0065-叉形件工藝及車床夾具設計

0065-叉形件工藝及車床夾具設計,叉形,工藝,車床,夾具,設計 叉形件加工工藝規(guī)程 工序卡片 零件名稱 材 料 硬度 工序名稱 工序號 設備 定位 夾緊 共 頁 第 頁 序號 加 工 要 求 說 明 夾具 刀具 量具 序 目 錄 產(chǎn)品型號 ZL——10 共2頁 零件組號 ZA10——10——13 第1 頁 工序號 工 序 名 稱 設 備 工序卡片數(shù) 附注 5 毛坯（棒料） 鋁床 1 10 下料 C620 1 15 車端面打中心孔 C620 1 20 粗車外圓,車錐度 C620 1 25 粗銑平面，銑槽 X60 1 30 打毛刺 鉗工臺 11 35 打中心孔 C620 1 40 打毛刺 鉗工臺 45 細車外圓 C620 1 50 鉆孔 Z518 1 55 打毛刺 鉗工臺 60 銑外圓 X52k 1 65 打毛刺 鉗工臺 70 銑平面 X52k 1 75 打毛刺 鉗工臺 80 打標記 鉗工臺 1 85 中檢 檢驗臺 1 90 熱處理 電爐 工 序 目 錄 產(chǎn)品型號 ZL——10 共2頁 零件組號 ZA10——10——13 第2頁 工序號 工 序 名 稱 設 備 工序卡片數(shù) 附注 95 修復基準 C620 1 100 精車外圓 C620 1 105 磨外圓 M114 1 110 磨平面及槽 MT120A 1 115 鏜孔 C620 1 120 磁粉探傷 探傷機 125 車螺紋 C620 1 130 鉆小孔 Z518 1 135 磨小臺 MT475A 1 140 表面處理 槽 1 145 終檢 檢驗臺 1 150 防銹，油封 槽 工序卡片 零件名稱 材 料 硬度 工序名稱 工序號 叉形件 30CrMnSiA YB674--73 毛坯 （棒料） 5 設備 鋁床 定位 夾緊 共1頁 第1頁 注：每個毛坯可生產(chǎn)20個。 序號 加 工 要 求 說 明 夾具 刀具 量具 1 毛坯由熱軋圓鋼經(jīng)退火處理 米尺 工序卡片 零件名稱 材 料 硬度 工序名稱 工序號 叉形件 30CrMnSiA YB674--73 下料 10 設備 C620 定位 夾緊 共1頁 第1頁 序號 加 工 要 求 說 明 夾具 刀具 量具 1 按上述要求下料，切斷刀寬不 三爪卡盤 切斷刀 游標卡尺 得大于5，切斷面與軸線垂直 工序卡片 零件名稱 材 料 硬度 工序名稱 工序號 叉形件 30CrMnSiA YB674--73 車端面 打中心孔 15 設備 鋁床 定位 夾緊 共1頁 第1頁 序號 加 工 要 求 說 明 夾具 刀具 量具 1 車端面 三爪卡盤 游標卡尺 2 打中心孔，孔深不得大于2.5 三爪卡盤 f1中心孔 塞規(guī) 3 調(diào)頭，重復上述步驟 工序卡片 零件名稱 材 料 硬度 工序名稱 工序號 叉形件 30CrMnSiA YB674--73 粗車外圓 車錐度 20 設備 C620 定位 夾緊 共1頁 第1頁 序號 加 工 要 求 說 明 夾具 刀具 量具 1 加工外圓表面 頂尖 Y714車刀 卡尺 2 粗車細外圓 頂尖 Y714車刀 卡尺 工序卡片 零件名稱 材 料 硬度 工序名稱 工序號 叉形件 30CrMnSiA YB674--73 粗銑平面 銑槽 25 設備 X60 定位 夾緊 共1頁 第1頁 序號 加 工 要 求 說 明 夾具 刀具 量具 1 銑槽 專用夾具 （三面刃銑刀）組合刀具 卡尺 尺規(guī) 下接NO.30,打毛刺 什錦銼 工序卡片 零件名稱 材 料 硬度 工序名稱 工序號 叉形件 30CrMnSiA YB674--73 打中心孔 35 設備 C620 定位 夾緊 共1頁 第1頁 序號 加 工 要 求 說 明 夾具 刀具 量具 1 中心鉆f1 下接NO.40,打毛刺 什錦銼 工序卡片 零件名稱 材 料 硬度 工序名稱 工序號 叉形件 30CrMnSiA YB674--73 細車外圓 45 設備 C620 定位 夾緊 共1頁 第1頁 序號 加 工 要 求 說 明 夾具 刀具 量具 1 細車外圓 專用頂尖 車刀 千分尺 工序卡片 零件名稱 材 料 硬度 工序名稱 工序號 叉形件 30CrMnSiA YB674--73 鉆孔 50 設備 Z518 定位 夾緊 共1頁 第1頁 序號 加 工 要 求 說 明 夾具 刀具 量具 1 鉆孔 鉆孔 專用夾具 麻花轉 塞規(guī) 2 要求孔軸線對外圓軸線的垂 直度為0.1 標準芯棒 3 鉆孔后打孔 下接NO.55,打毛刺 什錦銼 工序卡片 零件名稱 材 料 硬度 工序名稱 工序號 叉形件 30CrMnSiA YB674--73 銑外形 60 設備 X52K 定位 夾緊 共1頁 第1頁 序號 加 工 要 求 說 明 夾具 刀具 量具 1 銑外形 銑床夾具 f20指狀銑刀 卡尺 尺規(guī) 下接NO.65,去除毛刺 什錦銼 工序卡片 零件名稱 材 料 硬度 工序名稱 工序號 叉形件 30CrMnSiA YB674--73 銑平面 70 設備 X52K 定位 夾緊 共1頁 第1頁 序號 加 工 要 求 說 明 夾具 刀具 量具 1 銑外形 銑床夾具 指狀銑刀 深度尺 尺規(guī) 下接NO.75,打毛刺 什錦銼 工序卡片 零件名稱 材 料 硬度 工序名稱 工序號 叉形件 30CrMnSiA 打標記 80 設備 鉗工臺 定位 夾緊 共1頁 第1頁 序號 加 工 要 求 說 明 夾具 刀具 量具 1 按圖示要求打標記 虎銼 振動筆 工序卡片 零件名稱 材 料 硬度 工序名稱 工序號 叉形件 30CrMnSiA YB674--73 中檢 85 設備 檢驗臺 定位 夾緊 共1頁 第1頁 序號 加 工 要 求 說 明 夾具 刀具 量具 1 檢驗尺寸16.5-0.2 100% 千分尺 檢驗尺寸8.50.1 100% 下接NO.90，熱處理 硬度儀 后硬度為HRC36_41，進行 調(diào)質處理 工序卡片 零件名稱 材 料 硬度 工序名稱 工序號 叉形件 30CrMnSiA YB674--73 HRC36~41 修復基準 95 設備 C620 定位 夾緊 共1頁 第1頁 序號 加 工 要 求 說 明 夾具 刀具 量具 1 研磨中心孔，以去除熱處理 三爪卡盤 f1中心孔 塞規(guī) 后的氧化皮等 工序卡片 零件名稱 材 料 硬度 工序名稱 工序號 叉形件 30CrMnSiA YB674--73 HRC36~41 精車外圓 100 備設 C620 定位 夾緊 共1頁 第1頁 序號 加 工 要 求 說 明 夾具 刀具 量具 1 精車外圓f9.5-0.1 扁頂尖 頂尖 Y714車刀 千分尺 2 倒角0.3×30o 卡板 3 精車外圓f6.5-0.1 4 精車外圓f5-0.012 測量外圓時應卡在圓孔最低點 工序卡片 零件名稱 材 料 硬度 工序名稱 工序號 叉形件 30CrMnSiA YB674--73 HRC36~41 磨外圓 105 備設 M114 定位 夾緊 共1頁 第1頁 序號 加 工 要 求 說 明 夾具 刀具 量具 1 磨外圓f9.03h6 扁頂尖 頂尖 砂輪 千分卡尺 2 磨外圓f6h6 工序卡片 零件名稱 材 料 硬度 工序名稱 工序號 叉形件 30CrMnSiA YB674--73 HRC36~41 磨平面 及槽 110 備設 MT120A 定位 夾緊 共1頁 第1頁 序號 加 工 要 求 說 明 夾具 刀具 量具 1 磨床夾具 砂輪 千分尺 測量心軸 工序卡片 零件名稱 材 料 硬度 工序名稱 工序號 叉形件 30CrMnSiA YB674--73 HRC36~41 鏜孔 115 備設 C620 定位 夾緊 共1頁 第1頁 序號 加 工 要 求 說 明 夾具 刀具 量具 1 粗鏜孔f9.3+0.09 車床夾具 f9.3鏜刀 塞規(guī) 2 精鏜孔f9.8+0.036 f9.8鏜刀 3 鉸孔f10+0.015 f10鏜刀 4 倒角0.3×45o 锪鉆 下接NO.30,打毛刺 注：磁粉探傷前后均須清洗磁粉探傷要求表面無明顯裂紋，允許表面留有磁粉 工序卡片 零件名稱 材 料 硬度 工序名稱 工序號 叉形件 30CrMnSiA YB674--73 HRC36~41 車螺紋 125 備設 C620 定位 夾緊 共1頁 第1頁 序號 加 工 要 求 說 明 夾具 刀具 量具 1 車螺紋 軟三爪 螺紋車刀 螺紋量規(guī) 2 車端面 卡規(guī) 3 倒角0.5×45o 工序卡片 零件名稱 材 料 硬度 工序名稱 工序號 叉形件 30CrMnSiA YB674--73 HRC36~41 鉆小孔 130 備設 Z518 定位 夾緊 共1頁 第1頁 序號 加 工 要 求 說 明 夾具 刀具 量具 鉆床夾具 f1.5鉆頭 工序卡片 零件名稱 材 料 硬度 工序名稱 工序號 叉形件 30CrMnSiA YB674--73 HRC36~41 磨小臺 135 備設 M7475A 定位 夾緊 共1頁 第1頁 序號 加 工 要 求 說 明 夾具 刀具 量具 1 磨小臺 磨小臺 夾具 砂輪 游標卡尺 工序卡片 零件名稱 材 料 硬度 工序名稱 工序號 叉形件 30CrMnSiA HRC36~41 表面熱處理 140 備設 槽 定位 夾緊 共1頁 第1頁 注：L段和表面C鍍鎘，發(fā)蘭，其余表面鍍鎘8~12u，鈍化。 序號 加 工 要 求 說 明 夾具 刀具 量具 工序卡片 零件名稱 材 料 硬度 工序名稱 工序號 叉形件 30CrMnSiA HRC36~41 終檢 145 備設 檢驗臺 定位 夾緊 共1頁 第1頁 序號 加 工 要 求 說 明 夾具 刀具 量具 1 按圖示尺寸檢驗 卡尺 2 檢驗粗糙度 千分尺 尺規(guī) 終檢前后須清洗，最后須接 螺紋量規(guī) NO.150，防銹油封，按冶金 垂度直測具 說明書進行 比較樣板 叉形件工藝及其車床夾具設計,,設計思路：分析零件的特點、擬訂合理的工藝規(guī)程，選擇適當?shù)臋C床、設計合理的夾具。在機械加工零件中如果能夠廣泛地使用夾具，就能極大的節(jié)省加工時所用的時間，以減輕工人的勞動量，提高勞動生產(chǎn)率和產(chǎn)品的質量。 設計夾具一般先對原始材料進行分析，明確設計的要求和意圖，然后提出具體的定位和夾緊方案及車床夾具設計。本文采用5號莫氏錐體（錐柄式心軸）和彈簧片式自動定心裝置，來保證設計的可靠。,論文的結構和主要內(nèi)容,第一章 零件的分析 第二章 工藝規(guī)程設計 第三章 車床夾具設計 第四章 全文總結,第一章 零件的分析,1.1 零件的作用 叉形件零件是飛機液壓助力器執(zhí)行機構中的主要部之一。從整體上來看，飛機液壓助力器是安裝在飛機副翼縱機構中或方向舵操縱系統(tǒng)中，用于不可逆的液壓助力器縱。當飛機液壓系統(tǒng)損壞或壓力下降時，液壓助力器外筒左右兩腔溝通，即助力器當一拉桿使用，以實現(xiàn)人力應急操縱。每架飛機上裝有兩臺液壓助力器。分別操縱左右副翼或方向舵。如下圖所示 1.2 零件的結構與工藝分析 從叉形件的結構特征來看，它是長度大于直徑的回轉體零件，其被加工表面有外圓柱面、外圓錐面、螺紋、溝槽、孔等。根據(jù)它的結構特點和精度要求，應選擇合理的定位基準和加工方法。,,叉形件,設計基準是φ9的中心線；配合表面是外圓φ9，內(nèi)孔φ10，叉形件在裝配過程中，內(nèi)孔φ10H7 和外圓φ9h6在叉形組件中是配合表面，因此配合部分的尺寸公差、形位公差要求比較高，表面粗糙度要求較高，外圓φ10H7是設計基準表面；M5-6h螺紋上有一個φ1.5的小孔起漏氣漏油作用，因此這部分的精度要求不高。,第二章 工藝規(guī)程設計,2.1確定毛坯的制造形式 零件材料30CrMnSiA，為高級優(yōu)質合金結構鋼，并要求進行淬火后回火，保持硬度為HRC=36-41, 考慮到零件受力情況，批量的大小等因素，因此應該選用棒料。以使金屬纖維盡量不被切斷，保證零件工作可靠。由于零件屬于大批量生產(chǎn)，應保證尺寸的精確。這對提高生產(chǎn)率、保證加工質量也是有利的。 2.2 基準的選擇 粗基準選擇毛坯的外圓表面徑向基準，以端面作為軸向基準下料，這樣選擇可以保證在粗加工時零件精度。 零件圖紙的要求，又因為該零件工藝基準與設計基準重合，故而我們以設計基準φ9的中心線為零件的徑向精基準，這樣定位不僅滿足上述原則，同時也是多次裝夾和定位中精度最高的。,,方 案,叉形件工藝,第三章 車床夾具設計,3.2工件自由度分析 主要定位元件限制五個自由度：Y和Z方向的移動和轉動，圓柱面支撐限制了X軸的旋轉，保證鏜孔的深度。 3.3定位基準的選擇 本夾具主要是用來在叉形件上鏜孔.并且對孔φ10.0mm也有一定的技術要求（垂直度的偏移不能大于0.05mm，圓柱度的偏移不能大于0.1mm），由于孔還沒有加工，所以在本道工序加工時，主要應考慮如何保證加工質量、提高勞動生產(chǎn)率和降低勞動強度，故定位基準應選擇A和端面如圖,115工序 鏜孔 車床夾具 如圖,,,夾車床具設計,參考了一些車床類專用夾具的設計，最終確定下圖所示的車床夾具：,,,3.5夾具精度分析 在夾具結構方案確定及總圖設計完成之后，還應該對夾具精度進行分析和計算，以確保設計的夾具能滿足工件的加工要求。 1.影響精度的因素（造成誤差的原因） 在加工工序所規(guī)定的精度要求中，與夾具密切相關的是被加工表面的位置精度——位置尺寸和相互位置關系的要求。影響該位置精度的因素可分為δ定基δ安 裝，δ加工三部分，夾具設計者應充分考慮估算各部分的誤差，使其綜合影響不致超過工序所允許的限度。 2． 精度的分析 δ≥δ定基+δ定位+δ夾安+δ加工+δ夾緊 即0.05≥0+0.02+0+0+0.015 所以該夾具可以確保工件所要求的技術要求。,第四章 全文總結,本次畢業(yè)設計，到此為止基本完成了叉形件工藝及車床夾具設計。在工藝規(guī)程的編制中，首先通過分析零件圖，著重討論了各表面的加工余量、工序余量和工序平均尺寸等問題，繪制出毛坯圖。然后以第115號工序為例對切削余量及基本工時進行了計算。接著繪制出工藝卡片，在填寫、繪制工藝卡片的同時對每道工序的定位與夾緊方式順便做了分析和選擇。 在夾具設計方面，采用機床夾具手冊的相關知識和計算研究方法，首先對夾具結構類型、定位方案、加緊方案做出選擇，再對定位元件、夾緊裝置等各個部分進行具體設計，然后對夾具精度等做出分析，最終繪制出夾具裝配圖和圓盤等非標準件的零件圖。,謝 謝, 機械專業(yè)外語文獻翻譯 系 別 機電工程系 專 業(yè) 機械設計制造及其自動化 班 級 161001 學生姓名 劉立 學 號 103298 日 期 2014、6 2.2.5 Vector fields A vector-field is essentially a 2-Dimentional field with vectors. A vector consists of magnitude and angle, which represent importance or speed and demanded heading angle respectively. The magnitude interpretation as a an importance is useful when vector fields are combined by addition of each vector. The more important vector is longer, and therefore the resulting heading angle will be more into the direction of the more important vector. Some vector field generators, such as basic potential field methods, are not concerned about the magnitude. In this case the magnitude is often normalized. 2.2.5.1 Potential fields The theory of potential fields as trajectories is derived from an electrical field of a sphere in physics. The ormulae for an attractive field is as follows: where is a vector from the origin to the target position is a vector from the origin to the robot is the resultant vector with normalized length, indicating the direction of the field at the robots current position. The resultant is pointing towards the target. The attractive potential field is therefore related to line of sight guidance. A repulsive field is generating vectors pointing away from T. The formulae is Fig 6: attractive potential field Figure 6 shows a attractive potential field with a target point at T(0,0) . In an application usually only the vector at the current position of the robot is calculated, for demonstration graphs such as Figure 6 the robot is assumed to be in every possible position in the field, and therefore generating the vectors at each point. 2.2.5.2 Limit cycle based vector fields Limit cycles are part of nonlinear control theory. However the properties of a graph representing a limit cycle, Figure 7, can be adopted for path generation. For further reading see D-H Kim (2000). The limit-cycle characteristics of the 2nd order nonlinear function can be represented as a vector field containing a unit circle. Vectors outside the circle will be directed tangentially onto the circle. It can be seen as an arc/circle trajectory generator that lines up the robot coming in from any direction automatically. The resulting vector-field can be used like a arc trajectory generator or for obstacle avoidance. The disadvantage of the limit cycle method is that once the robot crosses the unit circle, the vector pointing towards a singularity in the centre. Therefore, a practical implementation is not easy, since is likely to overshoot the circle border slightly when arriving at the circle. A modification of the field within the circle is a proposed solution to the problem. Fig 7: limit cycle 2.2.5.3 Vector field fusion All discussed vector field methods can be applied at the same time. The author developed a way of combining (fusing) vector fields, which is published in Robinson P. (2004). Constraints and requirements: -Two or more vector fields are given -These vector fields contain normalized vectors The method is best described in an example. A typical combination of vector-field shall be analyzed where a Robot R avoids and obstacle Robot O on the way to a target point T. See figure 8 below. A weighting function is required to fuse the vector fields together. Experiments have shown that the Gaussian normal distribution function is an acceptable method of combining these fields. (A cylinder or cone would create a sudden change in heading angle and excites instability.) The angle Δ is the difference between the instant heading angle of the robot and the vector ro which points from robot to obstacle. Fig 8: avoidance scenario ThusΔ is an indication of how much the robot is on collision course with the obstacle. The smaller the angle, the more it is on collision course and the importance to avoid the obstacle is high. The mission of the robot is to go to T. In order to take into account the obstacle on its way towards the target it must consider how close the obstacle is. The distance to the obstacle is defined as ro . A smaller distance to an obstacle means that is more important to avoid it. An avoidance vector field VOshall be defined which is normal tot he mission vector field rt .The normalized target vector is VT. Suppose two vectors VTand VOare added together – ‘fused’ -with a Gaussian weighting function m*G(d). Where: is the resultant modified target vector Mis a additional constant weighting factor G() is the Gaussian distribution function. μ is the offset of the Gaussian hat is the distribution of the Gaussian hat We just learned that there are essentially two factors that define how important it is to avoid the obstacle. Δ and ro . The author will base the principle of vector field fusion by relating the length of each vector to importance towards the mission at a particular point in the field. Thus Δ and ro can be modelled as follows to influence the length of VO. -r1 is the maximum offset that Δ can cause. θ is steepness of the slope ( relationship of μ and Δ ) A larger θ will result in higher angles already to be considered as important. And the distance of the robot to the obstacle ro is modelled as the position parameter in the Gaussian function. Finally, the resultant vector field VMTindicates the new instant heading angle for the robot. Test results at different speeds with a robot football robot. The maximum speed is 100% corresponding to 3.0 m/sec. The coordinate system is in inches. Fig 9: avoidance path at 0.36 m/sec Fig 10: avoidance path at 0.51 m/sec Fig 11: avoidance path at 0.84 m/sec 2.2.6 Matching the trajectories to the dynamic model of mobile robots A current attempt of the author is to compare a path through a potential field with the robots dynamics model in order to determine if the robot can follow it. This can be done in frequency domain, by comparing the bandwidth of the robot plus controller model to the bandwidth of the input signal when trying to follow the path. This approach can be taken further. This could provide a basis of matching a vector-field by design to the robot’s bandwidth. 2.3 Modelling mobile robots This chapter is concerned with developing and understanding models of mobile robot kinematics and the control of each individual motor actuating the links within the kinematic model. Further reading is available in McKerrow P J (1991) chapter 8.1 which references to Muir P F and Neuman C P (1986). Muir and Neuman introduced a way of model ling wheeled mobile robots. It is related to model ling the kinematics of robot arms (manipulator kinematics). Differential driven Robot Differential driving is one of the simplest methods of model ling a mobile robot. This is probably why it is so common. The robot consists of 2 diagonally opposing wheels, see Fig. 12. If both wheels have the same velocity, the robot will go straight. If one wheel goes faster than the other the robot will follow a circular trajectory. If one wheel turns in the opposite direction of the other but with the same magnitude in speed, the robot will turn around its cent re, “on the spot”. The wheel Jacobian matrix is given and can be used as follows: Where v is the velocity forward of the centre of the robot and . is the angular velocity around the centre of the robot, see Fig 12. p& wheel Jacobian. p is the posture of the robot. The posture gives information about how the robot moves with respect to the floor. indicates the instant heading angle of the robot. Assuming no slip, the direction the vehicle is facing towards, is the same as the direction of the velocity vector (at and instant in time). An advantage of this fact, it simplifies calculations. A disadvantage however is that it can not move side wards. Fig 12: Differential driven Robot 3 DESIGN AND IMPLEMENTATION 3.1 Specification for fast autonomous mobile platform: faster than 1m/sec large enough for real world application, such as picking up goods space for a onboard laptop enough sensors for autonomous movements battery life for several hours inexpensive ( < ￡1000) 3.2 Mechanical Design Every part of the mechanical design is build from basic materials, only the caster wheels are a ready made construction. One focus of the project was to build the mechanical construction rather than buy a ready made gearbox and frame. As a benefit the authors machining skills has improved. 3.2.1 Frame The robot body consists of a steel frame that is welded together forming a box. Initially the frame was screwed together until the design was fully developed. Then the screws and brackets have been replaced by welded joints. The top rectangle can be taken of in order to do repair work. A large orange plastic sheet is mounted on top as a base for the circuit boards and the notebook. The battery is placed on top of the bottom frame. The key point is here that the bottom frame is lower than the wheel axis. It is placed just 2 cm above ground to prevent the robot from toppling at high speed. 3.2.2 Steering The steering consists of 2 links, i.e. 2 wheels. Fig 13: Explosion picture of one steering link One steering link consists of a medium duty caster wheel that has been welded to a plate. The plate and the underlying caster-wheel have a 12 mm shaft welded on in order to enable steering of the wheel. The wheel is not offset its centre, unlike on a shopping trolley for example. Therefore it must be controlled by active steering to line it up with the direction of movement. Both steering shafts are driven by a motor-gearbox combination (gear-ratio 1:50) over a belt system (ratio 1:2). The motor is a 12 Volt DC Motor. A potentiometer on the top of one shaft is read by a micro con troller to determine the current steering angle. The overall system is a servo system, since it has positional feedback, see section 3.3.5 for a description of the control. The above design, is the finally implemented one, the initial design had a stepper motor with controller circuit. However, the stepper motor was not powerful enough to turn the steering on rough surfaces. The implemented system responds quick and accurate within a fraction of a second to any angle. There are 3 ball bearings per link: one in the axis of the wheel and two in line with the 12mm steering shaft. This two ball-bearings shift the weight of the robot onto the wheel. One steering link is designed to carry a weight of 120Kg. One could argue that axial-ball bearings would have been better, but the axial load of the radial ball-bearings chosen is much higher than the maximum weight that the robot will ever experience. The two ball-bearings are placed in a machined al u minium housing. All the machining for the slot and the place to fit the bearing was done with a lathe and a milling machine. 3.2.3 Gearbox Fig 14: Gearbox in AutoCAD The two gearboxes are constructed out of 4 solid al u minium bars each, which are bolted together. On the bottom bar two slots are milled out, increasing the accuracy of their alignment with the other bars. During construction the bars where clamped together, in order to align the shaft holes of both bars precisely. The surfaces of the bars have been milled straight at the beginning, to have accurate reference during construction. The gearbox has 2 ball bearings on the shaft that is connected to the wheel. The other two shafts are for transmission gears. Each shaft has sleeves to adapt to the different diameters of the gears. The gear ratio is: n.b. Wheel diameter = 125mm Wheel circumference
392.7mm A further ball bearing with housing is mounted onto the frame. Thus the frame is connected to the housing and the housing to the gearbox. The holes marked with stripes in figure 15 are for fixing frame an housing together. Fig 15: Housing with 3 holes for gearbox-mount 3.2.4 Accuracy For the construction of the gearbox, only machine tools such as a lathe and a milling machine can achieve the accuracy. A stand drill is already problematic. The machines should be calibrated with a dial indicator. A dial indicator is a dial gauge that can measure distance in fractions of millime tres. It is mounted onto the lathe or milling machine to align the tool with the work piece. 3.3 Electronic Hardware Design Every circuit in the robot has been designed from basic principles. The design consists of two modular Micro controllers, the power electronics and the ultrasonic sensors. 3.3.1 Power Supply circuit The robot runs of a 12Volt battery. In the cent re of the frame is place to strap on a car battery or motor-cycle battery. With a car battery, the robot runs approximately 3-4 hours in constant action. The power is split up into signal power and motor power from the battery on wards to minimize noise distribution. The motor power goes through an emergency stop button before being fed to the electronics board. All circuits can be switched of through a lever switch added next to the emergency stop. A bipolar capacitor with 4700uF is placed on the power electronics board. Each power regulator is surrounded by capacitors as well. The larger electrolytic capacitors are always accompanied by a bipolar 10nF or 100nF ceramic capacitor. The tracks on the power electronics board have a diameter of 6mm. The motor power cables have a diameter of 4.4mm. The cable is originally designed for speakers. The noise amplitude on the 12Volt rail is less than 100mV. 3.3.2 Micro controller Module The modular micro controllers was designed to be an improvement from the popular robot football circuit, which is used by many students at the university. Unfortunately the chip used in the old circuit (90S8515) is discontinued and the new generation, the Atmel Mega series usually comes as surface mount device). At a development stage, surface mount is a problem. Firstly, it is not easy to unsolder asurface mount chip and secondly, a surface mount chip can not be stuck into a breadboard to do a quick design check. The module was designed with the following specification in mind: -similar amount of ports as the 90S8515 -only a bare minimum on components on board -serial and programming connector (Robot football compatible) -Avoid extra features such as test LEDs, I2C connector etc. since they are application dependant -Power LED for quick confirmation -Crystal with build-in capacitors -Plug-in design with a Pin distance usable for bread-boards The specification is appreciated by the technicians and other students of the University. Several other students already applied this design to their final year project, which proves the flexibility of the design. The author is currently writing a guide on how to develop with an At mel Mega and the new g cc 3.X compiler. A draft version of the guide can be found in the Appendix. Fig 16: At mel Mega16 Micro controller board used for designing the motor controllers Technical Details of the Microcontroller Module -Atmel Mega16-AI in TQFP package (Atmel Package Code 44A) -16 MHz Crystal -Atmel ISP Programming connector (IDC10, right angled) -Robot Football 4-Pin Molex Serial Port connector -3x 10Pin Single-in-Line connectors for IO-Ports 3.3.3 Ultra Sonic Sensors design The final design of the sensor is more simple than the original. The flexibility has increased since modulation and signal decoding is part of the software. Faster sensing is made possible through the changes. However, it demands more computing time. Features of the new design include: -frequency can be set by software -signal can be coded -reliable range 1.3 m The transmitter consists of a software running in a timer at 76 to 84 kHz and toggling the transistor Q1. The toggling divides the frequency by two. Unfortunately none of the timer frequency settings match the resonance frequency of the transducers. Therefore, the timer frequency must be programmed to sweep from a few kilohertz under the resonance frequency to a few over the resonance frequency. Fig 17: Ultra sonic distance measurement electronics The receiver end consists of a operational amplifier for signal boosting, a transistor Q2 for level shifting (12V to 5V) and a low pass filter R7,C7. The Op Amp is configured with a only positive rail at 12V. The positive input is clamped to 6V. Feedback resistor RV1 is a 47KOhm potentiometer in the final version, thus creating a variable gain from 1 to 48. Practically gain values over about 30 amplify noise created by the transmitter over the power rail. Even the extensive use of capacitors could not remove this problem. The sensor can detect flat objects, such as walls and boxes up to 3 meters away. Reliable detection of humans can only be achieved within 1.3 meters. Fig 18: design of a ultra sonic distance sensor with 8-bit bus connector (original design) Low pass Filter The micro controller recognizes a logical high at 3.5V and above, Atmel (2003), on an digital IO pin. The filter must be matched to give this voltage at the maximum acceptable frequency. Experiments show that, the a design with the 3dB point at 42KHz (Transducer frequency) has not enough safety margin and the micro controller does not always recognise the signal as high when it should be. Therefore the 3dB point is set to 49KHz. The question is which R and C values to choose in order to have 3.5 Volt at the output at 49 kHz. Fig 19: low pass filter (used in ultra sonic circuit) Initial formulae (15) rearranged for R. (16) n.b. the output impedance of the transistor circuit has been neglected, since it is lower than the low-pass circuit. The input impedance of the micro controller is much higher than the one of the low-pass circuit, and the impedance can be neglected in the calculation again. Fig 20: Ultrasonic sensor electronics (final design) 快速自動機器人人平臺-2 2.2.5向量場 一個向量場實質是由一個2-維向量組成的區(qū)域。一個向量由大小和方向組成，向量對于速度和航向角而言相當重要。 大小被認為是向量場中很重要的問題，大小對于通過每個向量組合成為向量場是很有用的。越重要的向量越長，航向角貼近的是更加重要的向量。 一些向量場產(chǎn)生器，像是基礎的勢場產(chǎn)生法，是不考慮大小的。這種情況下大小經(jīng)常被忽略。 2.2.5.1勢場 勢場的一些理論像是軌跡的概念是從物理領域中的電學部分中分化而出的。 引力場公式如下： 這里 是一個沖起始到目標位置的向量 是一個從起始指向機器人的向量 是一個表征機器人當前位置的單位化的長度和預計的角度。結果是指向目標的。引力場是關聯(lián)其中的可視的指引。斥力場產(chǎn)生背向目標的向量。等式是 表格6展示了一個引力場指向目標點（0.0）。在當前應用的機器人僅有當前位置的向量才加入計算 ，對于多為圖表像表格6這樣，機器人可以在場中任何可能的地方，同時也可以在任何點長生向量。 表格6：引力場 2.2.5.2基于極限環(huán)的向量場 極限環(huán)是非線性控制理論的一部分。但是一個表格能夠表現(xiàn)極限環(huán)的屬性，像是表格7，那么這個表格便可以適應路徑生成。此問題更深入的解讀請閱讀D-H Kim（2000）。極限環(huán)的非線性功能的第二位表現(xiàn)為一個向量場包含一個單位環(huán)。單位環(huán)外的向量將產(chǎn)生于單位環(huán)相切的方向。這可以看成是一個圓弧/圓軌跡生成率可以引導機器人自動從任何方向進入該圓。最終生成的向量場可以用來產(chǎn)生圓弧軌跡或者是用于避障。 極限環(huán)的缺點在于一旦機器恩跨過了單位元，向量場將指向中心。所以，具體實現(xiàn)極限環(huán)控制并不容易，因為機器人在接近單位圓時可能會稍稍的越過邊界。 這種場在單位環(huán)內(nèi)進行修改時一個解決此種問題的可行的措施。 對圖表7：極限環(huán) 2.2.5.3矢量場的融合 所有的可提供向量場都可以在同一時間進行討論。作者開發(fā)了一種可供合并向量場合并的方法，該方法在Robinson P(2004)中論述。 約束和要求： -兩個或者更多的向量場。 -這些向量場包含標準化的向量。 這種方法最好用一個例子來描述。一個典型的需要向量場合并的地方在于當一個機器人R需要避免和機器人O在路上相遇去目標T時?？聪旅鎴D表8。 在融合向量場過程中，需要一個加權函數(shù)。經(jīng)驗已經(jīng)證明，高斯正態(tài)分布函數(shù)在合并兩個場域是很合適的方式。（一個圓柱體或是一個椎體都可能產(chǎn)生一個突然的沖擊以使航向角發(fā)生變化并產(chǎn)生激發(fā)不穩(wěn)定現(xiàn)象。） 圖表8：回避方案 角和當前的機器人航向角q是不同的，ro向量是指向機器人回避方向。 那個角是表征機器人和障礙物碰撞程度的量。這個角度越小，碰撞事件發(fā)生的情況就越小，同時避開障礙物的可能性越高。 這個機器人的任務是走到T點。為了將攔在它和目標點之間的障礙物也納入考慮，那個機器人就必須計算障礙物和自己的距離。這個距離在式子中是以矢量ro定義的。和障礙物的距離越短就意味著避開障礙物的重要性越大。 一個回避向量場應該被定義的和任務向量場rt場一樣。標準化后的目標向量是。 提供的兩個向量和是用高斯加權方程加在一起的-融合