Design and implementation of a 6-DOF robot flexible bending system

This study proposed a new design, analytical algorithms, and control of a novel 6-DOF robot flexible bending (RFB) system to manufacture bending components with complex spatial structures. First, a novel 6-DOF RFB system was designed based on the principles of RFB technology. Then, novel analytical algorithms named the incremental analysis algorithm (IAA), and space attitude analysis algorithm (SAAA)) were proposed for the 6DOF RFB system to analyse the forming procedures of 3D complex-shaped hollow components. According to the IAA, a novel physical prototype and a control program of the 6-DOF RFB were built. The feasibility of the 6DOF RFB system and the reliability of the IAA were verified by the bending experimentation on the AA6061-T6 spatial spiral tube. The dimensions of the test sample were measured using a 3D optical scanner system to evaluate the forming precision of the established 6-DOF RFB system. The results showed that the 6-DOF RFB system could effectively form complex-shaped hollow components. However, there are still large deviations in the test sample, with an average error of 0.68% in the actual bending angle and an average deviation of 6.93 mm in the spatial axis.