveting. The functions of each end effector 10 include status monitoring, processing technology debugging and single-point equipment function debugging. Figure 5 As shown, the hammer rivet end effector 10 selects a pneumatic reverse riveting process based on the characteristics of the aircraft barrel product, such as poor openness, complex internal structure, and small internal robot load. That is, the riveting power source is compressed air, the rivet gun hammers the nail head from the outer surface of the aircraft, and the rivet rod is tightened with a push iron inside the aircraft component. The riveting is completed through multiple hammering. The product fastener information in the riveted area is obtained, and the riveting process test is carried out to determine the riveting process parameters. Based on the riveting process parameters and the characteristics of the reverse riveting process, the rivet gun parameters and the push iron quality are determined, and sensors such as smart cameras, displacement sensors, and force sensors are used to realize online detection of riveting quality. Finally, the various components are integrated to develop an external hammer riveting unit and an internal push riveting unit.

[0052] like Figure 6As shown, the blind rivet riveting unit realizes the function of pulling out the rivets from the outer surface of the aircraft. According to the product size and fastener information, a pneumatic rivet gun suitable for integration with the robot end effector 10 is selected. Figure 7 As shown, the stress wave riveting unit includes a stress wave riveting head, a linear feed mechanism, and an installation buffer mechanism. The stress wave riveting head is mounted on the linear feed mechanism via the installation buffer mechanism. The linear feed mechanism drives the rivet gun to move linearly, compressing the rivet and completing the riveting. The installation buffer mechanism installs and guides the stress wave riveting head and buffers the recoil force of the riveting.

[0053] Preferably, the measurement unit module is used to realize status monitoring and function debugging of all measurement modules of the system, which includes a normal alignment module, a reference detection module, a status monitoring module and a quality assessment module. Each monitoring module contains the real-time data of each measurement sensor, as well as the results after processing and calculation. The input variable of the normal alignment module is to calculate the angular error between the current spindle direction and the normal of the product skin surface based on the data of the four sensors read from the PLC, and to judge whether the normal is vertical by the judgment method, that is, when the robot reaches a given position. If it is not vertical, the normal leveling algorithm is called for correction, and the output variable is the coordinates of the robot after posture adjustment and correction; the reference detection module is to study the input camera scanning pixel point data through the reference detection algorithm, and output the reference coordinates in the robot coordinate system; the main function of the status monitoring module is to monitor various process parameters including spindle speed and feed speed when the robot is making holes. The clamping force, tool position and tool breakage detection results are displayed in real time in the form of waveforms. The quality assessment module performs inspections after hole making is completed to check whether process parameters such as hole diameter, hole edge distance, countersink depth, verticality, and flatness are qualified. At the same time, hole diameter detection, countersink depth detection, verticality measurement, rivet flatness and surface roughness are displayed in graphs.

[0054] Preferably, the system management module includes functions such as user management, equipment status monitoring, NC code specification, system log and alarm information.

[0055] Preferably, the tooling management module is a module that realizes the control and monitoring of the digital tooling of the entire system, which includes the control and monitoring of the internal robot mobile positioning platform, rotating tooling and zero-point positioning device. Figure 10As shown, the assembly tooling and ground auxiliary system mainly consists of five parts: conformal tooling, assembly jig, rotary tooling, AGV, and zero-point positioning system 6. The tooling adopts a movable conformal tooling and is locked by the zero-point positioning system 6. First, the conformal tooling is fixed to the assembly jig by the zero-point positioning system 6, and the product is pre-assembled in the assembly jig unit with the main beam, frame structure and part of the skin; then, it is unloaded by the AGV transfer vehicle and transported to the robot automatic drilling and riveting station, where it falls on the zero-point positioning system 6, slides into the rotary tooling through the pulley assembly, and is positioned by the combination pin structure; finally, the AGV transfer vehicle moves the mobile frame assembly out of the work area, and the automatic drilling and riveting robot is in place to carry out the drilling and riveting work.

[0056] The control unit hardware primarily consists of a high-level controller, a low-level controller, a remote control module, a servo motor, an ultrasonic sensor, a circuit breaker, and relays. The high-level controller is the core of the entire AGV control system, responsible for loading the control system's management software, running system programs, and coordinating the operation of other functional units. Hardware specifications such as the high-level controller's speed and capacity directly impact the performance of the entire AGV control system. Given the real-time requirements of the AGV control system, the selected controller should have sufficiently fast processing speed and a comprehensive set of external device interfaces. After comparing various design options, drawing on relevant domestic and international design experience, and comprehensively considering various requirements and factors, the designed AGV uses a Beckhoff CX50 series embedded industrial computer as the high-level controller. It receives digital and analog signals from the remote control module, vision sensor, and radar sensor, invokes the corresponding software modules, and performs calculations to output two signals: a direction and speed signal, which is transmitted to the servo driver to adjust the servo motor's direction and speed; and a start / stop signal, which is transmitted to the servo driver to start and stop the servo motor.

[0057] Example 3:

[0058] An integrated management and control system for dual-robot intelligent drilling and riveting of complex aircraft components. The overall system framework architecture is described as follows: Based on the process knowledge base technology route of process experiments and expert experience, a process parameter prediction method based on a neural network model is proposed, and a predictive reasoning mechanism for process parameters is established. The drilling and riveting process parameter knowledge system is designed. The drilling and riveting process parameter knowledge base system software is redeveloped based on VisualStudio and Oracle to implement three major functions: data management, process knowledge acquisition, and predictive reasoning. Test results verify the consistency between the predicted results and the actual values. The developed drilling and riveting process parameter knowledge base system is integrated with the robot intelligent drilling and riveting system. The obtained drilling and riveting process parameter data is output to the offline programming software to generate NC files, providing scientific and reasonable process parameters and NC processing files for the robot's automatic drilling and riveting processing.

[0059] like Figure 2 As shown, the NC file generated by the offline programming software uses coordinate transformation to convert points in the aircraft coordinate system into coordinate values ​​in the robot coordinate system. With precision compensation, coordinate corrections are performed based on local datums to create an executable NC machining file. After the file is parsed, it is finally managed by the NC execution manager. The NC file contains execution commands such as: moving the KUKA robot to a specified position; moving the internal parallel robot to a specified position; drilling, hammer riveting, and stress wave riveting; setting process parameters; benchmark inspection; quality assessment; and tooling movement. The ADS server, serving as the intermediate management and transmission layer, transmits NC instructions issued by the NC execution manager in the form of data to each execution unit. After each unit completes the specified action, it provides feedback on the execution results to the NC execution manager.

[0060] like Figure 1 As shown, the mid-fuselage assembly system in this embodiment includes: an internal guide rail platform 1, an internal robot, a rotary positioning tool 2, a rear fuselage component 4, a transfer station 5, a zero-point positioning system 6, an external guide rail platform 7, a slide 8 for an external robot 9, an end effector 10, and a mobile column 11. The external robot 9 is mounted on the external guide rail platform 7 and can move in the Y direction; the fixed column and the mobile column 11 are used to mount and support the internal guide rail platform 1; the internal robot is mounted on the internal guide rail platform 1 and can move in the Y direction; and the mobile column 11 can move in the X direction. The rear fuselage component 4 is positioned horizontally and positioned by a conformal tooling, which is positioned by the zero-point positioning system 6.

[0061] Specific implementation method 2: Figure 3 As shown in the figure, based on the design principle and working characteristics of the multifunctional end effector 10, the control process is sorted out and the control system structure framework is built. A mature industrial-grade CNC system is used, and the servo drives of each axis are connected via the EtherCAT / ProfiNet bus to achieve real-time control of multi-axis motion, including spindle hole making, countersinking control, and station conversion control. Distributed I / O modules are used to realize normal detection and adjustment, nail feeding system, riveting unit parameter control, etc., and the industrial computer realizes the precise positioning of the camera system based on the TCP protocol. Figure 4 As shown, the entire hole-making process of a single cycle of the robot drilling and riveting end effector 10 includes: reference detection, normal alignment and subsequent hole-making countersinking, hole detection, nail insertion, riveting, and zero return.

[0062] Specific implementation method three: Figure 8As shown, the control method of the robot collaborative control module is: the external robot 9 moves to the specified position according to the offline program, and after completing the posture adjustment, the position and posture of the parallel robot are solved, the parallel robot mobile platform is driven to move to the appropriate position and the posture information of the parallel robot is transmitted. The parallel robot controller completes the inverse operation, drives each axis to reach the specified position and completes the posture adjustment.

[0063] The process is as follows:

[0064] (1) Initialization operation of integrated control system;

[0065] (2) According to the offline program, the industrial robot moves to the specified position, performs normal measurement and posture adjustment;

[0066] (3) Drive the feed axis to make holes and obtain hole position information;

[0067] (4) The end effector 10 switches positions and moves to the riveting position;

[0068] (5) The control system "robot collaborative control module" calculates the theoretical position of the parallel robot;

[0069] (6) Drive the parallel robot's mobile platform motor to move to X0, and at the same time send a command requesting the parallel robot to move to the specified position;

[0070] (6) After the parallel robot control system moves to the specified position, it feeds back to the integrated control system and takes photos for positioning again. Based on the imaging results, the control system drives the parallel robot mobile platform motor to perform secondary positioning and deviation correction;

[0071] (7) Deliver nails and rivet.

[0072] (8) Repeat (2) to (7) until the process is completed.

[0073] Specific implementation method four: Figure 9 As shown, the parallel-guide 6-HTRT and 6-SPS (Stewart platform) parallel mechanisms were compared based on the performance metrics of workspace size, load-bearing capacity, and the ease of inverse position solution. The final configuration was determined after comprehensive consideration. In the 6-SPS structure, all forces acting on the members are directly provided by the members, while in the parallel-guide 6-HTRT parallel mechanism, the forces acting on the members are partially provided by the guide rail bracket and partially by the drive mechanism. In other words, the drive mechanism only needs to provide one component of the total force acting on the members.

[0074] The 6-PTRT parallel robot has the following features:

[0075] (1) The input quantity is the motion displacement of the moving pair along the guide rail axis. The position and posture of the moving platform are only related to the differential combination of the six input quantities, which reduces the calculation work in kinematics and dynamics and makes modeling and analysis easier.

[0076] (2) The driving force required by the driving element is reduced, and the driving force and the support reaction force form a combined force acting on the branch chain link;

[0077] (3) The position of the driving element is not constrained by the branch chain, reducing the problem of interference during movement;

[0078] (4) The workspace has good translational properties in the direction of motion of the moving pair, which is suitable for working environments with small working environments, many external interference conditions, and the need for lifting to avoid obstacles.

[0079] Specific implementation method five: Figure 11 As shown in the figure, information integration primarily enables data exchange between the intelligent drilling and riveting system's subsystems and the master control system. The master control system transmits motion execution instructions to each execution unit, which then feeds back status values ​​to the master control system via sensors and other components. This is primarily achieved through ADS or OPC communication between the master control system's host and slave computers, and TCP / IP communication between the master control system's slave computers and each subsystem.

[0080] Specific implementation method six: Figure 12 As shown in the figure, focusing on the drilling and riveting process and intelligent drilling and riveting characteristics of special-shaped and heterogeneous components, information integration technology is studied, information interaction variables between each subsystem and the integrated control system are defined, and a control architecture for system information interaction is constructed. The characteristics of each subsystem are studied, and combined with the characteristics of multi-system integrated control, a control strategy suitable for robotic intelligent drilling and riveting is proposed. The system control structure is designed, integrated control software is developed, and an integrated control system is manufactured. Ultimately, the hardware and software integration of the robotic intelligent drilling and riveting system is achieved, forming a robotic intelligent drilling and riveting system.

[0081] The digital integrated control system for robotic drilling and riveting utilizes a combination of computer integrated control, robotic control, multi-axis CNC, servo drive, process monitoring, and sensor measurement technologies to meet the demands of digital drilling and riveting. It features standardized interfaces with other control systems and software systems. Fieldbus technology enables real-time information acquisition and online control. The CNC control system utilizes protocols such as TCP / IP to communicate with the host computer and other peripheral devices. The robotic drilling and riveting system utilizes a mature industrial-grade CNC system and its EtherCAT bus control method. An industrial computer coordinates the robot, drive system, field distributed I / O, and corresponding algorithms, logic, and safety control. The vision positioning system primarily locates the reference hole, and the normal adjustment system automatically adjusts the verticality of the end effector 10. The end effector 10 and top riveting robot utilize a master-slave collaborative control mode, using specified communication methods. The servo drive system provides motion control for the end effector 10, feed axis, spindle, and external axes.

[0082] The above description is only a preferred embodiment of the present invention and does not limit the present invention in any form. Any simple modification or equivalent change made to the above embodiment based on the technical essence of the present invention shall fall within the scope of protection of the present invention.

Claims

1. A dual-robot intelligent drilling and riveting integrated management and control system for complex aircraft components, characterized by: It includes a master control system and several subsystems that interact with each other. The master control system includes an NC master control module, a measurement unit module, a system management module, a robot control module, an end effector module, and a tooling management module. The NC master control module is used to process, parse, and run NC files, and import and execute the generated NC numerical control code. The measurement unit module is used to monitor the status and debug the functions of all measurement modules in the system. The robot control module is used to control the Kuka robot and the internal parallel robot. The end effector module is used to control the three end effectors of hammer riveting, pull riveting, and top riveting. The tooling management module is used to control and monitor the digital tooling system.

2. The dual-robot intelligent drilling and riveting integrated management and control system for complex aircraft components according to claim 1 is characterized in that: The master control system includes a master control system host computer and a master control system slave computer, and several subsystems include a digital tooling system, a dual-robot drilling and riveting system, and auxiliary equipment; the master control system host computer interacts with the master control system slave computer through ADS communication or OPC communication, and the master control system slave computer interacts with the digital tooling system, the dual-robot drilling and riveting system, and auxiliary equipment through TCP / IP; the dual-robot drilling and riveting system includes a hole-making robot system and a parallel robot system; the master control system host computer includes an NC master control module, a measurement unit module, and a system management module, and the master control system slave computer includes a PLC and a robot control module, an end effector module, and a tooling management module respectively connected to the PLC.

3. The dual-robot intelligent drilling and riveting integrated management and control system for complex aircraft components according to claim 2 is characterized in that: The digital tooling system includes a drive system, which includes a motor horizontal unit, a motor rotation unit, and a motor column return unit. The motor horizontal unit, the motor rotation unit, and the motor column return unit are respectively provided with a position feedback unit.

4. The dual-robot intelligent drilling and riveting integrated management and control system for complex aircraft components according to claim 2 is characterized in that: The master control system's lower computer also includes a camera system, an I / O module, a drive system, and an industrial robot connected to the PLC. The camera system is connected to the PLC via a TCP interface, and the I / O module, the drive system, and the industrial robot are respectively connected to the PLC via an industrial bus. The camera system includes a positioning reference unit; the I / O module includes a pressure foot unit, a normal measurement unit, a riveting unit, a nail feeding system, and a nail feeding station; the drive system includes a hole countersinking unit and a workstation conversion unit.

5. The dual-robot intelligent drilling and riveting integrated management and control system for complex aircraft components according to any one of claims 1 to 4, characterized in that: The NC master control module includes an NC file generation unit, a coordinate conversion unit, a precision supplement unit, a coordinate correction unit, a file parsing unit, and an NC execution management unit, which are connected in sequence from front to back; the NC file generation unit is used to obtain the NC file based on process knowledge acquisition and predictive reasoning, the coordinate conversion unit is used to convert the coordinates of the processing points in the NC numerical control code into the coordinate values ​​in the robot coordinate system, the coordinate correction unit is used to perform coordinate correction according to the local reference to form an executable NC file, the file parsing unit is used to load the converted NC file into the system and import it into the NC line management unit, the NC execution management unit is used to issue NC instructions and receive execution feedback results, and transmit data through the ADS server as the intermediate management transmission layer.

6. The dual-robot intelligent drilling and riveting integrated management and control system for complex aircraft components according to claim 5 is characterized in that: The execution commands contained in the NC file are any one or more of moving the KUKA robot to a specified position, moving the internal parallel robot to a specified position, hole making, hammer riveting, stress wave riveting, setting process parameters, benchmark detection, quality assessment, and tooling movement.

7. A dual-robot intelligent drilling and riveting integrated management and control system for complex aircraft components according to any one of claims 1 to 4, characterized in that: The measurement unit module includes a normal alignment module, a reference detection module, a state monitoring module and a quality assessment module; the normal alignment module is used to calculate the angular error between the current spindle direction and the normal of the product skin surface, and determine whether the normal is vertical based on the robot reaching a given position. If not, the normal leveling algorithm is called for correction, and the output variable is the robot coordinate after posture correction; the reference detection module is used to process the input camera scanning pixel point data through the reference detection algorithm and output the reference coordinates in the robot coordinate system; the state monitoring module is used to monitor any one or more process parameters including spindle speed, feed speed, clamping force, tool position and broken tool detection results when the robot is making holes and display them in real time in the form of a waveform graph; the quality assessment module is used to perform detection after the hole making is completed to detect whether any one or more process parameters including hole diameter, hole margin, countersink depth, verticality and flatness are qualified, and display the hole diameter detection, countersink depth detection, verticality measurement, rivet flatness and surface roughness in a graph.

8. The dual-robot intelligent drilling and riveting integrated management and control system for complex aircraft components according to any one of claims 1 to 4, characterized in that: The robot control module includes a Kuka robot control unit and an internal parallel robot control unit; the Kuka robot control unit is used to realize any one or more of releasing the robot, retracting the robot, turning on external automation, putting back and grabbing the hammer rivet end effector, putting back and grabbing the pull rivet end effector, robot safety confirmation, robot motion stop, robot reset, and robot status feedback for the Kuka robot; the internal parallel robot control unit is used to realize any one or more of starting the robot, disconnecting the robot, starting the robot to run, stopping motion, resetting, and motion of the robot to a specified position.

9. A dual-robot intelligent drilling and riveting integrated management and control system for complex aircraft components according to any one of claims 1 to 4, characterized in that: The end effector module includes a hammer rivet end effector, a pull rivet end effector, and a top rivet end effector. The hammer rivet end effector, the pull rivet end effector, and the top rivet end effector are respectively used to realize status monitoring, processing technology debugging, and single-point equipment function debugging; any one or more of the hammer rivet end effector, the pull rivet end effector, and the top rivet end effector are integrated to obtain an external hammer rivet unit and an internal top rivet unit.

10. A dual-robot intelligent drilling and riveting integrated management and control system for complex aircraft components according to any one of claims 1 to 4, characterized in that: The system management module includes any one or more of a user management unit, a device status monitoring unit, an NC code specification unit, a system log unit, and an alarm information unit.

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