2012 Volume 30 Issue 2 Pages 188-194
To make an operator feel reactive forces in teaching operations of metal spinning works with in smooth trajectories, a novel manufacturing system is proposed. Metal spinning is a plastic rotary-forming process in which a metal sheet is formed onto a rotating mandrel by forcing with a roller. A teaching device which is composed of a XY table and a handlebar with a force sensor was prototyped, instead of a joystick in common use. To conduct a shear spinning task from aluminum sheets of 0.8[mm] thickness to cone shells, the force-feedback function was implemented using a robotic bilateral master-slave control method based on a virtual internal model. While in a conventional spinning task of hemispherical parts, to smoothly operate the roller, a virtual non-holonomic model was applied, in reference to a kinematical constraint of a tool position in human-powered spinning works. It was verified that the enhanced system is easier to use than the simple bilateral master slave system through the forming experiments.
