Due to complex nonlinear closed-loop constraints and structural flexibility, the dynamic modeling and control issue on flexible parallel robots is much more challenging compared to serial counterparts. Oriented to the demand of the high-end manufacturing field, this paper proposes a novel lightweight redundant parallel robot with cross layout of guide rail. Based on assumed mode discretization and Kane’s formulation, a general rigid-flexible coupling dynamic model of arbitrary branch incorporating n-order modes is derived. Leveraging modular ideology, the complete rigid-flexible coupling dynamic model of the system is established combining with nonlinear constraint equations, which is solved by the Runge-Kutta algorithm, modal truncation and forward dynamics methodology. The dynamic response comparison results between the redundant parallel robot and the non-redundant parallel robot reveal that the redundant actuation can suppress the elastic vibration. The rigid-flexible coupling dynamic model is then validated by a physical simulation model developed through the MATLAB/Simscape® platform using the finite segment approach. The electromechanical coupling dynamic model is further formulated by integrating the rigid-flexible coupling dynamic model with the permanent magnet synchronous motor and smart material. An adaptive intelligent composite control strategy is proposed to achieve trajectory tracking and vibration suppression. The comparison results with the other three control strategies demonstrate that the adaptive intelligent composite control strategy has superior control performance, exhibiting potential application prospects.
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