Dynamic Modeling and Simulation of a Rotating Single Link Flexible Robotic Manipulator Subject to Quick Stops

Single link robotic manipulators are extensively used in industry and research operations. The main design requirement of such manipulators is to minimize link dynamic deflection and its active end vibrations, and obtain high position accuracy during its high speed motion. To achieve these requirements, accurate mathematical modeling and simulation of the initial design, to increase system stability and precision and to obtain very small amplitudes of vibration, should be considered. In this paper the modeling of such robotic arm with a rigid guide and a flexible extensible link subject to quick stops after each complete revolution is considered and its dynamical behavior analyzed. The extensible link which rotates with constant angular velocity has one end constrained to a predefined trajectory. The constrained trajectory allows trajectory control and obstacle avoidance for the active end of the robotic arm. The dynamic evolution of the system is investigated and the flexural response of the flexible link analyzed under the combined effect of clearance and flexibility.

Modeling and control of a two-arm elastic robot in gravity

This thesis develops and experimentally verifies a model of a two arm robot with highly elastic arms. The model is later used in this research to evaluate control algorithms. The model includes the effects of gravity. The dimensions of the arms are chosen to maximize the coupling between the flexible and large scale motion of the robot. The model is then linearized and a new analytical solution is presented for the natural frequencies and mode shapes of the robot at given equilibrium positions. This analytical solution is then compared to the assumed mode shape solutions to determine the accuracy relative to the number of assumed modes included in the model. An experimental test rig is built and tests are conducted to verify the model. A number of different amounts of end mass and torsional stiffness at the joints are used during the validation. For 12 cases tested, the measured first four natural frequencies are within ±7% of the frequencies predicted by the model with an average error of only 2.89%. Finally, the model is used to design a control algorithm for end effector control of the robot using a torque input at each of the two joints. An optimal control algorithm developed using LQR with the prescribed degree of stability method results in effective end effector control with short response time and little overshoot

Design and Development of an Affordable Haptic Robot with Force-Feedback and Compliant Actuation to Improve Therapy for Patients with Severe Hemiparesis

The study describes the design and development of a single degree-of-freedom haptic robot, Haptic Theradrive, for post-stroke arm rehabilitation for in-home and clinical use. The robot overcomes many of the weaknesses of its predecessor, the TheraDrive system, that used a Logitech steering wheel as the haptic interface for rehabilitation. Although the original TheraDrive system showed success in a pilot study, its wheel was not able to withstand the rigors of use. A new haptic robot was developed that functions as a drop-in replacement for the Logitech wheel. The new robot can apply larger forces in interacting with the patient, thereby extending the functionality of the system to accommodate low-functioning patients. A new software suite offers appreciably more options for tailored and tuned rehabilitation therapies. In addition to describing the design of the hardware and software, the paper presents the results of simulation and experimental case studies examining the system\u27s performance and usability

Design of an Elastic Actuation System for a Gait-Assistive Active Orthosis for Incomplete Spinal Cord Injured Subjects

A spinal cord injury severely reduces the quality of life of affected people. Following the injury, limitations of the ability to move may occur due to the disruption of the motor and sensory functions of the nervous system depending on the severity of the lesion. An active stance-control knee-ankle-foot orthosis was developed and tested in earlier works to aid incomplete SCI subjects by increasing their mobility and independence. This thesis aims at the incorporation of elastic actuation into the active orthosis to utilise advantages of the compliant system regarding efficiency and human-robot interaction as well as the reproduction of the phyisological compliance of the human joints. Therefore, a model-based procedure is adapted to the design of an elastic actuation system for a gait-assisitve active orthosis. A determination of the optimal structure and parameters is undertaken via optimisation of models representing compliant actuators with increasing level of detail. The minimisation of the energy calculated from the positive amount of power or from the absolute power of the actuator generating one human-like gait cycle yields an optimal series stiffness, which is similar to the physiological stiffness of the human knee during the stance phase. Including efficiency factors for components, especially the consideration of the electric model of an electric motor yields additional information. A human-like gait cycle contains high torque and low velocities in the stance phase and lower torque combined with high velocities during the swing. Hence, the efficiency of an electric motor with a gear unit is only high in one of the phases. This yields a conceptual design of a series elastic actuator with locking of the actuator position during the stance phase. The locked position combined with the series compliance allows a reproduction of the characteristics of the human gait cycle during the stance phase. Unlocking the actuator position for the swing phase enables the selection of an optimal gear ratio to maximise the recuperable energy. To evaluate the developed concept, a laboratory specimen based on an electric motor, a harmonic drive gearbox, a torsional series spring and an electromagnetic brake is designed and appropriate components are selected. A control strategy, based on impedance control, is investigated and extended with a finite state machine to activate the locking mechanism. The control scheme and the laboratory specimen are implemented at a test bench, modelling the foot and shank as a pendulum articulated at the knee. An identification of parameters yields high and nonlinear friction as a problem of the system, which reduces the energy efficiency of the system and requires appropriate compensation. A comparison between direct and elastic actuation shows similar results for both systems at the test bench, showing that the increased complexity due to the second degree of freedom and the elastic behaviour of the actuator is treated properly. The final proof of concept requires the implementation at the active orthosis to emulate uncertainties and variations occurring during the human gait

Modelling and Control of a 2-DOF Robot Arm with Elastic Joints for Safe Human-Robot Interaction

Collaborative robots (or cobots) are robots that can safely work together or interact with humans in a common space. They gradually become noticeable nowadays. Compliant actuators are very relevant for the design of cobots. This type of actuation scheme mitigates the damage caused by unexpected collision. Therefore, elastic joints are considered to outperform rigid joints when operating in a dynamic environment. However, most of the available elastic robots are relatively costly or difficult to construct. To give researchers a solution that is inexpensive, easily customisable, and fast to fabricate, a newly-designed low-cost, and open-source design of an elastic joint is presented in this work. Based on the newly design elastic joint, a highly-compliant multi-purpose 2-DOF robot arm for safe human-robot interaction is also introduced. The mechanical design of the robot and a position control algorithm are presented. The mechanical prototype is 3D-printed. The control algorithm is a two loops control scheme. In particular, the inner control loop is designed as a model reference adaptive controller (MRAC) to deal with uncertainties in the system parameters, while the outer control loop utilises a fuzzy proportional-integral controller to reduce the effect of external disturbances on the load. The control algorithm is first validated in simulation. Then the effectiveness of the controller is also proven by experiments on the mechanical prototype.publishedVersio

Preliminary results on noncollocated torque control of space robot actuators

In the Space Station era, more operations will be performed robotically in space in the areas of servicing, assembly, and experiment tending among others. These robots may have various sets of requirements for accuracy, speed, and force generation, but there will be design constraints such as size, mass, and power dissipation limits. For actuation, a leading motor candidate is a dc brushless type, and there are numerous potential drive trains each with its own advantages and disadvantages. This experiment uses a harmonic drive and addresses some inherent limitations, namely its backdriveability and low frequency structural resonances. These effects are controlled and diminished by instrumenting the actuator system with a torque transducer on the output shaft. This noncollocated loop is closed to ensure that the commanded torque is accurately delivered to the manipulator link. The actuator system is modelled and its essential parameters identified. The nonlinear model for simulations will include inertias, gearing, stiction, flexibility, and the effects of output load variations. A linear model is extracted and used for designing the noncollocated torque and position feedback loops. These loops are simulated with the structural frequency encountered in the testbed system. Simulation results are given for various commands in position. The use of torque feedback is demonstrated to yield superior performance in settling time and positioning accuracy. An experimental setup being finished consists of a bench mounted motor and harmonic drive actuator system. A torque transducer and two position encoders, each with sufficient resolution and bandwidth, will provide sensory information. Parameters of the physical system are being identified and matched to analytical predictions. Initial feedback control laws will be incorporated in the bench test equipment and various experiments run to validate the designs. The status of these experiments is given

Dynamic modeling, property investigation, and adaptive controller design of serial robotic manipulators modeled with structural compliance

Research results on general serial robotic manipulators modeled with structural compliances are presented. Two compliant manipulator modeling approaches, distributed and lumped parameter models, are used in this study. System dynamic equations for both compliant models are derived by using the first and second order influence coefficients. Also, the properties of compliant manipulator system dynamics are investigated. One of the properties, which is defined as inaccessibility of vibratory modes, is shown to display a distinct character associated with compliant manipulators. This property indicates the impact of robot geometry on the control of structural oscillations. Example studies are provided to illustrate the physical interpretation of inaccessibility of vibratory modes. Two types of controllers are designed for compliant manipulators modeled by either lumped or distributed parameter techniques. In order to maintain the generality of the results, neither linearization is introduced. Example simulations are given to demonstrate the controller performance. The second type controller is also built for general serial robot arms and is adaptive in nature which can estimate uncertain payload parameters on-line and simultaneously maintain trajectory tracking properties. The relation between manipulator motion tracking capability and convergence of parameter estimation properties is discussed through example case studies. The effect of control input update delays on adaptive controller performance is also studied

Design and Characterization of a Low-Cost and Efficient Torsional Spring for ES-RSEA

The design of torsional springs for series elastic actuators (SEAs) is challenging, especially when balancing good stiffness characteristics and efficient torque robustness. This study focuses on the design of a lightweight, low-cost, and compact torsional spring for use in the energy storage-rotary series elastic actuator (ES-RSEA) of a lumbar support exoskeleton. The exoskeleton is used as an assistive device to prevent lower back injuries. The torsion spring was designed following design for manufacturability (DFM) principles, focusing on minimal space and weight. The design process involved determining the potential topology and optimizing the selected topology parameters through the finite element method (FEM) to reduce equivalent stress. The prototype was made using a waterjet cutting process with a low-cost material (AISI-4140-alloy) and tested using a custom-made test rig. The results showed that the torsion spring had a linear torque-displacement relationship with 99% linearity, and the deviation between FEM simulation and experimental measurements was less than 2%. The torsion spring has a maximum torque capacity of 45.7 Nm and a 440 Nm/rad stiffness. The proposed torsion spring is a promising option for lumbar support exoskeletons and similar applications requiring low stiffness, low weight-to-torque ratio, and cost-effectiveness