Modeling, Control and Estimation of Reconfigurable Cable Driven Parallel Robots

The motivation for this thesis was to develop a cable-driven parallel robot (CDPR) as part of a two-part robotic device for concrete 3D printing. This research addresses specific research questions in this domain, chiefly, to present advantages offered by the addition of kinematic redundancies to CDPRs. Due to the natural actuation redundancy present in a fully constrained CDPR, the addition of internal mobility offers complex challenges in modeling and control that are not often encountered in literature. This work presents a systematic analysis of modeling such kinematic redundancies through the application of reciprocal screw theory (RST) and Lie algebra while further introducing specific challenges and drawbacks presented by cable driven actuators. It further re-contextualizes well-known performance indices such as manipulability, wrench closure quality, and the available wrench set for application with reconfigurable CDPRs. The existence of both internal redundancy and static redundancy in the joint space offers a large subspace of valid solutions that can be condensed through the selection of appropriate objective priorities, constraints or cost functions. Traditional approaches to such redundancy resolution necessitate computationally expensive numerical optimization. The control of both kinematic and actuation redundancies requires cascaded control frameworks that cannot easily be applied towards real-time control. The selected cost functions for numerical optimization of rCDPRs can be globally (and sometimes locally) non-convex. In this work we present two applied examples of redundancy resolution control that are unique to rCDPRs. In the first example, we maximize the directional wrench ability at the end-effector while minimizing the joint torque requirement by utilizing the fitness of the available wrench set as a constraint over wrench feasibility. The second example focuses on directional stiffness maximization at the end-effector through a variable stiffness module (VSM) that partially decouples the tension and stiffness. The VSM introduces an additional degrees of freedom to the system in order to manipulate both reconfigurability and cable stiffness independently. The controllers in the above examples were designed with kinematic models, but most CDPRs are highly dynamic systems which can require challenging feedback control frameworks. An approach to real-time dynamic control was implemented in this thesis by incorporating a learning-based frameworks through deep reinforcement learning. Three approaches to rCDPR training were attempted utilizing model-free TD3 networks. Robustness and safety are critical features for robot development. One of the main causes of robot failure in CDPRs is due to cable breakage. This not only causes dangerous dynamic oscillations in the workspace, but also leads to total robot failure if the controllability (due to lack of cables) is lost. Fortunately, rCDPRs can be utilized towards failure tolerant control for task recovery. The kinematically redundant joints can be utilized to help recover the lost degrees of freedom due to cable failure. This work applies a Multi-Model Adaptive Estimation (MMAE) framework to enable online and automatic objective reprioritization and actuator retasking. The likelihood of cable failure(s) from the estimator informs the mixing of the control inputs from a bank of feedforward controllers. In traditional rigid body robots, safety procedures generally involve a standard emergency stop procedure such as actuator locking. Due to the flexibility of cable links, the dynamic oscillations of the end-effector due to cable failure must be actively dampened. This work incorporates a Linear Quadratic Regulator (LQR) based feedback stabilizer into the failure tolerant control framework that works to stabilize the non-linear system and dampen out these oscillations. This research contributes to a growing, but hitherto niche body of work in reconfigurable cable driven parallel manipulators. Some outcomes of the multiple engineering design, control and estimation challenges addressed in this research warrant further exploration and study that are beyond the scope of this thesis. This thesis concludes with a thorough discussion of the advantages and limitations of the presented work and avenues for further research that may be of interest to continuing scholars in the community

Inverse Dynamics of a Redundantly Actuated Four-Bar Mechanism Using an Optimal Control Formulation

This paper presents an approach to estimating joint torques in a four-bar closed-chain mechanism with prescribed kinematics and redundant actuation, i.e., with more actuators than degrees of freedom. This problem has several applications in industrial robots, machine tools, and biomechanics. The inverse dynamics problem is formulated as an optimal control problem (OCP). The dynamical equations are derived for an open-chain mechanism, what keeps the formulation simple and straightforward. Sets of constraints are explored to force the three-link open-chain to behave as a four-bar mechanism with a crank rotating at a constant velocity. The controls calculated from the OCP are assumed to be the input joint torques. The standard case with one torque actuator is solved and compared to cases with two and three actuators. The case of two actuators presented the smallest peak and mean torques, using one specific set of constraints. Such torques were smaller than the solution obtained using an alternative method existing in literature that solves the redundancy problem by means of the pseudo-inverse matrix. Comparison with inverse dynamics solutions using well-established methods for the one-actuator closedloop four-bar were equal. Reconstructed kinematical trajectories from forward integration of the closed-loop mechanism with the OCP obtained torques were essentially similar. The results suggest that the adopted procedure is promising, giving solutions with lower torque requirements than the regularly actuated case and redundantly actuated computed with other approaches. The applicability of the method has been shown for the four-bar mechanism. Other classes of redundantly actuated, closed-loop mechanisms could be tested using a similar formulation. However, the numerical parameters of the OCP must be chosen carefully to achieve convergence

Proceedings of the NASA Conference on Space Telerobotics, volume 2

These proceedings contain papers presented at the NASA Conference on Space Telerobotics held in Pasadena, January 31 to February 2, 1989. The theme of the Conference was man-machine collaboration in space. The Conference provided a forum for researchers and engineers to exchange ideas on the research and development required for application of telerobotics technology to the space systems planned for the 1990s and beyond. The Conference: (1) provided a view of current NASA telerobotic research and development; (2) stimulated technical exchange on man-machine systems, manipulator control, machine sensing, machine intelligence, concurrent computation, and system architectures; and (3) identified important unsolved problems of current interest which can be dealt with by future research

Path planning for assembly of strut-based structures

A path planning method with collision avoidance for a general single chain nonredundant or redundant robot is proposed. Joint range boundary overruns are also avoided. The result is a sequence of joint vectors which are passed to a trajectory planner. A potential field algorithm in joint space computes incremental joint vectors delta-q = delta-q(sub a) + delta-q(sub c) + delta-q(sub r). Adding delta-q to the robot's current joint vector leads to the next step in the path. Delta-q(sub a) is obtained by computing the minimum norm solution of the underdetermined linear system J delta-q(sub a) = x(sub a) where x(sub a) is a translational and rotational force vector that attracts the robot to its goal position and orientation. J is the manipulator Jacobian. Delta-q(sub c) is a collision avoidance term encompassing collisions between the robot (links and payload) and obstacles in the environment as well as collisions among links and payload of the robot themselves. It is obtained in joint space directly. Delta-q(sub r) is a function of the current joint vector and avoids joint range overruns. A higher level discrete search over candidate safe positions is used to provide alternatives in case the potential field algorithm encounters a local minimum and thus fails to reach the goal. The best first search algorithm A* is used for graph search. Symmetry properties of the payload and equivalent rotations are exploited to further enlarge the number of alternatives passed to the potential field algorithm

Proceedings of the NASA Conference on Space Telerobotics, volume 1

The theme of the Conference was man-machine collaboration in space. Topics addressed include: redundant manipulators; man-machine systems; telerobot architecture; remote sensing and planning; navigation; neural networks; fundamental AI research; and reasoning under uncertainty

Experiments in Nonlinear Adaptive Control of Multi-Manipulator, Free-Flying Space Robots

Sophisticated robots can greatly enhance the role of humans in space by relieving astronauts of low level, tedious assembly and maintenance chores and allowing them to concentrate on higher level tasks. Robots and astronauts can work together efficiently, as a team; but the robot must be capable of accomplishing complex operations and yet be easy to use. Multiple cooperating manipulators are essential to dexterity and can broaden greatly the types of activities the robot can achieve; adding adaptive control can ease greatly robot usage by allowing the robot to change its own controller actions, without human intervention, in response to changes in its environment. Previous work in the Aerospace Robotics Laboratory (ARL) have shown the usefulness of a space robot with cooperating manipulators. The research presented in this dissertation extends that work by adding adaptive control. To help achieve this high level of robot sophistication, this research made several advances to the field of nonlinear adaptive control of robotic systems. A nonlinear adaptive control algorithm developed originally for control of robots, but requiring joint positions as inputs, was extended here to handle the much more general case of manipulator endpoint-position commands. A new system modelling technique, called system concatenation was developed to simplify the generation of a system model for complicated systems, such as a free-flying multiple-manipulator robot system. Finally, the task-space concept was introduced wherein the operator's inputs specify only the robot's task. The robot's subsequent autonomous performance of each task still involves, of course, endpoint positions and joint configurations as subsets. The combination of these developments resulted in a new adaptive control framework that is capable of continuously providing full adaptation capability to the complex space-robot system in all modes of operation. The new adaptive control algorithm easily handles free-flying systems with multiple, interacting manipulators, and extends naturally to even larger systems. The new adaptive controller was experimentally demonstrated on an ideal testbed in the ARL-A first-ever experimental model of a multi-manipulator, free-flying space robot that is capable of capturing and manipulating free-floating objects without requiring human assistance. A graphical user interface enhanced the robot usability: it enabled an operator situated at a remote location to issue high-level task description commands to the robot, and to monitor robot activities as it then carried out each assignment autonomously

Advanced Strategies for Robot Manipulators

Amongst the robotic systems, robot manipulators have proven themselves to be of increasing importance and are widely adopted to substitute for human in repetitive and/or hazardous tasks. Modern manipulators are designed complicatedly and need to do more precise, crucial and critical tasks. So, the simple traditional control methods cannot be efficient, and advanced control strategies with considering special constraints are needed to establish. In spite of the fact that groundbreaking researches have been carried out in this realm until now, there are still many novel aspects which have to be explored

Parallel Manipulators

In recent years, parallel kinematics mechanisms have attracted a lot of attention from the academic and industrial communities due to potential applications not only as robot manipulators but also as machine tools. Generally, the criteria used to compare the performance of traditional serial robots and parallel robots are the workspace, the ratio between the payload and the robot mass, accuracy, and dynamic behaviour. In addition to the reduced coupling effect between joints, parallel robots bring the benefits of much higher payload-robot mass ratios, superior accuracy and greater stiffness; qualities which lead to better dynamic performance. The main drawback with parallel robots is the relatively small workspace. A great deal of research on parallel robots has been carried out worldwide, and a large number of parallel mechanism systems have been built for various applications, such as remote handling, machine tools, medical robots, simulators, micro-robots, and humanoid robots. This book opens a window to exceptional research and development work on parallel mechanisms contributed by authors from around the world. Through this window the reader can get a good view of current parallel robot research and applications