Self-adaptive control system and robot for disassembling complex geometrical shapes

Abstract

The invention discloses a self-adaptive control system for disassembling a complex geometrical shape and a robot. The system comprises a contact type vertical tool setting module, a series mechanical arm linear walking module, a laser ranging feedback module and a control center. The method comprises the following steps: controlling a cutting head and a workpiece surface to perform multi-point contact sampling before operation, calculating a normal vector and adjusting the posture of the cutting head; and during operation, the mechanical arm is driven to execute linear feeding by utilizing an inverse kinematics algorithm based on a preset path, and meanwhile, motion parameters are corrected in real time according to laser ranging data so as to keep a constant operation height. The system further integrates the functions of multi-source signal logic verification, environmental adaptability dust removal and rigidity coupling self-adaptive cruising. The sinking type electrical cabinet and the system are carried through the crawler chassis, and the problem of high-precision automatic disassembly of the variable-cross-section curved surface workpiece in the field unstructured environment is solved.

Description

Technical Field

[0001] This invention relates to the field of automation technology for engineering machinery, and in particular to an adaptive control system and robot for disassembling complex geometries. Background Technology

[0002] With the adjustment of energy structure and the upgrading of industrial facilities, a large number of decommissioned wind turbine blades and other equipment need to be scrapped in the field. These objects to be dismantled usually have complex geometric features such as variable cross-section conical cylinders or irregular curved surfaces, and after long-term service and transportation and stacking, their surfaces often have unpredictable deformation, twisting or collapse. Current field dismantling operations usually use equipment with tracked chassis and industrial robotic arms, utilizing the flexibility of the robotic arms for cutting.

[0003] The motion of a serial robotic arm is based on joint rotation, and it relies on high-frequency inverse kinematics calculations when performing linear cutting tasks in Cartesian space. When dealing with workpieces with uneven surfaces, relying solely on fixed trajectories generated by offline programming or teaching and reproduction is insufficient to adapt to the random undulations of the workpiece surface. This makes it difficult for the cutting head to maintain a consistently vertical posture or a stable cutting focal length, which can easily lead to problems such as incomplete cuts, reduced cut quality, or the cutting nozzle colliding with the workpiece, affecting the continuity and safety of the operation.

[0004] Dismantling sites are typically accompanied by high concentrations of metallic fumes and intense light interference, and large, variable-section workpieces often contain residual stress. Existing control systems often lack effective mechanisms for filtering environmental noise and are insufficient to proactively protect against the risk of tool clamping caused by stress release during the cutting process. Furthermore, traditional equipment often has independently external control cabinets, resulting in cumbersome wiring and a high center of gravity, which is detrimental to flexible, mobile, and stable operation in complex waste disposal sites. Summary of the Invention

[0005] The purpose of this invention is to provide an adaptive control system and robot for disassembling complex geometries, in order to solve the problems mentioned in the background art.

[0006] In a first aspect, the present invention provides an adaptive control system for disassembling complex geometries, comprising: The contact-type vertical tool setting module is used to control the cutting head to perform multi-point contact sampling with the surface of the workpiece to be disassembled before the disassembly operation begins. Based on the sampling data, the normal vector of the contact area is calculated, and the posture of the cutting head is adjusted so that its axis is parallel to the normal vector. The tandem robotic arm linear motion module is used to calculate the motion parameters of each joint of the tandem robotic arm based on a preset disassembly path using an inverse kinematics algorithm, and control the cutting head to perform multi-axis linkage linear feed motion along the surface of the workpiece to be disassembled. The laser ranging feedback module is used to monitor the vertical distance between the cutting head and the surface of the workpiece to be disassembled in real time during the linear feed motion of the cutting head, and to feed the monitoring data back to the control center. The control center is connected to the contact-type vertical tool setting module, the tandem robotic arm linear travel module, and the laser ranging feedback module, respectively, and is used to correct the motion parameters of the tandem robotic arm in real time based on the monitoring data, so as to maintain a constant working height between the cutting head and the workpiece surface.

[0007] Optionally, the contact-type vertical tool setting module is equipped with a contact force sensing unit; When the probe on the cutting head touches the workpiece surface and the contact force reaches a preset threshold, the contact-type vertical tool setting module locks the current coordinates. By obtaining the coordinates of at least three non-collinear points in the same local region, a tangent plane is fitted to determine the normal vector.

[0008] Optionally, the linear motion module of the serial robotic arm includes a trajectory smoothing processing unit, which is used to discretize the linear trajectory command in Cartesian space into a continuous angular displacement sequence in joint space, and to smooth the velocity and acceleration of each joint to eliminate the jitter of the serial robotic arm when performing linear motion.

[0009] Optionally, the laser ranging feedback module is set with an optimal cutting focal length threshold range; When the monitored data exceeds the threshold range, the control center generates a Z-axis compensation command, driving the serial robotic arm to perform normal fine-tuning while maintaining linear feed.

[0010] Optionally, the system also includes an environmentally adaptable dust control module, used to synchronously adjust the negative pressure power of the external dust removal equipment according to the feed speed of the linear walking module of the serial robotic arm, so as to ensure that the dust collection rate at the cutting head matches the current cutting efficiency.

[0011] Optionally, the control center is pre-configured with disassembly process packages for different complex geometries, including the variable cross-section conical body of wind turbine blades and the surface of irregularly shaped steel structures.

[0012] Optionally, the system has an abnormal interruption protection function. When the contact vertical tool setting module detects an abnormal change in contact force or the laser ranging feedback module loses data, the control center immediately locks the posture of the serial robotic arm and triggers an alarm.

[0013] Optionally, the system also includes a multi-source signal logic verification module to solve the problem of interference from high concentrations of smoke and dust at the dismantling site on laser ranging; The multi-source signal logic verification module obtains the distance change rate of the laser ranging feedback module and the instantaneous current load value of each joint motor of the serial robotic arm. The control center has a light-force mutual verification logic: when the distance change rate exceeds the preset mutation threshold, but the instantaneous current load value remains within the steady-state fluctuation range, it is determined that the data of the laser ranging feedback module is distorted due to smoke and dust obstruction. The control center then blocks the current Z-axis compensation command and maintains the cutting height of the previous moment. The control center performs normal fine-tuning of the serial robotic arm only when the rate of change of distance is positively correlated with the trend of change of instantaneous current load value.

[0014] Optionally, the system also includes a stiffness-coupled adaptive cruise module to address the risk of tool clamping caused by stress release inside the variable cross-section workpiece; The stiffness-coupled adaptive cruise module monitors the current arm span and drive current in the feed direction of the serial robotic arm in real time. The control center is preset with a dynamic load threshold table based on the arm span length. The longer the arm span length, the lower the dynamic load threshold is set. When the drive current is detected to exceed the current dynamic load threshold, the control center determines that there is a risk of tool clamping and generates a micro-retraction command and a deceleration command. It controls the serial robotic arm to first move in the reverse direction along the original path to release stress, and then feed again at a reduced speed.

[0015] Secondly, the present invention provides a field dismantling robot, including a tracked mobile chassis, a series of robotic arms mounted on the chassis, a cutting head assembly disposed at the end of the series of robotic arms, a dust cover covering the cutting head assembly, and a sunken electrical cabinet integrated on the chassis. The robot is equipped with an adaptive control system for disassembling complex geometries as described in any of the first aspects; The host computer of the adaptive control system is directly integrated into the robot body to realize localized control of the serial robotic arm and cutting head assembly.

[0016] The present invention has achieved the following beneficial effects: This invention achieves high-precision adaptive disassembly of complex curved workpieces through the coordinated control of contact-type vertical tool setting and laser ranging feedback. The system uses physical contact sampling to establish the normal vector reference of the local cutting plane, ensuring that the cutting head enters the tool vertically. Combined with real-time ranging data, it dynamically corrects the vertical motion parameters of the robotic arm, effectively eliminating the influence of workpiece surface deformation and unevenness on cutting quality. This ensures that the cutting head maintains a constant working height and optimal focal length during the feeding process, improving the flatness of the cut.

[0017] This invention constructs a multi-source signal logic verification mechanism and a stiffness-coupled adaptive protection strategy, enhancing the system's robustness under harsh working conditions. By fusing the laser distance change rate and the joint motor current load characteristics, the system can accurately eliminate false signals caused by smoke and dust obstruction, preventing malfunctions of the robotic arm. Simultaneously, the logic of dynamically adjusting the load threshold based on the robotic arm's reach length enables the system to sensitively detect tool clamping risks and automatically perform micro-retraction and deceleration recutting, effectively mitigating the risk of equipment damage caused by the release of internal stress in the workpiece.

[0018] This invention employs a recessed electrical cabinet layout and environmentally adaptable dust control, achieving comprehensive optimization of overall machine performance. The embedded design of the electrical cabinet lowers the chassis's center of gravity using its own weight, improving anti-tipping capability and providing physical protection for core control components. The environmentally adaptable dust control module can proactively adjust the negative pressure power according to the cutting speed, ensuring high dust collection rates while avoiding excessive negative pressure interference with the electric arc, enabling the equipment to handle high-intensity dismantling tasks in unstructured outdoor environments.

[0019] Other features and advantages of the invention will be set forth in the following description, and will be apparent in part from the description, or may be learned by practicing the invention. The objects and other advantages of the invention may be realized and obtained by means of the structures particularly pointed out in the written description and the accompanying drawings.

[0020] The technical solution of the present invention will be further described in detail below with reference to the accompanying drawings and embodiments. Attached Figure Description

[0021] The accompanying drawings are provided to further illustrate the invention and form part of the specification. They are used in conjunction with embodiments of the invention to explain the invention and do not constitute a limitation thereof. In the drawings: Figure 1 This is a schematic diagram of an adaptive control system for disassembling complex geometries according to an embodiment of the present invention. Detailed Implementation

[0022] The preferred embodiments of the present invention will be described below with reference to the accompanying drawings. It should be understood that the preferred embodiments described herein are for illustration and explanation only and are not intended to limit the present invention.

[0023] This invention relates to a robot specifically designed to address the challenge of high-precision, automated dismantling of waste materials with complex curved surfaces and variable cross-sectional geometry, such as wind turbine blades, in unstructured outdoor environments. In practical applications, such as decommissioned wind farms, the ground environment is often covered with gravel, mud, or is on slopes, and the power supply is unstable. This necessitates that the robot possess extremely high environmental adaptability and self-sufficient control capabilities.

[0024] The field dismantling robot provided in this embodiment has a main structure including a tracked mobile chassis, a series of robotic arms mounted on the front rotating platform of the chassis, a cutting head assembly located at the end flange of the series of robotic arms, a dust cover covering the cutting head assembly, and a sunken electrical cabinet integrated into the internal frame of the chassis.

[0025] Specifically, the tracked mobile chassis serves as the mobile base and power source for the entire system. Considering the accessibility requirements of the dismantling site, the chassis uses wide, engineering-grade rubber tracks, preferably 400mm to 600mm wide, with an internal high-strength steel wire mesh layer. These tracks provide low ground pressure and excellent obstacle-crossing ability, preventing the vehicle from getting stuck in muddy work areas. The chassis's drive system uses dual hydraulic motors to independently drive the tracks on both sides, coupled with a planetary gear reducer, enabling 360-degree zero-radius turning on the spot, greatly improving mobility in narrow waste piles. To ensure overall stability during long-reach operations (e.g., extending beyond 3 meters) with the tandem robotic arm and to prevent the risk of tipping over due to excessive arm length, hydraulically driven auxiliary support legs are designed at the four corners of the chassis. In stationary operation mode, the support legs extend downwards and lift the chassis, suspending the tracks and forming a rigid four-point support platform, completely eliminating the impact of elastic deformation of the travel suspension system on cutting accuracy.

[0026] Unlike traditional mobile robots that stack control cabinets directly on top of the vehicle body, this embodiment designs the electrical cabinet as a sunken structure embedded in the internal cavity of the chassis frame. This electrical cabinet integrates an industrial control computer (host computer), a PLC logic controller, a multi-axis servo drive group, a high-voltage frequency converter (for the dust removal fan), an isolation transformer, and a large-capacity lithium iron phosphate battery pack. This sunken layout is based on three main engineering considerations: First, utilizing the significant physical weight of the electrical components (typically exceeding 200kg) as counterweight significantly lowers the center of gravity, improving anti-tipping capabilities and allowing the robotic arm to carry heavier cutting equipment. Second, the high-strength alloy steel plate structure of the chassis provides physical protection for the delicate electrical components, effectively preventing heavy scrap or splashing molten steel from damaging the control system during disassembly. Finally, the sunken layout shortens the wiring distance between the servo drives, chassis drive motors, and robotic arm base motors, effectively reducing electromagnetic interference (EMI) generated by the power cables and improving the signal-to-noise ratio of low-voltage control signals.

[0027] The serial robotic arm is mounted at the front of the chassis, preferably an industrial-grade articulated robotic arm with six or seven degrees of freedom (adding redundant elbow joints). Compared to Cartesian robots, the serial robotic arm offers a larger workspace and more flexible posture adjustment capabilities, easily navigating obstacles such as reinforcing ribs, flanges, and manholes on workpiece surfaces, achieving omnidirectional coverage of complex geometries. Each joint of the robotic arm is designed with an IP67 protection rating, and double-layer sealing rings are installed at joint gaps to prevent metal dust from entering the reducer. The end effector of the robotic arm connects to the cutting head assembly via a quick-change device.

[0028] The cutting head assembly is the core end effector for performing disassembly operations. In this embodiment, the assembly integrates a high-frequency arc-igniting plasma cutting torch, suitable for cutting various metals and composite materials with thicknesses ranging from 5mm to 50mm. The cutting head assembly also integrates multiple sensors, including a force probe (or force sensor) for initial contact sensing and a laser displacement sensor for real-time distance measurement. The mounting positions of these sensors are calibrated to maintain a fixed geometric transformation relationship with the center of the cutting nozzle.

[0029] To address the smoke and dust pollution generated during the cutting process, the cutting head assembly is externally encased in a hydrodynamically optimized dust collection hood. Preferably, this dust collection hood is a negative pressure chamber with a flexible skirt. The flexible skirt is made of high-temperature resistant (withstanding temperatures above 500°C) and wear-resistant silicone fiberglass cloth, which can closely conform to the uneven surface of the workpiece, forming a semi-enclosed suction space. The dust collection hood is connected to the dust collection equipment integrated into the chassis via a negative pressure-resistant corrugated pipe, ensuring that smoke and dust are efficiently extracted the moment they are generated.

[0030] The host computer for the adaptive control system used in the robot's disassembly of complex geometries is directly integrated into the robot's recessed electrical cabinet. Complex kinematic calculations, sensor data fusion, and adaptive decision-making logic are all completed locally on the robot, without relying on remote servers or cloud computing.

[0031] like Figure 1 As shown, the adaptive control system in this embodiment includes four core functional modules: a contact-type vertical tool setting module, a serial robotic arm linear motion module, a laser ranging feedback module, and a control center. In addition, to handle special working conditions, it also includes an environmentally adaptive dust removal control module, a multi-source signal logic verification module, and a stiffness-coupled adaptive cruise module. These modules are based on time-slice scheduling tasks using a real-time operating system (RTOS) and interact with the underlying servo drivers and sensors in real time via a high-speed industrial fieldbus (such as EtherCAT or Profinet).

[0032] Before dismantling begins, the orientation of the cutting head relative to the workpiece surface is usually unknown. Due to long-term exposure to wind and sun or the pressure of transportation, the surface of the workpiece to be dismantled (such as discarded wind turbine blades) may suffer severe deformation, twisting, or collapse. If the cutting head cannot be perpendicular to the workpiece surface, it will result in dispersed cutting energy (incomplete cut), a beveled cut (causing a bevel), or even damage to the cutting nozzle. Traditional vision-based tool setting methods are prone to failure in strong outdoor light or under conditions of oily or reflective workpiece surfaces. Therefore, this system designs a physical contact-based vertical tool setting module.

[0033] This module is equipped with a highly sensitive contact force sensing unit. This unit can be a six-dimensional force / torque sensor integrated between the end flange and the tool of the robotic arm, or it can be a sensorless force control algorithm module based on a joint motor current loop observer. Its core logic lies in establishing geometric references using physical contact. The specific workflow is as follows: First, the control center, based on the operator's instructions, controls the robotic arm to move the cutting head to a preparatory point above the area to be cut.

[0034] Subsequently, the system enters the exploration mode. In this mode, the contact vertical tool setting module controls the cutting head to approach the workpiece at an extremely low speed (e.g., 2 mm / s to 5 mm / s) along the negative Z-axis of the tool coordinate system (i.e., the direction the cutting nozzle is pointing).

[0035] When the probe (or nozzle protective cap) on the cutting head touches the workpiece surface, and the contact force detected by the contact force sensing unit reaches a preset threshold (e.g., 3N to 10N, which is set according to the workpiece material stiffness to ensure reliable triggering while preventing damage to the workpiece), the module immediately triggers a position latching signal. The control center responds to this signal, instantly locking the encoder values ​​of each joint, and records the base coordinate system spatial coordinates P1 of the current point through forward kinematics calculation.

[0036] To obtain the normal vector of the workpiece surface, this module executes a multi-point topology sampling strategy. A single point cannot determine the planar orientation. Therefore, the system controls the robotic arm to perform a sequence of actions—retraction, translation, and re-exploration—within the same local area (e.g., within a 50mm radius centered on the tool entry point)—to acquire the spatial coordinates of at least three non-collinear points: P1(x1,y1,z1), P2(x2,y2,z2), and P3(x3,y3,z3). To improve fitting accuracy, acquiring five points is preferred.

[0037] Subsequently, the geometric processing unit inside the control center uses the coordinates of these three (or more) points to fit the tangent plane of the local region using spatial geometric algorithms (such as the vector cross product method or least squares plane fitting), and calculates the unit normal vector of the tangent plane. .

[0038] Once the normal vector is obtained The control center then calculates the current cutting head axis vector. With normal vector Rotation matrix between Finally, attitude adjustment commands are generated to drive the wrist joints (J4, J5, J6 axes) of the tandem robotic arm to perform a compound rotation, ensuring that the axis of the cutting head is strictly parallel to the normal vector. This allows for vertical tool setting.

[0039] Dismantling operations typically require cutting straight slits to facilitate the packaging and transportation of waste materials. However, the inherent motion property of a serial robotic arm is joint rotation; to move in a straight line in Cartesian space, high-precision inverse kinematics calculations are essential. The serial robotic arm linear motion module is responsible for calculating the motion parameters of each joint of the serial robotic arm in real time based on a preset dismantling path (starting point S, ending point E, velocity V).

[0040] This module integrates a trajectory smoothing unit. In actual control, if a straight path is simply interpolated linearly, the nonlinear dynamics of the robotic arm (such as the change in moment of inertia with attitude) may cause sudden changes in joint angular velocity or excessive angular acceleration at certain locations (especially near singular points), resulting in low-frequency vibrations of the robotic arm body. These vibrations will be directly reflected on the cut surface, forming wavy lines or sawtooth patterns.

[0041] Therefore, the trajectory smoothing unit adopts a control strategy that combines discretization with dynamic constraints. The specific implementation steps are as follows: The first step is discretization: the straight trajectory command in Cartesian space is discretized into a series of dense path point sequences according to the control period (e.g., 1ms).

[0042] The second step is inverse kinematics: perform inverse kinematics calculations for each path point to obtain the corresponding joint angle sequence.

[0043] The third step is smoothing constraints: S-curve velocity profile planning is performed on the angle sequence of each joint. This unit monitors and limits the velocity, acceleration, and jerk (rate of change of acceleration) of each joint in real time. If a certain trajectory segment is detected that causes the jerk of any joint to exceed the motor's tolerance limit, the unit will automatically stretch the time axis of that trajectory segment, that is, while keeping the geometric path unchanged, locally reduce the feed rate to achieve smoother motion.

[0044] This deep smoothing process eliminates the rigid impact and vibration of the serial robotic arm when performing linear motion, ensuring that the cutting head has sufficient trajectory tracking accuracy and dynamic stability when performing multi-axis linkage linear feed motion along the surface of the workpiece to be disassembled.

[0045] Furthermore, during the cutting head's movement, the surface undulations of the workpiece are dynamically changing and unpredictable (e.g., the variable cross-sectional characteristics of wind turbine blades). Initial tool setting data alone cannot guarantee a constant cutting height (i.e., focal length) throughout the entire cutting process. Therefore, this system incorporates a laser ranging feedback module.

[0046] This module utilizes a high-frequency laser displacement sensor (preferably with a sampling rate of 1kHz or higher) mounted on the side of the cutting head to monitor the vertical distance between the nozzle end face of the cutting head and the surface of the workpiece to be disassembled in real time during the linear feed motion of the cutting head. .

[0047] This module has an optimal cutting focal length threshold range set. For example, for 100A plasma cutting, the optimal arc voltage height is 8mm, with an allowable deviation of ±1mm, so the range is [7mm, 9mm].

[0048] When monitoring data When the system is within this threshold range, it is considered to be in normal operating condition and no intervention is performed (a dead zone is introduced to avoid oscillation).

[0049] When monitoring data When it exceeds the threshold range (e.g.) (This indicates that the workpiece surface is raised, posing a risk of impact with the gun). The module immediately feeds back the deviation value to the control center.

[0050] The control center is connected to the contact-type vertical tool setting module, the serial robotic arm linear travel module, and the laser ranging feedback module.

[0051] When the distance deviation signal is received from the laser ranging feedback module, the control center generates a compensation command superimposed on the Z-axis direction (tool coordinate system). This command drives the tandem robotic arm to maintain a linear feed speed in the XY plane. While remaining constant, it undergoes slight vertical movement along the Z-axis. This composite motion mode allows the cutting head to adaptively conform to the undulations of the workpiece surface, maintaining a constant working height at all times.

[0052] In actual dismantling operations, especially when using plasma cutting or laser cutting, high concentrations of metallic fumes and intense electric arc light are generated. These environmental factors can easily interfere with laser displacement sensors, causing their readings to become distorted. For example, if a cloud of smoke drifts under the sensor, the sensor may falsely report a sudden change in distance to 0 (thinking it has hit an obstacle), or the optical path may be blocked, resulting in no reading. If the system directly relies on data from a single sensor, it can lead to malfunctions of the robotic arm (such as sudden lifting or abrupt stopping), severely impacting operational efficiency and safety.

[0053] To address this issue, this system introduces a multi-source signal logic verification module. Optical signals (ranging) are easily affected by environmental interference, but force / electrical signals (motor load) reflect actual physical contact and are less susceptible to visual interference. The specific implementation logic of this module is as follows: This module acquires the distance data and its rate of change from the laser ranging feedback module in real time. ), and the instantaneous current load values ​​of the motors of each joint of the serial robotic arm ( ) and its changing trends.

[0054] The control center has a pre-installed light-force mutual verification logic algorithm: Scenario 1 (Smoke and Dust Interference): When the rate of change in distance to the laser sensor is detected... If the abrupt change exceeds a preset threshold (e.g., a distance jump exceeding 20mm within 10ms, indicating extremely high acceleration, typically achievable without mechanical motion), the system enters a suspicious state. At this point, the system immediately checks the instantaneous current load value of the joint motor. If the current load remains within the steady-state fluctuation range (i.e., the robotic arm is not experiencing additional physical resistance or undergoing drastic acceleration or deceleration), the control center determines that the laser data abrupt change is a false signal caused by smoke obstruction. In this case, the control center disables the current Z-axis compensation command, forcibly maintaining the cutting height from the previous moment and continuing inertial feed until the laser signal returns to normal or a timeout alarm is triggered.

[0055] Scenario 2 (Real Sudden Change): Only when the rate of change of distance and the trend of change of instantaneous current load value are positively correlated, for example, when the laser shows that the distance is decreasing sharply (approaching the workpiece), and at the same time the current load of the joint motor related to the Z-axis has indeed increased significantly (suggesting that it has been subjected to the reaction force of the air cushion or slight physical contact), will the control center determine that it is a real sudden change in the shape of the workpiece or a collision risk, and immediately perform normal fine adjustment or emergency stop to avoid danger.

[0056] Through this logical verification, the system effectively shields against false alarms caused by smoke and dust interference, ensuring the robot's robustness in harsh environments.

[0057] Furthermore, when cutting large variable cross-section workpieces (such as the beam structure of wind turbine blades), the cut often closes during the cutting process due to the release of residual stress within the material, tightly clamping the cutting head. This "clinging" phenomenon has a significant impact on rigidly connected serial robotic arms, potentially leading to motor overload and burnout or gear breakage in the reducer.

[0058] Traditional collision detection typically uses a fixed current threshold. However, a serial robotic arm is a typical variable stiffness system: it is highly stiff when in a coiled position and less stiff when fully extended, with the motor experiencing a very high torque-to-lever ratio. Using a fixed threshold might result in false alarms due to normal gravitational torque during long arm extensions, or sluggish response to the gripper during short arm extensions.

[0059] The stiffness-coupled adaptive cruise module of this system monitors the current arm span of the tandem robotic arm in real time. (Euclidean distance from the end to the center of the base) and the drive current in the feed direction.

[0060] The control center has a preset dynamic load threshold table based on arm span length. This table utilizes the inverse relationship: arm span length... The longer the duration, the higher the set dynamic load threshold. The lower the threshold, the more sensitive the protection; the shorter the arm span, the higher the threshold, allowing for greater cutting forces.

[0061] When the drive current exceeds the current dynamic load threshold, When the control center detects a risk of tool clamping, the system does not immediately stop (as an emergency stop could cause the tool head to become stuck). Instead, it generates a small retraction command and a speed reduction command. The control center then instructs the tandem robotic arm to first make a slight reverse movement along the original path (e.g., retract 2mm) to release the stress clamping, and then retry feeding at a reduced speed (e.g., 50% of the original speed). This significantly improves the adaptability to complex stress conditions.

[0062] In existing field dismantling operation technology systems, dust removal systems are often regarded as auxiliary facilities independent of the robot itself, typically possessing only simple start-stop control functions, i.e., open-loop constant power mode. However, the operating status of the dust removal system is strongly coupled with the cutting quality and sensor accuracy.

[0063] Specifically, when the robotic arm is in a low-speed precision cutting state (such as cutting small holes or complex intersection lines), if the dust removal system maintains the rated high-power negative pressure suction, it is very easy to cause the plasma arc or protective airflow at the cutting nozzle to be blown off course, which will affect the perpendicularity of the cut or even cause the arc to break. Conversely, when the robotic arm is in a high-speed linear cutting state, the amount of metal dust generated per unit time increases exponentially. The constant dust removal power often cannot capture the burst of dense smoke in time. The overflowing smoke will directly block the optical path of the laser rangefinder, causing the optical-force mutual verification logic mentioned in the above embodiment to be frequently triggered, which seriously reduces the smoothness of system operation.

[0064] Therefore, the environmentally adaptable dust removal control module in this embodiment is a feedforward and feedback composite control system based on a speed-dust generation physical model. In terms of hardware connectivity, this module reads the planned end-effector composite feed speed from the linear motion module of the serial robotic arm in real time via an industrial fieldbus (such as EtherCAT or ModbusTCP), and controls the variable frequency drive of the external dust removal fan via an analog interface or communication protocol. In terms of specific control logic, the module executes the following steps: First, a dust generation prediction model is established. The control center is pre-loaded with dust generation characteristic curves for different materials (such as carbon steel, stainless steel, and fiberglass). These curves are constructed based on physical facts: at different cutting thicknesses... Under fixed conditions, the volume of smoke and dust generated per unit time With feed rate They are positively correlated, that is For composite materials such as fiberglass, the thermal decomposition of their resin matrix produces a large amount of dense smoke, resulting in a high dust generation coefficient. It is set at 1.5 to 2 times that of carbon steel.

[0065] Secondly, timing advance compensation (feedforward control) is implemented. Considering the large rotational inertia of the dust collector fan rotor, accelerating from idle to full speed typically takes several seconds (response lag), while the robotic arm's acceleration is often completed within hundreds of milliseconds. To address this physical time lag issue, the control center employs a look-forward control strategy. The control center reads future data from the motion planning buffer... The command speed is set at a specific moment (e.g., 1500 milliseconds in the future). When the system detects that a high-speed linear cutting command is about to be executed, it sends an up-frequency command to the dust collector inverter before the robotic arm actually accelerates. This arrangement ensures that when the cutting head actually reaches the high-speed cutting state and generates a large amount of dust, the negative pressure flow field inside the dust collector hood is precisely established to the optimal collection intensity (e.g., -3000 Pa), achieving precise matching.

[0066] Finally, attitude and differential pressure compensation (feedback control) are implemented. A micro differential pressure sensor is integrated into the suction throat of the dust collector hood to monitor the actual negative pressure status in real time. When the cutting head undergoes a large-angle flip (e.g., a roll angle greater than 45 degrees) while disassembling complex curved surfaces, the gap between the flexible skirt of the dust collector hood and the workpiece surface increases, leading to increased air leakage and a decrease in effective negative pressure. At this time, regardless of the feedforward command, the module will, based on the feedback from the micro differential pressure sensor, forcibly increase the fan speed to compensate for air leakage loss, always maintaining an effective capture air velocity inside the hood of no less than 20 m / s.

[0067] The root of a wind turbine blade typically presents as a cone-shaped cylinder with a gradually changing diameter, and the wall thickness gradually decreases from 50 mm at the root towards the tip. The challenges in disassembling it lie in: the material's poor thermal conductivity (leading to heat accumulation), the significant thickness variation resulting in varying energy demands, and the ease with which cuts can self-heal due to resin melting. To address this challenge, this process package integrates the following strategies: In terms of geometric path planning, the process package generates a continuous trajectory that spirals along the generatrix of the cone, rather than segmented circumferential cutting (to prevent cylinder collapse). During execution, the system uses the surface model obtained by the contact-type vertical tool setting module to calculate the normal vector of the cutting head's tangent plane at each point in real time, driving the robotic arm's wrist joint to make continuous micro-posture corrections, ensuring that the high-temperature jet always penetrates the cylinder wall radially and vertically.

[0068] To prevent molten resin from re-adheding behind the cut, the process package activates a high-frequency micro-motion mode. The control center drives the robotic arm to feed along the main path while simultaneously superimposing a sinusoidal micro-motion perpendicular to the feed direction, with a frequency of 2 Hz to 5 Hz and an amplitude of 2 mm to 4 mm. This zigzag motion widens the kerf, making it easier for the molten slag to be blown away by the high-pressure airflow.

[0069] In addition, the process package includes a built-in stroke-wall thickness mapping table. As the cutting head moves from the blade root to the tip, the system linearly reduces the output current of the plasma power supply (e.g., from 130 amps to 60 amps) and the gas pressure via an analog interface based on the estimated wall thickness reduction trend, effectively preventing carbonization or combustion of the matrix material due to excessive heat input at thin-walled areas.

[0070] Furthermore, considering the unstructured nature of field operations and the unmanned or minimally staffed working conditions, safety is the highest priority in this system design. This embodiment constructs a three-level interruption protection system, specifically including: Level 1 protection, predictive pause: Triggering conditions: The laser ranging feedback module detects data loss (such as instantaneous strong light or dense smoke obstruction) but the duration is less than 200 milliseconds; or the stiffness coupling adaptive cruise module detects slight fluctuations in cutting resistance (current increase is less than 15%).

[0071] Response Action: The control center executes zero-speed hold. That is, the robotic arm pauses feeding at the current trajectory point, maintains its posture, and does not extinguish the guide arc, but waits for the signal to recover. If the signal returns to normal within a set time (e.g., 2 seconds), the system automatically resumes feeding without manual intervention. This design avoids frequent shutdowns caused by transient sensor noise, ensuring the continuity of operation.

[0072] Level 2 protection: Controlled emergency stop and reversal: Triggering conditions: The stiffness coupling module detects that the drive current exceeds the dynamic load threshold (meaning that "clamping" or "jamming" has occurred); or it detects an arc interruption signal.

[0073] Response action: The control center immediately triggers the interrupt service routine, instructing the servo drive to stop moving at maximum deceleration.

[0074] Automatic micro-retraction logic: Controls the robotic arm to move in the reverse direction along the original path vector. (e.g., 5 mm) to release the mechanical clamping force between the cutter head and the workpiece.

[0075] The robotic arm is raised to a safe height (Z+20 mm) and sends a fault alarm code to the operator, awaiting manual confirmation or replacement of vulnerable parts. This logic not only protects the equipment but also greatly reduces the difficulty of handling situations where the tool jams.

[0076] Level 3 protection: Hardware-level fuse: Triggering conditions: The contact vertical tool setting module detects a step change in contact force (e.g., greater than 50 Newtons, indicating a rigid collision); or the underlying EtherCAT communication is lost (heartbeat timeout).

[0077] Response Action: This protection does not rely on the host computer software logic, but is implemented by the internal hardware circuitry of the servo drive. Once triggered, the drive directly activates the STO (Safe Torque Off) function, cutting off the motor power supply. The mechanical brake instantly and physically locks all joint axes to prevent the robotic arm from falling due to gravity. Simultaneously, the main contactor of the plasma power supply is disconnected. In this state, the system must be manually reset by a qualified professional.

[0078] The field dismantling robot of this invention has its adaptive control system's host computer (industrial personal computer, IPC) physically integrated into a sunken electrical cabinet within the tracked chassis. This electrical cabinet employs a unique double-layer vibration isolation and thermal balance design, enabling it to adapt to harsh outdoor environments characterized by high and low temperatures, high dust levels, and severe vibrations.

[0079] Obviously, those skilled in the art can make various modifications and variations to this invention without departing from its spirit and scope. Therefore, if these modifications and variations fall within the scope of the claims of this invention and their equivalents, this invention also intends to include these modifications and variations.

Claims

1. An adaptive control system for complex geometry disassembly, characterized by, include: The contact-type vertical tool setting module is used to control the cutting head to perform multi-point contact sampling with the surface of the workpiece to be disassembled before the disassembly operation begins. Based on the sampling data, the normal vector of the contact area is calculated, and the posture of the cutting head is adjusted so that its axis is parallel to the normal vector. The tandem robotic arm linear motion module is used to calculate the motion parameters of each joint of the tandem robotic arm based on a preset disassembly path using an inverse kinematics algorithm, and control the cutting head to perform multi-axis linkage linear feed motion along the surface of the workpiece to be disassembled. The laser ranging feedback module is used to monitor the vertical distance between the cutting head and the surface of the workpiece to be disassembled in real time during the linear feed motion of the cutting head, and to feed the monitoring data back to the control center. The control center is connected to the contact-type vertical tool setting module, the tandem robotic arm linear travel module, and the laser ranging feedback module, respectively, and is used to correct the motion parameters of the tandem robotic arm in real time based on the monitoring data, so as to maintain a constant working height between the cutting head and the workpiece surface.

2. The adaptive control system for disassembling complex geometries according to claim 1, characterized in that, The contact-type vertical tool setting module is equipped with a contact force sensing unit; When the probe on the cutting head touches the workpiece surface and the contact force reaches a preset threshold, the contact-type vertical tool setting module locks the current coordinates. By obtaining the coordinates of at least three non-collinear points in the same local region, a tangent plane is fitted to determine the normal vector.

3. The adaptive control system for disassembling complex geometries according to claim 1, characterized in that, The linear motion module of the serial robotic arm includes a trajectory smoothing unit, which is used to discretize the linear trajectory command in Cartesian space into a continuous angular displacement sequence in joint space, and to smooth the velocity and acceleration of each joint to eliminate the jitter of the serial robotic arm when performing linear motion.

4. The adaptive control system for disassembling complex geometries according to claim 1, characterized in that, The laser ranging feedback module is set with an optimal cutting focal length threshold range. When the monitored data exceeds the threshold range, the control center generates a Z-axis compensation command, driving the serial robotic arm to perform normal fine-tuning while maintaining linear feed.

5. The adaptive control system for disassembling complex geometries according to claim 1, characterized in that, The system also includes an environmentally adaptive dust control module, which is used to synchronously adjust the negative pressure power of the external dust removal equipment according to the feed speed of the linear walking module of the serial robotic arm, so as to ensure that the dust collection rate at the cutting head matches the current cutting efficiency.

6. The adaptive control system for disassembling complex geometries according to claim 1, characterized in that, The control center is pre-loaded with disassembly process packages for different complex geometries, including the variable cross-section conical body of wind turbine blades and the surface of irregularly shaped steel structures.

7. The adaptive control system for disassembling complex geometries according to claim 1, characterized in that, The system has an abnormal interruption protection function. When the contact vertical tool setting module detects an abnormal change in contact force or the laser ranging feedback module loses data, the control center immediately locks the posture of the serial robotic arm and triggers an alarm.

8. The adaptive control system for disassembling complex geometries according to claim 1, characterized in that, The system also includes a multi-source signal logic verification module to solve the problem of interference from high concentrations of smoke and dust at the dismantling site on laser ranging; The multi-source signal logic verification module obtains the distance change rate of the laser ranging feedback module and the instantaneous current load value of each joint motor of the serial robotic arm. The control center has a light-force mutual verification logic: when the distance change rate exceeds the preset mutation threshold, but the instantaneous current load value remains within the steady-state fluctuation range, it is determined that the data of the laser ranging feedback module is distorted due to smoke and dust obstruction. The control center then blocks the current Z-axis compensation command and maintains the cutting height of the previous moment. The control center performs normal fine-tuning of the serial robotic arm only when the rate of change of distance is positively correlated with the trend of change of instantaneous current load value.

9. The adaptive control system for disassembling complex geometries according to claim 1, characterized in that, The system also includes a stiffness-coupled adaptive cruise module to address the risk of tool clamping caused by stress release inside the variable cross-section workpiece; The stiffness-coupled adaptive cruise module monitors the current arm span and drive current in the feed direction of the serial robotic arm in real time. The control center is preset with a dynamic load threshold table based on the arm span length. The longer the arm span length, the lower the dynamic load threshold is set. When the drive current is detected to exceed the current dynamic load threshold, the control center determines that there is a risk of tool clamping and generates a micro-retraction command and a deceleration command. It controls the serial robotic arm to first move slightly in the opposite direction along the original path to release stress, and then feed again at a reduced speed.

10. A field dismantling robot, characterized in that, It includes a tracked mobile chassis, a series of robotic arms mounted on the chassis, a cutting head assembly located at the end of the series of robotic arms, a dust cover covering the cutting head assembly, and a sunken electrical cabinet integrated on the chassis. The robot is equipped with an adaptive control system for disassembling complex geometries as described in any one of claims 1 to 9; The host computer of the adaptive control system is directly integrated into the robot body to realize localized control of the serial robotic arm and cutting head assembly.

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