Topology and dimension synchronous optimization design of 5-DoF parallel robots for in-situ machining of large-scale steel components

• Published in: Mechanism and machine theory 2023-01, Vol.179, p.105105, Article 105105
• Main Authors: Chen, Kaixuan, Wang, Meng, Huo, Xinming, Wang, Panfeng, Sun, Tao
• Format: Article
• Language: English
• Subjects: 5-DoF Parallel robot; In-situ machining; Large-scale steel components; Topology and dimension synchronous design
• ISSN: 0094-114X; 1873-3999
• DOI: 10.1016/j.mechmachtheory.2022.105105

•A class of 5-DoF parallel robots for in-situ machining is designed.•A topology and dimension synchronous design approach is proposed.•A novel full-size 5-DoF robot prototype is fabricated. Robotic machining has been successfully applied in thin-walled aluminum alloy components, but its ability to machine large steel components in-situ remains to be improved. To address this issue, a class of five-degree-of-freedom (5-DoF) parallel machining robots with high stiffness-mass ratio, easy installation, compact structure and reconfigurability is designed. To solve the problem of separation of topology and dimension designs, a topology and dimension synchronous optimization design method is proposed by parametric characterization and performance differential map of the robot. Three performance indices, namely, axial stiffness, feed stiffness, and mass are mainly considered. The influences of topology and layout on the performance are extensively investigated. We developed a full-size prototype according to the optimization results. Prototype data demonstrates that the 5-DoF parallel robot offers satisfactory static behavior, thereby fulfilling the essential requirements for the in-situ machining of large-scale steel components. Lastly, several in-situ machining robotic solutions are presented, thereby laying the foundation for other in-situ machining of large-scale steel components.