A steady state tip control strategy for long reach robots

The work presented in this thesis describes the development of a novel strategy for the steady state tip position control of a single link flexible robot arm. Control is based upon a master/slave relationship. Arm trajectory is defined by through 'master' positioning head which moves a laser through a programmed path. Tip position is detected by an optical system which produces an error signal proportional to the displacement of the tip from the demand laser spot position. The error signal and its derivative form inputs to the arm 'slave' controller so enabling direct tip control with simultaneous correction for arm bending. Trajectory definition is not model-based as it is defined optically through movement of the positioning head alone. A critical investigation of vacuum tube and solid state sensing methods is undertaken leading to the development of a photodiode quadrant detector beam tracking system. The effect of varying the incident light parameters on the beam tracker performance are examined from which the optimum illumination characteristics are determined. Operational testing of the system on a dual-axis prototype robot using the purpose-built beam tracker has shown that successful steady state tip control can be achieved through a PD based slave controller. Errors of less than 0.05 mm and settling times of 0.2 s are obtained. These results compare favourably with those for the model-based tip position correction strategies where tracking errors of ± 0.6 mm are recorded

Middeck Active Control Experiment (MACE), phase A

A rationale to determine which structural experiments are sufficient to verify the design of structures employing Controlled Structures Technology was derived. A survey of proposed NASA missions was undertaken to identify candidate test articles for use in the Middeck Active Control Experiment (MACE). The survey revealed that potential test articles could be classified into one of three roles: development, demonstration, and qualification, depending on the maturity of the technology and the mission the structure must fulfill. A set of criteria was derived that allowed determination of which role a potential test article must fulfill. A review of the capabilities and limitations of the STS middeck was conducted. A reference design for the MACE test article was presented. Computing requirements for running typical closed-loop controllers was determined, and various computer configurations were studied. The various components required to manufacture the structure were identified. A management plan was established for the remainder of the program experiment development, flight and ground systems development, and integration to the carrier. Procedures for configuration control, fiscal control, and safety, reliabilty, and quality assurance were developed

Enabling hybrid process metrology in roll-to-roll nanomanufacturing: design of a tip-based tool for topographic sampling on flexible substrates

This work seeks to demonstrate the efficacy of a novel approach for topography measurement of nano-scale structures fabricated on a flexible substrate in a roll-to-roll (R2R) fashion. R2R manufactured products can be extremely cost competitive compared to more traditional, silicon wafer or glass panel based nanofabrication solutions, in addition to the unique and often desirable mechanical properties inherent to flexible substrates. As such, flexible nanomanufacturing is an area of immense research interest. However, despite the significant potential of these products for a variety of applications, developing manufacturing systems from lab-scale prototypes to pilot- or high volume manufacturing (HVM) has often proven both difficult and infeasibly expensive as research investment and achievable process yield limit advancement. One of the most significant capability gaps in current art, and roadblocks on the path towards adoption of R2R nanomanufacturing, is the lack of high-throughput, nanometer-scale metrology for process development, real-time control, and yield enhancement. This dissertation presents the design of a tip-based measurement tool implementing atomic force microscope (AFM) probes manufactured with a micro-electro-mechanical system (MEMS) approach to the challenge of sub-micron topography measurement which is also compatible with R2R manufacturing on flexible substrates. A proof-of-concept prototype tool with subsystems to regulate a flexible web, isolate and position the atomic force microscope probe, and measure features on the substrate, all coordinated by a real-time embedded control system, was designed and fabricated. The positioning subsystem was evaluated dynamically to ensure initial design requirements were met, and stationery, step-and-scan results were presented. However, to wholly meet this extent need for in-line R2R metrology, a system capable of atomic force microscope scanning despite a continuous, non-zero substrate velocity is required - any regular stoppage of the web in a R2R process all but dooms economically viable production throughput. Refinement and redesign of the proof-of-concept tool was driven by new system requirements to meet this goal, in addition to lessons learned from the initial prototype. Improvements focused on upgrading the web handling spindle design and mechatronics, tool power electronics, moving structures, and control algorithms used for high-speed synchronous positioning of the atomic force microscope and web. The culmination of this work will serve to introduce a new measurement framework which may be used to accelerate and enable future research in R2R manufacturing of nanofeatured products.Mechanical Engineerin

Mechatronics of systems with undetermined configurations

This work is submitted for the award of a PhD by published works. It deals with some of the efforts of the author over the last ten years in the field of Mechatronics. Mechatronics is a new area invented by the Japanese in the late 1970's, it consists of a synthesis of computers and electronics to improve mechanical systems. To control any mechanical event three fundamental features must be brought together: the sensors used to observe the process, the control software, including the control algorithm used and thirdly the actuator that provides the stimulus to achieve the end result. Simulation, which plays such an important part in the Mechatronics process, is used in both in continuous and discrete forms. The author has spent some considerable time developing skills in all these areas. The author was certainly the first at Middlesex to appreciate the new developments in Mechatronics and their significance for manufacturing. The author was one of the first mechanical engineers to recognise the significance of the new transputer chip. This was applied to the LQG optimal control of a cinefilm copying process. A 300% improvement in operating speed was achieved, together with tension control. To make more efficient use of robots they have to be made both faster and cheaper. The author found extremely low natural frequencies of vibration, ranging from 3 to 25 Hz. This limits the speed of response of existing robots. The vibration data was some of the earliest available in this field, certainly in the UK. Several schemes have been devised to control the flexible robot and maintain the required precision. Actuator technology is one area where mechatronic systems have been the subject of intense development. At Middlesex we have improved on the Aexator pneumatic muscle actuator, enabling it to be used with a precision of about 2 mm. New control challenges have been undertaken now in the field of machine tool chatter and the prevention of slip. A variety of novel and traditional control algorithms have been investigated in order to find out the best approach to solve this problem

Fuzzy PD control of an optically guided long reach robot

This thesis describes the investigation and development of a fuzzy controller for a manipulator with a single flexible link. The novelty of this research is due to the fact that the controller devised is suitable for flexible link manipulators with a round cross section. Previous research has concentrated on control of flexible slender structures that are relatively easier to model as the vibration effects of torsion can be ignored. Further novelty arises due to the fact that this is the first instance of the application of fuzzy control in the optical Tip Feedback Sensor (TFS) based configuration. A design methodology has been investigated to develop a fuzzy controller suitable for application in a safety critical environment such as the nuclear industry. This methodology provides justification for all the parameters of the fuzzy controller including membership fUllctions, inference and defuzzification techniques and the operators used in the algorithm. Using the novel modified phase plane method investigated in this thesis, it is shown that the derivation of complete, consistent and non-interactive rules can be achieved. This methodology was successfully applied to the derivation of fuzzy rules even when the arm was subjected to different payloads. The design approach, that targeted real-time embedded control applicat.ions from the outset, results in a controller implementation that is suitable for cheaper CPU constrained and memory challenged embedded processors. The controller comprises of a fuzzy supervisor that is used to alter the derivative term of a linear classical Proportional + Derivative (PD) controller. The derivative term is updated in relation to the measured tip error and its derivative obtained through the TFS based configuration. It is shown that by adding 'intelligence' to the control loop in this way, the performance envelope of the classical controller can be enhanced. A 128% increase in payload, 73.5% faster settling time and a reduction of steady state of over 50% is achieved using fuzzy control over its classical counterpart

DESIGN AND CONTROL OF A HUMMINGBIRD-SIZE FLAPPING WING MICRO AERIAL VEHICLE

Flying animals with flapping wings may best exemplify the astonishing ability of natural selection on design optimization. They evince extraordinary prowess to control their flight, while demonstrating rich repertoire of agile maneuvers. They remain surprisingly stable during hover and can make sharp turns in a split second. Characterized by high-frequency flapping wing motion, unsteady aerodynamics, and the ability to hover and perform fast maneuvers, insect-like flapping flight presents an extraordinary aerial locomotion strategy perfected at small size scales. Flapping Wing Micro Aerial Vehicles (FWMAVs) hold great promise in bridging the performance gap between engineered flying vehicles and their natural counterparts. They are perfect candidates for potential applications such as fast response robots in search and rescue, environmental friendly agents in precision agriculture, surveillance and intelligence gathering MAVs, and miniature nodes in sensor networks

Definition of Throw-Away Detectors (TADs) and VLF antenna for the AMPS laboratory

A Throw Away Detector (TAD)/subsatellite to be used as an experiment platform for the test flights to map the EMI from the shuttle and during the AMPS science flights is defined. A range of instrument platforms of varying capabilities is examined with emphasis on the EMI test vehicle. The operational support requirements of TAD/subsatellites are determined. The throw away detector is envisioned as a simple instrument package for supporting specific experiments

A continuum robotic platform for endoscopic non-contact laser surgery: design, control, and preclinical evaluation

The application of laser technologies in surgical interventions has been accepted in the clinical domain due to their atraumatic properties. In addition to manual application of fibre-guided lasers with tissue contact, non-contact transoral laser microsurgery (TLM) of laryngeal tumours has been prevailed in ENT surgery. However, TLM requires many years of surgical training for tumour resection in order to preserve the function of adjacent organs and thus preserve the patient’s quality of life. The positioning of the microscopic laser applicator outside the patient can also impede a direct line-of-sight to the target area due to anatomical variability and limit the working space. Further clinical challenges include positioning the laser focus on the tissue surface, imaging, planning and performing laser ablation, and motion of the target area during surgery. This dissertation aims to address the limitations of TLM through robotic approaches and intraoperative assistance. Although a trend towards minimally invasive surgery is apparent, no highly integrated platform for endoscopic delivery of focused laser radiation is available to date. Likewise, there are no known devices that incorporate scene information from endoscopic imaging into ablation planning and execution. For focusing of the laser beam close to the target tissue, this work first presents miniaturised focusing optics that can be integrated into endoscopic systems. Experimental trials characterise the optical properties and the ablation performance. A robotic platform is realised for manipulation of the focusing optics. This is based on a variable-length continuum manipulator. The latter enables movements of the endoscopic end effector in five degrees of freedom with a mechatronic actuation unit. The kinematic modelling and control of the robot are integrated into a modular framework that is evaluated experimentally. The manipulation of focused laser radiation also requires precise adjustment of the focal position on the tissue. For this purpose, visual, haptic and visual-haptic assistance functions are presented. These support the operator during teleoperation to set an optimal working distance. Advantages of visual-haptic assistance are demonstrated in a user study. The system performance and usability of the overall robotic system are assessed in an additional user study. Analogous to a clinical scenario, the subjects follow predefined target patterns with a laser spot. The mean positioning accuracy of the spot is 0.5 mm. Finally, methods of image-guided robot control are introduced to automate laser ablation. Experiments confirm a positive effect of proposed automation concepts on non-contact laser surgery.Die Anwendung von Lasertechnologien in chirurgischen Interventionen hat sich aufgrund der atraumatischen Eigenschaften in der Klinik etabliert. Neben manueller Applikation von fasergeführten Lasern mit Gewebekontakt hat sich die kontaktfreie transorale Lasermikrochirurgie (TLM) von Tumoren des Larynx in der HNO-Chirurgie durchgesetzt. Die TLM erfordert zur Tumorresektion jedoch ein langjähriges chirurgisches Training, um die Funktion der angrenzenden Organe zu sichern und damit die Lebensqualität der Patienten zu erhalten. Die Positionierung des mikroskopis chen Laserapplikators außerhalb des Patienten kann zudem die direkte Sicht auf das Zielgebiet durch anatomische Variabilität erschweren und den Arbeitsraum einschränken. Weitere klinische Herausforderungen betreffen die Positionierung des Laserfokus auf der Gewebeoberfläche, die Bildgebung, die Planung und Ausführung der Laserablation sowie intraoperative Bewegungen des Zielgebietes. Die vorliegende Dissertation zielt darauf ab, die Limitierungen der TLM durch robotische Ansätze und intraoperative Assistenz zu adressieren. Obwohl ein Trend zur minimal invasiven Chirurgie besteht, sind bislang keine hochintegrierten Plattformen für die endoskopische Applikation fokussierter Laserstrahlung verfügbar. Ebenfalls sind keine Systeme bekannt, die Szeneninformationen aus der endoskopischen Bildgebung in die Ablationsplanung und -ausführung einbeziehen. Für eine situsnahe Fokussierung des Laserstrahls wird in dieser Arbeit zunächst eine miniaturisierte Fokussieroptik zur Integration in endoskopische Systeme vorgestellt. Experimentelle Versuche charakterisieren die optischen Eigenschaften und das Ablationsverhalten. Zur Manipulation der Fokussieroptik wird eine robotische Plattform realisiert. Diese basiert auf einem längenveränderlichen Kontinuumsmanipulator. Letzterer ermöglicht in Kombination mit einer mechatronischen Aktuierungseinheit Bewegungen des Endoskopkopfes in fünf Freiheitsgraden. Die kinematische Modellierung und Regelung des Systems werden in ein modulares Framework eingebunden und evaluiert. Die Manipulation fokussierter Laserstrahlung erfordert zudem eine präzise Anpassung der Fokuslage auf das Gewebe. Dafür werden visuelle, haptische und visuell haptische Assistenzfunktionen eingeführt. Diese unterstützen den Anwender bei Teleoperation zur Einstellung eines optimalen Arbeitsabstandes. In einer Anwenderstudie werden Vorteile der visuell-haptischen Assistenz nachgewiesen. Die Systemperformanz und Gebrauchstauglichkeit des robotischen Gesamtsystems werden in einer weiteren Anwenderstudie untersucht. Analog zu einem klinischen Einsatz verfolgen die Probanden mit einem Laserspot vorgegebene Sollpfade. Die mittlere Positioniergenauigkeit des Spots beträgt dabei 0,5 mm. Zur Automatisierung der Ablation werden abschließend Methoden der bildgestützten Regelung vorgestellt. Experimente bestätigen einen positiven Effekt der Automationskonzepte für die kontaktfreie Laserchirurgie

Control Of Flexible Structures-2 (COFS-2) flight control, structure and gimbal system interaction study

The second Control Of Flexible Structures Flight Experiment (COFS-2) includes a long mast as in the first flight experiment, but with the Langley 15-m hoop column antenna attached via a gimbal system to the top of the mast. The mast is to be mounted in the Space Shuttle cargo bay. The servo-driven gimbal system could be used to point the antenna relative to the mast. The dynamic interaction of the Shuttle Orbiter/COFS-2 system with the Orbiter on-orbit Flight Control System (FCS) and the gimbal pointing control system has been studied using analysis and simulation. The Orbiter pointing requirements have been assessed for their impact on allowable free drift time for COFS experiments. Three fixed antenna configurations were investigated. Also simulated was Orbiter attitude control behavior with active vernier jets during antenna slewing. The effect of experiment mast dampers was included. Control system stability and performance and loads on various portions of the COFS-2 structure were investigated. The study indicates possible undesirable interaction between the Orbiter FCS and the flexible, articulated COFS-2 mast/antenna system, even when restricted to vernier reaction jets