Design analysis and structural parameter optimization for magnetic adsorption module of wall-climbing robot

doi:10.3785/j.issn.1006-754X.2024.03.225

Chinese Journal of Engineering Design

2024, Vol. 31

Issue (5): 592-602 DOI: 10.3785/j.issn.1006-754X.2024.03.225

Optimization Design

Design analysis and structural parameter optimization for magnetic adsorption module of wall-climbing robot

Pei YANG(

),Minglu ZHANG,Lingyu SUN(

)

School of Mechanical Engineering, Hebei University of Technology, Tianjin 300130, China

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Abstract

As a vital component of the magnetic adsorption wall-climbing robot, the structure of the magnetic adsorption module usually affects the overall mass and adsorption stability of the robot. Aiming at the problems of complex magnetic circuit coupling relationship and complicated optimization design of magnetic adsorption modules, a magnetic adsorption module structure optimization method is proposed by combining virtual simulation technology, surrogate model and dung beetle optimization algorithm to improve the efficiency of magnetic force calculation and optimization design process. Firstly, the structure design scheme for the wall-climbing robot was introduced, and through the simulation analysis of the existing Halbach array magnetic circuit modes, it was determined that the three-magnetic circuit mode had relatively high adsorption efficiency. At the same time, the magnetic force simulation model of the magnetic adsorption module was experimentally verified based on the initial parameters, which laid the foundation for establishing subsequent surrogate models. Then, an optimization model with the robot's adsorption stability and structural parameters as constraints and the lightweight of the magnetic adsorption module as objective was established. A fourth-order response surface model between the magnetic force and the structural parameters of the magnetic adsorption module was established by the optimal Latin hypercube design, ANSYS parametric modeling and surrogate model technology, and its credibility was verified. The structural parameter optimization model of the magnetic adsorption module was solved by using the dung beetle optimization algorithm. The results showed that the prediction error of the established surrogate model was tiny, and the relationship between the magnetic force and the structural parameters of the magnetic adsorption module could be well expressed. After optimization, the mass of the magnetic adsorption module was reduced by 12.7%. Finally, the correctness of the optimization process was verified through robot load experiments. The research results can provide reference for the magnetic force analysis and structure optimization of other magnetic adsorption robots.

Key words： wall-climbing robot magnetic adsorption module surrogate model parameter optimization magnetic circuit simulation

Received: 26 December 2023 Published: 30 October 2024

CLC:

TP 242.2

Corresponding Authors: Lingyu SUN E-mail: yang_p1993@163.com;sunly@hebut.edu.cn

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Cite this article:

Pei YANG,Minglu ZHANG,Lingyu SUN. Design analysis and structural parameter optimization for magnetic adsorption module of wall-climbing robot. Chinese Journal of Engineering Design, 2024, 31(5): 592-602.

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https://www.zjujournals.com/gcsjxb/10.3785/j.issn.1006-754X.2024.03.225 OR https://www.zjujournals.com/gcsjxb/Y2024/V31/I5/592

爬壁机器人磁吸附模块设计分析与结构参数优化

作为磁吸附式爬壁机器人的关键部件，磁吸附模块的结构通常会影响机器人的整体质量及吸附稳定性。针对磁吸附模块磁路耦合关系复杂、优化设计困难等问题，结合虚拟仿真技术、代理模型和蜣螂优化算法提出了一种磁吸附模块结构优化方法，以提高其磁力计算和优化设计过程的效率。首先，介绍了爬壁机器人的结构设计方案，并通过对现有的Halbach阵列磁路模式进行仿真分析，确定了三磁路模式具有相对较高的吸附效率；同时，基于初设参数对磁吸附模块磁力仿真模型进行了实验验证，为后续代理模型的建立奠定了基础。然后，建立了以机器人吸附稳定性和结构参数为约束、以磁吸附模块轻量化为目标的优化模型。采用最优拉丁超立方设计、ANSYS参数化建模以及代理模型技术建立了磁吸附模块磁力与结构参数之间的四阶响应面模型，并对其可信度进行了验证。利用蜣螂优化算法对磁吸附模块的结构参数优化模型进行了求解。结果表明，所建立的代理模型的预测误差很小，能够较好地表征磁吸附模块磁力与结构参数之间的关系；优化后磁吸附模块的质量减小了12.7%。最后，通过机器人负载实验验证了优化过程的正确性。研究结果可为其他磁吸附式机器人的磁力分析与结构优化提供参考。

关键词： 爬壁机器人, 磁吸附模块, 代理模型, 参数优化, 磁路仿真分析

Fig.1 Overall structure of wall-climbing robot

Fig.2 Structure of four magnetic circuit modes

Fig.3 Variation of magnetic force with air gap distance under different magnetic circuit modes

Fig.4 Structure schematic of magnetic adsorption module with three-magnetic circuit

Fig.5 Optimization strategy for structural parameters of magnetic adsorption module

Fig.6 Variation of magnetic force under different wall thicknesses

Table 1 Range of each design parameter of magnetic adsorption module

Fig.7 Force analysis of wall-climbing robot

Fig.8 Minimum magnetic force required to resist three types of instability situations

Fig.9 Experimental platform of magnetic force test for magnetic adsorption module

Fig.10 Comparison of simulated and measured magnetic force values of magnetic adsorption module

Fig.11 Sampling effect of different experimental design methods

Table 2 Partial sample points and corresponding magnetic force simulation values for constructing magnetic force surrogate model

Table 3 Precision evaluation index of surrogate models

Fig.12 Comparison of prediction effect of different surrogate models

Table 4 Relative error comparison of magnetic force under different structural parameter combinations

Fig.13 Optimization solution process of structural parameters of magnetic adsorption module based on DBO algorithm

Table 5 Main parameters of DBO algorithm

Fig.14 Optimization solution iterative process based on 2-RSM and 4-RSM

Table 6 Optimization results of structural parameters of magnetic adsorption module

Fig.15 Wall-climbing robot load experiment site


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