巨型重载操作装备是制造产业链中的基础装备，体现国家极端制造能力和制造水平，影响国民经济和国防建设重大工程的实施。研究巨型重载操作装备的基础科学问题，旨在揭示极端载荷条件下多自由度操作装备的运动特征、力学行为与动态响应规律，提供巨型重载操作装备设计、制造与控制的关键技术，为核电、造船、化工、国防等领域亟需的大型构件精确高效制造提供理论支撑与技术保障。
巨型重载操作装备需要具备极端载荷条件下的多维灵巧操作能力。由于操作过程中存在强外场作用、多维运动耦合及机构的过约束特征，重载操作装备易产生力流畸变和操作灵巧性丧失，其电液伺服系统易产生紊流和随机空化，从而导致装备运动界面的间隙变化与润滑失效、结构力学性能衰退、运动约束冲突、控制系统失稳、末端精度丧失甚至功能失效。因此，大承载灵巧操作机构与恒力夹持机构设计、重载界面低摩擦润滑、偏载和异常内力的预测与控制、大载荷过约束系统的同步与协调是重载操作装备的关键技术。为突破上述关键技术，本项目围绕“多自由度重载操作机构构型与操作性能的映射规律”、“重载操作装备的非线性力学行为与界面失效机理”、“重载操作装备的多源能量传递规律与动态控制”三个基础科学问题，开展以下七个课题研究：
 1.大型构件制造操作运动轨迹建模；
 2.重载装备多自由度操作性能度量与机构设计原理；
 3.非连续工况下重载装备界面行为与力学特征；
 4.大尺度重型构件稳定夹持原理与夹持系统驱动策略；
 5.大流量电液伺服系统的介质流动规律；
 6.重载大惯量装备的快速协调控制；
 7.巨型重载操作装备的性能仿真与优化。
本项目将揭示巨型重载操作装备的操作灵巧性、力承载能力、刚度等性能与机构构型的映射规律，重载非连续运动条件下的界面行为与失效机理，大流量、大流差电液伺服系统的非定常介质流动规律，系统参数失配与冗余驱动约束冲突对装备动力学行为的影响规律；提出巨型重载装备多维力位操作性能与操作灵巧性的度量方法，重载运动副的低摩擦润滑方法，超静定结构中的内力预测方法，冗余输入多自由度机构的约束相容准则，快速精确多机协调控制方法；构建巨型重载操作装备及大型构件成形制造过程的仿真平台。
通过本项目研究，使我国巨型重载操作装备的基础研究水平跻身于世界前列，通过理论与技术成果在国内重型装备制造企业的应用，提升我国大型制造装备的自主创新设计能力和大型构件的独立制造能力，实现极端制造技术的突破。

Heavy manipulators are used in manufacturing industries to automate the manufacturing process, increase the productivity of manufacturing systems and the quality of products. As one of the basic functional requirements, heavy manipulators are desired to achieve high manipulability, dexterity, and reliability in extreme work conditions and environments (high temperature, high loads, etc.), which challenges the theory and strategies for mechanical design and manipulation control.

This project investigates the theory and methodology which are fundamental for design, manufacturing and control of multi-DOF heavy manipulators. The research topics span a wide range of areas including mechanism design, kinematics and dynamics, reliability, sensor and actuation, control theory and algorithms, etc., with the emphasis being placed on the following fundamental problems:
(1) Measure of manipulability of heavy manipulators and the mapping between manipulability and mechanism configuration—How to achieve desired manipulability with appropriate mechanism design?
(2) The nonlinear nature of contact interfaces and the dynamics of rigid-flexible coupling mechanical systems—How to increase the reliability of heavy manipulators in extreme work conditions?
(3) Dynamic behaviors of heavy manipulators—How to actuate and control the motion and manipulation of heavy manipulators?
The research topics of this project are organized into seven sub-projects:
  1) Manipulator motion trajectory planning in large parts manufacturing
  2) Manipulability analysis and mechanism design of multi-DOF heavy manipulators
  3) Mechanical behaviors of contact interfaces and dynamic force distribution in heavy manipulators
  4) Grasping and workholding strategies for high-load manipulation
  5) Flow mechanism of electro-hydraulic servo system with time-variant mass flowrate
  6) Theory and algorithms for manipulation control of heavy manipulators
  7) Comprehensive performance simulation and optimization of heavy manipulators

It is expected that this multi-disciplinary research endeavor will result in comprehensive theory and techniques on mechanism design, structure topology optimization, lubrication, sensor and measurement, actuation, and control. The aim of the project is to provide fundamental theories and technological supports for the development heavy manipulators.