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河南理工大學(xué)萬(wàn)方科技學(xué)院
本科畢業(yè)設(shè)計(jì)（論文）中期檢查表
指導(dǎo)教師： 職稱：
所在院（系）： 機(jī)械與動(dòng)力工程系 教研室（研究室）： 系部辦公樓317
題 目
四履帶搜救機(jī)器人的結(jié)構(gòu)設(shè)計(jì)—行星減速器設(shè)計(jì)
學(xué)生姓名
專業(yè)班級(jí)
學(xué)號(hào)
一、選題質(zhì)量：
1.本題目符合機(jī)械設(shè)計(jì)專業(yè)的培養(yǎng)目標(biāo)，能夠充分鍛煉和培養(yǎng)分析問(wèn)題和實(shí)際操作能
力，能夠體現(xiàn)綜合訓(xùn)練的要求
2.設(shè)計(jì)任務(wù)難易程度和工作量適中，符合本科畢業(yè)設(shè)計(jì)要求，能在規(guī)定的時(shí)間內(nèi)完成。
3.所選題目較為新穎，故所收集的資料較少，工作量較大。
4.所選題目與實(shí)際貼合比較緊密，在實(shí)際的救援中也很重要。在設(shè)計(jì)過(guò)程中，對(duì)機(jī)
器人各個(gè)結(jié)構(gòu)和零件的設(shè)計(jì)、計(jì)算對(duì)我來(lái)說(shuō)，是對(duì)以往所學(xué)知識(shí)的總結(jié)和應(yīng)用，所以
能夠滿足綜合訓(xùn)練的要求。但是在設(shè)計(jì)過(guò)程中，對(duì)于我來(lái)說(shuō)還是具有很大的難度，對(duì)
于這方面的涉足也并不是很多，并且且這方面的資料也是比較少，所以這對(duì)我來(lái)說(shuō)也
是一個(gè)挑戰(zhàn)。
二、開(kāi)題報(bào)告完成情況：
根據(jù)自己在各方面資料的收集和整理，通過(guò)對(duì)可行性的分析，結(jié)合老師給的題目
的選擇，我完成了這次設(shè)計(jì)的選題。
在選題結(jié)束之后，通過(guò)自己認(rèn)真查閱相關(guān)的資料，最后結(jié)合本身的實(shí)際情況和設(shè)
計(jì)的時(shí)間任務(wù)完成了開(kāi)題報(bào)告。
經(jīng)過(guò)指導(dǎo)老師同意，完成開(kāi)題報(bào)告，同意開(kāi)題。
三、階段性成果：
1.通過(guò)對(duì)搜救機(jī)器人的了解，再加上指導(dǎo)老師對(duì)我們的講解，算是對(duì)其有了一個(gè)大概的了解。前期階段主要是對(duì)有關(guān)于搜救機(jī)器人的各方面的文獻(xiàn)和資料進(jìn)行搜集，為以后的設(shè)計(jì)做了必要的準(zhǔn)備。
2.中期階段主要是依據(jù)參考資料，從上面找到一些關(guān)于關(guān)于搜救機(jī)器人結(jié)構(gòu)設(shè)計(jì)的信息，首先對(duì)其結(jié)構(gòu)有了大致的了解，其次是已有了大概的設(shè)計(jì)方法，并開(kāi)始了一些基本的結(jié)構(gòu)設(shè)計(jì)。
3.正在進(jìn)行裝配圖的CAD畫圖和進(jìn)行設(shè)計(jì)說(shuō)明書的部分工作。
4.正在進(jìn)行我在小組中所負(fù)責(zé)的主體部分的設(shè)計(jì)，包括履帶、齒輪和軸等部件的選材
以及數(shù)據(jù)計(jì)算等工作。
四、存在主要問(wèn)題：
1、這次設(shè)計(jì)對(duì)我來(lái)說(shuō)是個(gè)比較大挑戰(zhàn)，和同學(xué)的配合剛開(kāi)始有很多不恰當(dāng)?shù)牡胤?，但隨著設(shè)計(jì)的進(jìn)行和不斷的討論磨合，也逐漸克服了這一問(wèn)題。
2、搜救機(jī)器人設(shè)計(jì)對(duì)我是個(gè)新題，并且在搜索資料方面發(fā)現(xiàn)，關(guān)于搜救機(jī)器人的資料也并不是很多。
3、設(shè)計(jì)過(guò)程中關(guān)于自己所設(shè)計(jì)的方面不是太明確，經(jīng)過(guò)和同組同學(xué)的商量明確了自己
的任務(wù)。
4.由于資料過(guò)于稀少，沒(méi)有可參考的材料，在計(jì)算數(shù)據(jù)、校核、選材方面還有很大的
不明之處。
五、指導(dǎo)教師對(duì)學(xué)生在畢業(yè)實(shí)習(xí)中，勞動(dòng)、學(xué)習(xí)紀(jì)律及畢業(yè)設(shè)計(jì)（論文）進(jìn)展等方面的評(píng)語(yǔ)
指導(dǎo)教師： （簽名）
年 月 日
3
Mobile platform of rocker-type coal
mine rescue robot
LI Yun wang *, GE Shirong, ZHU Hua, FANG Haifang, GAO Jinke
School of Mechanical and Electrical Engineering, China University of Mining & Technology, Xuzhou 221008, China
Abstract: After a coal mine disaster, especially a gas and coal dust explosion, the space-restricted and unstructured underground terrain and explosive gas require coal mine rescue robots with good obstacle-surmounting performance and explosion-proof capability. For this type of environment, we designed a mobile platform for a rocker-type coal mine rescue robot with four independent drive wheels. The composition and operational principles of the mobile platform are introduced, we discuss the flameproof design of the rocker assembly, as well as the operational principles and mechanical structure of the bevel gear differential and the main parameters are provided. Motion simulation of the differential function and condition of the robot running on virtual, uneven terrain is carried out with ADAMS. The simulation results show that the differential device can maintain the main body of the robot at an average angle between two rockers. The robot model has good operating performance. Experiments on terrain adaptability and surmounting obstacle performance of the robot prototype have been carried out. The results indicate that the prototype has good terrain adaptability and strong obstacle-surmounting performance.
Keywords: coal mine; rescue robot; rocker suspension; differential; explosion-proof design
1 Introduction
In the rescue mission of a gas and coal dust explosion ,rescuers easily get poisoned in underground coal mines full of toxic gases, such as high-concentrationCH4 and CO, if ventilation and protection are not up to snuff. Furthermore, secondary or multiple gas explosions may be caused by extremely unstable gases after such a disaster and may cause casualties among the rescuers [1]. Therefore, in order to perform rescue missions successfully, in good time and decrease casualties, it is necessary to develop coal mine rescue robots. They are then sent to enter the disaster area instead of rescuers and carry out tasks of environmental detection, searching for wounded miners and victims after the disaster has occurred. The primary task of the robots in rescue work is to enter the disaster area. It is difficult for robots to move into restricted spaces and unstructured underground terrain, so these mobile systems require good obstacle-surmounting performance and motion performance in this rugged environment [2]. The application of some sensors used for terrain identification are severely restricted by low visibility and surroundings full of explosive gas and dust; hence, a putative mobile system should, as much as possible, be independent from sensing and control systems[3].
Studies of coal mine rescue robots are just beginning at home and abroad. Most robot prototypes are simple wheel type and track robots. The mine exploration robot RATLER, developed by the Intelligent Systems and Robotics Center (ISRC) of Sandia National Laboratories, uses a wheel type mobile system [4]. The Carnegie Mellon University Robot Research Center developed an autonomous mine exploration robot, called “groundhog [5]. Both the mine rescue robot V2 produced by the American Remote Company and the mine search and rescue robot CUMT developed by China University of Mining and Technology, use a two-track fixed type moving system[6-7]. These four prototypes are severely limited in underground coal mines. Rocker type robots have demonstrated good performance on complex terrain. All three Mars rovers, i.e., Sojourner, Spirit and Opportunity used mobile systems with six independent drive wheels[8-9]. Rocker-Bogie, developed by the American JPL laboratory has landed successfully on Mars. The SRR robot from the JPL laboratory with four independent drive and steering wheels consists of a moving rocker assembly system, similar to the four wheel-drive SR2 developed by the University of Oklahoma, USA [10]. Both tests and practical experience have shown that this type of system has good motion performance, can adapt passively to uneven terrain, possesses the ability of self-adaptation and performs well in surmounting obstacles. Given the unstructured underground terrain environment and an atmosphere of explosive gases, we investigated a coalmine rescue robot with four independent drive wheels and an explosion-proof design, based on a rocker assembly structure. We introduce the composition and operational principles of this mobile system, discuss the design method of its rocker assembly and differential device and carried out motion simulation of the kinematic performance of the robot with ADAMS, a computer software package. In the end, we tested the terrain adaptability and performance of the prototype in surmounting obstacles.
2 Mobile platform [11-12]
As shown in Fig. 1, the mobile platform of the rocker-type four-wheel coal mine rescue robot includes a main body, a gear-type differential device, two rocker suspensions and four wheels. The shell of the differential device is attached to the interior of the main body. The two extended shafts of the differential device are supported by the axle seats in the lateral plate of the main body and connected to the rocker suspensions installed at both sides of the main body. The four wheels are separately connected to the bevel gear transmission at the terminal of the four landing legs. The four wheels are independently driven by a DC motor, installed inside the landing legs of the rocker suspension. A flameproof design of
the legs has been developed, which includes a flameproof motor cavity and a flameproof connection cavity. Via a cable entry device, the power and control cables of the DC motor are connected to the power and controller of the main body.
2.1 Rocker suspension
2.1.1 Function
The primary role of the rocker suspension is to provide the mobile platform with a mobile system that can adapt to the unstructured underground terrain, such as rails, steps, ditches and deposit of rock and coal dumps because of the collapse of the tunnel roof after a disaster. By connecting the differential device intermediate between the two rocker suspensions, the four drive wheels can touch the uneven ground passively and the wheels can bear the average load of the robot so that it is able to cross soft terrain. The wheels can supply enough propulsion, which allows the robot to surmount obstacles and pass through uneven terrain.
2.1.2 Structure
As shown in Fig. 1, the rocker suspension is composed of a connecting block, landing legs and bevel gear transmissions. The angle between the landing legs on each side of the main body is carefully calibrated. The legs are connected to the connecting block and the terminals, which in turn are connected to the bevel gear transmissions. Fig. 2 illustrates the structure of the landing leg. It is divided into an upper and a bottom section. The bottom section is cylindrical. The DC motor is in the leg and fixed to the connecting cylinder. The motor shaft connects to the bevel gear transmission and the wheel is also connected to the transmission. The upper section has a blind center hole through witch a connection is formed to the bottom section, via a connection cavity. Through the cable entry device of the upper section, the motor power and control cable from the main body of the robot are put into the connection cavity and connect to the wiring terminals which, in turn, connect to the guidance wires in the wire holder. Another end of the guidance wires connects to the motor in the bottom section.
2.1.3 Flameproof design
A coal mine environment is full of explosive gases; hence, a rescue robot must be designed to be flameproof. The DC motors, for driving each wheel, are installed in the landing legs of the rocker suspensions. At the present low-powered DC motors, available in the market, are of a standard design and not flameproof, hence a flameproof structure for these motors must be designed. Given the structural features of the rocker suspension, it is very much necessary that a flameproof design for the landing legs be carried out.
There are two important points to be considered in this flameproof design. First, a flameproof cavity is needed, in which the standard DC motor is installed. Given the flameproof design requirements, a group of flameproof joints should be formed between the motor shaft and the shaft hole. Generally, the motor shaft made by the manufacturer is too short to comply with the requirement of flameproof joints, so the motor shaft needs to be extended. Second, a flameproof connection cavity should be designed to lead the c a- Fig. 1 Rocker-type four-wheel mobile platform Main body Rocker suspension Landing leg Wheel Rocker suspension Connecting block Differential device Bevel gear transmission Axle seat Upper section Wire holder Bottom section DC motor Flameproof joints Flameproof joints Bevel gear transmission Connecting cylinder Shaft sleeve Wheel Cable entry into the connection cavity through a flameproof cable entry device. DC motors, especially brush DC motors, may generate sparks in normal running and when the motor load is high, the working current may be more than 5 A, which exceeds the current limit in Appendix C2 of the National Standard GB3836.2- 2000 of China. Therefore, the motor power and control cable cannot be directly in the connection cavity。
Given these requirements, the landing legs have been designed as flameproof units, as shown in Fig. 2. An elongated shaft sleeve has been assembled from the motor shaft, with the same inside radius as that of the motor shaft and this is how the motor shaft is extended. The front flange of the motor is fixed to the intermediate plate of the connecting cylinder. The motor shaft with the shaft sleeve passes through the center hole embedded with a brass bush and then connects to the input gear of the bevel gear transmission at the end of the bottom section of the landing leg. Therefore, flameproof joints are formed between the motor shaft and the shaft sleeve, as well as between the shaft sleeve and the brass bush. The terminal of the bottom section of the leg connects to the connecting cylinder and a flameproof joint is formed between the external cylindrical surface of the terminal and the inner cylinder surface of the connecting cylinder.
There is also a flameproof connection cavity in the upper section of the leg. In order to save space, the guidance wire is sealed together with the wire holder using a sealant. The seat of the guide wire is installed in the hole of the upper section of the landing leg. Another flameproof joint is formed between the wire holder and the hole. The cavity of the upper section connects to the rabbet structure of the bottom section, with yet another flameproof joint. There is a flameproof cable entry device at the end of the upper section of the landing leg. Hence, a flameproof connection cavity is formed in the upper section of the leg. Based on the structure described, the standard DC motor was installed in the flameproof cavity of the bottom section of the leg. The power and control cables of the motor connect to the flameproof connection cavity of its upper section through a wire holder. Moreover, the cable from the flameproof main body of the robot connects to the connection cavity via the flameproof cable entry device. Thus, the flameproof design of the landing leg of the rocker suspension
section was completed.
2.2 Differential device[13-15]
2.2.1 Characteristics of the differential mechanism
The differential mechanism of a rocker-type robot is a motion transfer mechanism with two degrees of freedom, which can transform the two rotating inputs into a rotating output. The output is the linear mean values of the two inputs. If we let 1 ω and 2 ω be two angular velocity inputs, ω the angular velocity
Two rotational input components connect to the left and the right rocker suspension of the robot and the output component connects to the main body of the robot. In this way, the swing angles of the left and right rocker suspensions are averaged by the differential mechanism and the mean value, transformed into the swing angle (pitching angle) of the main body, is the output. It is effective in decreasing the swing of the main body and thus reduces the terrain effect. Taking the main swing angle of the main body as input and the swing angles of the left and the right rocker suspension as outputs, the rotational input is decomposed into two different rotational outputs. If the output is the mean value of two inputs, it is helpful to allocate the average weight of the body to each wheel which can adjust its position passively alone in the terrain.
Given the characteristics and operating requirements of differential mechanisms, a bevel gear type differential mechanism has been designed. We have analyzed the working principle of the bevel gear differential mechanism and present its detailed structural design.
2.2.2 Principle of the bevel gear differential mechanism
Fig. 3 shows the schematic diagram of the bevel gear differential mechanism. Two semi-axle bevel gears 1 and 2 mesh with the planetary bevel gear 3 orthogonally. Carrier H connects to planetary bevel gear 3 coaxially. Let the angular velocities of gears 1,
It can clearly be seen that this bevel gear differential mechanism can be used in the rocker-type mobile robot.
2.2.3 Bevel gear differential device
Given the above principle of a bevel gear differential mechanism, we designed such a bevel gear differential device, shown in Fig. 4. Fig. 4a is the outline of the differential device, and Fig. 4 bitsinte rnalstructure .
This bevel gear differential device is composed of a shell, end covers, an axle base, semi-axle bevel gears, planetary bevel gears, a connecting shaft, etc. The end covers and axle beds connect to the shell by screws. In the shell, two planetary bevel gears are coaxial and symmetrically installed at the connecting shaft, with the shaft terminals supported at the end covers. There are bearings between the connecting shaft and bevel gears. The circlips are installed on the connecting shaft to limit the load on the bearings. Two semi-axle bevel gears are housed in the two axle beds separately, two axle beds are fixed on the shell symmetrically and two semi-axle bevel gears mesh with two planetary bevel gears orthogonally. The two
axle bases have the same structure. The semi-axle bevel gears are located by the bearings, shaft sleeve and circlips in the axle beds. When the differential device is installed on the robot, the two axles of the left and right semi-axle bevel gears are connected to the left and right rockers. The shell of the differential is fixed on the main body of the robot.
3 Mobile platform Test
3.1 Simulation test
Accurate, simulated 3D model of the robot was imported into the ADAMS software. Using the kinematic pairs in the joints database of the ADAMS/View, the movement of each part of the simulation model is constrained. For simulating the differential action of differential devices acting on the robot body, a revolute joint between the left and right rockers of the model and the “Ground” is established. Random moments of forces are exerted to the left and right rockers to simulate the rough action of the terrain on the rockers. For simulating the movements of the differential device accurately, contact forces are exerted to the pair of gears of the differential device. After corresponding marker points on the robot are
established, the swinging angles of the left and right rockers and the robot body are measured and the curves of the swinging angles along with the time are obtained via the ADAMS/Post processor module, shown in Fig. 6. Curves 1 and 2 are swing angle curves of the two rockers, while curve 3 is the swing angle curve of the main body.
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The bevel gear differential device can average the swing angles of the right and left rockers, and the average value is the swing angle of the main body. The gap between two teeth and other factors cause the return difference of the gear drive, so when the main body is swinging at the early start-up and through the zero angle, there is a slight swinging angle deviation between the simulated and theoretical values.
Typical steps, channels, slopes and other complex terrain models are built in the Solid Works software. For testing the traffic ability characteristics and ride comfort of the four wheel robot, all-terrains models are imported into the ADAMS software[16-17]. Then the joints and restraints are rebuilt, Contact Force between the terrain and the wheels is exerted and torque is exerted to each wheel. The running condition of the robot is simulated on the complex terrain, as shown in Fig. 7a. The vertical displacement, velocity and acceleration curves of the centroid of the body and the centers of the four wheels can be obtained, as shown in Figs. 7b~7d. According to the curves, the curve of the centroid displacement of the main body (main body d curve) is very smooth and the velocity and acceleration of the main body is approximately the mean of that of the four wheels. The simulation results show that the mobile platform of the robot has good trafficability and rides comfortably on the complex terrain.
3.2 Prototype test
In order to verify the performance of the robot in surmounting obstacles and adapting to a complex terrain, an obstacle-surmounting test of the robot was carried out on a simple obstacle course built in the laboratory and on a complex outdoor terrain bestrewn with messy bricks and stones. Fig. 8 shows the video image of the robot when moving on the complex terrain. The tests indicate that the four drive wheels of the robot can passively keep contact with the uneven ground and the robot performed well in surmounting obstacles. When moving on uneven ground, the swing angle of the main body was small and the differential device could effectively reduce the effect ofthe changing terrain to the main body. One side of the robot can cross a 260 mm-high obstacle. Only large obstacles between the landing legs of the rockers appear to block progress. The performance in surmounting obstacles by the four wheels of the robots is clearly better than that of a track-type robot of the same size.
4 Conclusions
1) Coal mine accidents, especially gas and coal dust explosions, occur frequently. Therefore, it is necessary to investigate and develop coal mine rescue robots that can be sent into mine disaster areas to carry out tasks of environmental detection and rescue missions after disasters have occurred, instead of
sending rescuers which might become exposed to danger.
2) An underground coal mine environment presents a space-restricted, unstructured terrain environment, with a likely explosive gas atmosphere after a disaster. Hence, any mobile system would require a high motion performance and obstacle-surmounting performance on complex terrain.
3) Given an unstructured underground terrain environment and an explosive atmosphere, we investigated an explosion-proof coal mine rescue robot with four independent drive wheels, based on a rocker type structure. Our simulation and test results indicate that the robot performs satisfactorily, can passively adapt to uneven terrain, is self-adaptive and performs well in surmounting obstacles.
4) In our study, we only investigated the rocker type mobile platform of a coal mine rescue robot. In order to adapt to the underground coal mine environment, we also carried out a flameproof design for the main body. It was necessary to improve the rocker suspensions in order for the robot to be able to adjust the angle between two landing legs