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Abstract
The main objective of this work is the establishment of a model-based framework allowing the simulation, analysis and optimization of the friction stir welding (FSW) of metallic structures using industrial robots, with a particular emphasis on the assembly of aircraft components made of aerospace aluminum alloys.
After a first part of the work dedicated to the kinetostatic and dynamic identification of the robotic manipulator, a complete analytical model of the process is developed, incorporating a dynamical model of the robot, a multi-axis visco-elastic model of the FSW process and a force / position control unit. These different modules are subsequently implemented in a high fidelity multi-rate dynamical simulation.
The developed simulation infrastructure allowed analyzing and understanding of the interaction between the industrial robot, the control architecture and the manufacturing process involving heavy load cases in different configurations. Several critical process-induced perturbations such as tool oscillations and lateral / rotational deviations were observed, analyzed and quantified during the simulated operations.
This simulation platform will constitute one of the key technology to develop a robust robotic FSW workcell, allowing both the development of optimal workcell layouts / process parameters and the validation of advanced real-time control laws for robust handling of critical process-induced perturbations. These deliverables will be incorporated in the resulting robotic FSW technology packaged for deployment in production environments.
