Abstract
Residual features of large casting parts in small batch are random in distribution, size, and shape. The manual mode is inefficient, dangerous, and labor-intensive. The automatic mode spends a lot of time on trajectory planning and programming. To overcome the challenges, a novel teleoperation machining mode and a modified master-slave control structure are proposed. Moreover, a hierarchical control strategy based on variable motion mapping (VMM) and elastic compensation (EC) is presented to improve machining efficiency by realizing the constant cutting force. The control laws of VMM, EC and interactive force are designed to reduce operator fatigue and mental burden. The forbidden virtual fixture (RVF) is generated by employing a six-degree-of-freedom (6-DoF) articulated measuring arm to constraint the movement of slave robot and protect the workpiece from being overcut. The velocity and acceleration constraints are formulated to avoid the impact of the slave robot. A large casting part (train bolster) is considered to carry out comparative experiments. The effectiveness of the teleoperation mode and control strategy are confirmed by experiment results, which strongly promotes the progress of unstructured workpiece manufacturing and provides a reference for other machining.
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