Lightweight design of Stewart type six-axis force sensor

doi:10.3785/j.issn.1006-754X.2022.00.058

Chin J Eng Design

2022, Vol. 29

Issue (4): 419-429 DOI: 10.3785/j.issn.1006-754X.2022.00.058

Optimization Design

Lightweight design of Stewart type six-axis force sensor

Chen WANG¹(

),Bo GAO²(

),Xu YANG³

^1.Department of Aeronautical Engineering, Shaanxi Polytechnic Institute, Xianyang 712000, China
^2.Shaanxi Electric Appliance Research Institute, China Aerospace Science and Technology Corporation, Xi'an 710065, China
^3.Beijing Institute of Spacecraft System Engineering, Beijing 100094, China

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Abstract

Spatial composite force measurement is one of the important development directions of spatial sensing technology. As a main spatial composite force measuring device, the six-axis force sensor is widely used in rocket engine thrust test, spacecraft docking and other fields. At present, lightweight has become one of the main research directions of six-axis force sensors. However, due to the large number of design indicators and mutual constraints among various indicators, the method of theoretical derivation, numerical simulation and experimental verification was adopted in the research. Firstly, the force mapping model of Stewart type six-axis force sensor under ideal conditions was established based on the spiral theory, and the structural parameters when the theoretical isotropy was optimal were determined by solving the comprehensive performance objective function. Then, the simulation model of Stewart type six-axis force sensor was built by using the ABAQUS finite element analysis software, and the mass, stiffness, strength and sensitivity of its initial prototype were analyzed in detail. On this basis, the influence of the main structural parameters of upper and lower loading plates on the mass, stiffness and strength of sensor was analyzed, the structural parameters of upper and lower loading plates were optimized, and a hemispherical weight reduction structure with regular tetrahedron characteristics was designed, which realized the lightweight design of sensor. Finally, the performance of optimized Stewart type six-axis force sensor was simulated and verified by experiments. The results showed that multi-objective parameter optimization combined with numerical simulation and experimental verification could effectively improve design efficiency and reduce design cost; the designed weight reduction structure could effectively improve the mass distribution of Stewart type six-axis force sensor and improve its mass utilization. After optimization, the mass of the sensor was reduced by 17.65% and its comprehensive performance was excellent. The research results can provide reference for lightweight design and comprehensive performance optimization of six-axis force sensors.

Key words： six-axis force sensor numerical simulation quality stiffness sensitivity accuracy

Received: 19 November 2021 Published: 05 September 2022

CLC:

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Corresponding Authors: Bo GAO E-mail: 1064336813@qq.com;gaobo8868@163.com

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Cite this article:

Chen WANG,Bo GAO,Xu YANG. Lightweight design of Stewart type six-axis force sensor. Chin J Eng Design, 2022, 29(4): 419-429.

URL:

https://www.zjujournals.com/gcsjxb/10.3785/j.issn.1006-754X.2022.00.058 OR https://www.zjujournals.com/gcsjxb/Y2022/V29/I4/419

Stewart式六维力传感器轻量化设计

空间复合力测量是空间感知技术的重要发展方向之一。六维力传感器作为主要的空间复合力测量装置，被广泛应用于火箭发动机推力测试、航天器对接等领域。目前，轻量化已成为六维力传感器的主要研究方向之一，但由于其设计指标多且各项指标间存在相互制约，故采用理论推导、数值仿真及实验验证相结合的方法进行研究。首先，利用螺旋理论建立Stewart式六维力传感器在理想条件下的力映射模型，通过求解综合性能目标函数来确定其各向同性度理论最优时的结构参数。然后，利用ABAQUS有限元分析软件构建Stewart式六维力传感器仿真模型，并对其初始样机的质量、刚度、强度和灵敏度进行了详细分析；在此基础上，分析了上、下加载盘主要结构参数对传感器质量、刚度和强度的影响，进而对加载盘结构参数进行了优化并设计了一种具有正四面体特征的半球形减重结构，实现了传感器的轻量化设计。最后，对优化后Stewart式六维力传感器的性能进行了仿真分析和实验验证。结果表明，基于多目标参数优化结合数值仿真、实验验证可有效提高设计效率和降低设计成本；所设计的减重结构可有效改善Stewart式六维力传感器的质量分布和提高其质量利用率，优化后传感器的质量减小了17.65%且综合性能优异。研究结果可为六维力传感器的轻量化设计和综合性能优化提供参考。

关键词： 六维力传感器, 数值仿真, 质量, 刚度, 灵敏度, 精度

Fig.1 Structural diagram of Stewart type six-axis force sensor

Table 1 Structural parameters of Stewart type six-axis force sensor with optimum theoretical isotropy

各向同性度	数值
$η 1$	0.362 1
$η 1$	0.784 5
$η 3$	0.388 4
$η 4$	0.744 2

Table 2 Theoretical optimum isotropy of Stewart type six-axis force sensor

Table 3 Range of Stewart type six-axis force sensor

Fig.2 Initial prototype of Stewart type six-axis force sensor

Fig.3 Analysis results of grid density influence independence of Stewart type six-axis force sensor finite element model

Fig.4 Finite element model of Stewart type six-axis force sensor

荷载 F/N，M/Nm	$σ m a x$ /MPa	$ε m a x$ /10^-6	$σ e a v$ /MPa	K_F /(N/m)， K_M /(Nm/rad)			T/(mV/V)
荷载 F/N，M/Nm	$σ m a x$ /MPa	$ε m a x$ /10^-6	$σ e a v$ /MPa	设计值	仿真值	测试值	仿真值	测试值
F_x=1 500	31.39	138	17.85	0.40×10⁸	0.809 1×10⁸	0.783 2×10⁸	0.24	0.25
F_y=1 500	45.28	187	18.79	0.40×10⁸	0.821 7×10⁸	0.795 9×10⁸	0.25	0.26
F_z =1 500	23.77	112	15.83	0.40×10⁸	1.533 0×10⁸	1.399 0×10⁸	0.19	0.17
M_x=2 000	282.89	916	178.57	0.50×10⁶	1.557 0×10⁶	1.269 0×10⁶	1.18	1.41
M_y=2 000	417.79	1 124	216.11	0.50×10⁶	1.299 0×10⁶	1.093 0×10⁶	1.43	1.71
M_z=2 000	293.57	897	173.24	0.50×10⁶	2.451 0×10⁶	2.195 0×10⁶	1.12	1.29

Table 4 Performance comparison of initial prototype of Stewart type six-axis force sensor

Table 5 Mass distribution of initial prototype of Stewart type six-axis force sensor

Fig.5 Half-section diagram of upper loading plate

Fig.6 Half-section diagram of lower loading plate

Fig.7 Effect of H₁, H₂ on maximum stress of Stewart type six-axis force sensor

Fig.8 Effect of H₁, H₂ on tension stiffness of Stewart type six-axis force sensor

Fig.9 Effect of H₁, H₂ on torsional stiffness of Stewart type six-axis force sensor

Fig.10 Effect of H₁, H₂ on mass of Stewart type six-axis force sensor

Fig.11 Schematic diagram of original weight reduction structure of loading plate

Fig.12 Schematic diagram of hemispherical weight reduction structure

Fig.13 Definition of position circle of hemispherical weight reduction structure

Fig.14 Optimization scheme 1 of upper loading plate

Fig.15 Optimization scheme 2 of upper loading plate

Fig.16 Optimization scheme 1 of lower loading plate

Fig.17 Optimization scheme 2 of lower loading plate

Fig.18 Optimization design process of loading plate weight reduction structure

Fig.19 Schematic diagram of end face structure of loading plate after optimization

荷载F/N，M/Nm	$σ m a x$ /MPa	$ε m a x$ /10^-6	$σ e a v$ /MPa	K_F /(N/m)，K_M /(Nm/rad)	T/(mV/V)
F_x=1 500	35.15	163	19.36	0.749 1×10⁸	0.27
F_y=1 500	50.21	258	21.07	0.773 7×10⁸	0.29
F_z =1 500	26.25	147	17.24	1.279 0×10⁸	0.22
M_x=2 000	325.19	1 031	202.14	1.369 0×10⁶	1.42
M_y=2 000	396.21	1 271	208.97	1.206 0×10⁶	1.39
M_z=2 000	318.93	974	187.31	2.193 0×10⁶	1.26

Table 6 Performance of Stewart type six-axis force sensor after optimization

Fig.20 Stress cloud diagram of Stewart type six-axis force sensor after optimization

Fig.21 Optimized prototype of Stewart type six-axis force sensor

Fig.22 Calibration device of Stewart type six-axis force sensor

Table 7 Stiffness and sensitivity of optimized prototype of Stewart type six-axis force sensor


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