An Improved Method for Online Calculation and Compensation of the Static Deflection at a Robot End-Effector

Traditionally, robotic deflection analysis for a low-weight robot has been performed based on an assumption that each link is treated as a cantilever beam, which leads to no angular deflection at a joint. In practice, a robotic intermediate joint is linearly and angulary deflected when a load is applied at the end-effector. It is found in this study that the additional link deflection resulting from the angular deflection of a robotic revolute joint substantially contributes to the end-effector\u27s total deflection. This article presents an improved method via a combination of classical beam theory, energy methods and the concepts of differential relationships to more accurately calculate the static deflection at the end-effector. A systematic approach to deflection calculation through three different Jacobians are presented. The study also shows that the end-effector\u27s deflection heavily depends on robotic arm configurations. The deflection is then compensated based on the selected optimum configuration. The theoretical deflection analysis is verified by experimental results. A planar two-link robot and a six-degree-of-freedom Elbow Manipulator are used for numerical illustration and calculation procedure

An Improved Method for Online Calculation and Compensation of the Static Deflection at a Robot End-Effector

Traditionally, robotic deflection analysis for a low-weight robot has been performed based on an assumption that each link is treated as a cantilever beam, which leads to no angular deflection at a joint. In practice, a robotic intermediate joint is linearly and angulary deflected when a load is applied at the end-effector. It is found in this study that the additional link deflection resulting from the angular deflection of a robotic revolute joint substantially contributes to the end-effector\u27s total deflection. This article presents an improved method via a combination of classical beam theory, energy methods and the concepts of differential relationships to more accurately calculate the static deflection at the end-effector. A systematic approach to deflection calculation through three different Jacobians are presented. The study also shows that the end-effector\u27s deflection heavily depends on robotic arm configurations. The deflection is then compensated based on the selected optimum configuration. The theoretical deflection analysis is verified by experimental results. A planar two-link robot and a six-degree-of-freedom Elbow Manipulator are used for numerical illustration and calculation procedure

A quasi-static model-based control methodology for articulated mechanical systems

Hazardous environments encountered in nuclear clean-up tasks mandate the use of complex robotic systems in many situations. The operation of these systems is now performed primarily under teleoperation. This is, at best, five times slower than equivalent direct human contact operations.One way to increase remote work efficiency is to use automation for specific tasks. However, the unstructured, complex nature of the environment along with the inherent structural flexibility of mobile robot work systems makes task automation difficult and in meiny cases impossible.This research considers a quasi-static macroscopic modeling methodology that could be combined with sensor-guided manipulation schemes to achieve the needed operational accuracies for remote work task automation. Application of this methodology begins with an off-line analysis phase in which the system is identified in terms of the ideal D-H parameters and its structural elements. Themanipulator is modeled with fundamental components (i.e. beam elements, hydraulic elements, etc)and then analyzed to determine load dependent functions that predict deflections at each joint and the end of each link. Next, forces applied at the end-effector and gravity loads are projected into local link coordinates using the undeflected pose of the manipulator. These local loads are then used to calculate deflections which are expressed as 4 by 4 homogeneous transformations and inserted into the original manipulator transformations to predict end-effector position and orientation (anderror/deflection vector). The error/deflection vector is then used to determine corrective actions based on the manipulator flexibilities, pose and loading. This corrective action alters the manipulator commands such that the manipulator end-effector is moved to the desired location based on the error between the model predictions and commanded position using the ideal kinematics.The modeling methodology can readily be applied to any kinematic chain. This allows analysis of a conceptual system in terms of basic mechanics and structural deflections. The methodology allows components such as actuators or links to be interchanged in simulation so that alternative designs may be tested. This capability could help avoid potentially costly conceptual design flaws at a very early stage in the design process.Real-time compensation strategies have been developed so as to lessen concerns with structural deformation during use. The compensation strategies presented here show that the modeling methods can be used to increase the end-effector accuracy by calculating the deflections and command adjustments iteratively in real-time. The iterations show rapid convergence of the adjusted command positions to reach the desired end-effector location. The compensation methods discussed are easily altered to fit systems of any complexity, only requiring changes in the number of variables and the number of equations to solve. Most importantly, however, is that the modeling methodology,in conjunction with the compensation methods, can be used to correct for a significant fraction of the errors associated with manipulator flexibility effects. Implementation in a real-time system only involves changes in path planning, not in low-level control.The modeling methods and deflection predictions were verified using a sub-system of the OakRidge National Laboratory\u27s Dual Arm Work Platform. The experimental method used simple,non-contact measurement devices that are minimally intrusive to the manipulator\u27s workspace. The Results show good correlation between model and experimental results for some configurations. Experimental results can be extrapolated to predict that errors could be reduced from several inches to several tenths of an inch for systems like the Dual Arm Work Platform in some configurations.Continuing work will investigate applications to selective automation for Decontamination and Dismantlement tasks, using this work as a necessary foundation

A reconfigurable, tendon-based haptic interface for research into human-environment interactions

Human reaction to external stimuli can be investigated in a comprehensive way by using a versatile virtual-reality setup involving multiple display technologies. It is apparent that versatility remains a main challenge when human reactions are examined through the use of haptic interfaces as the interfaces must be able to cope with the entire range of diverse movements and forces/torques a human subject produces. To address the versatility challenge, we have developed a large-scale reconfigurable tendon-based haptic interface which can be adapted to a large variety of task dynamics and is integrated into a Cave Automatic Virtual Environment (CAVE). To prove the versatility of the haptic interface, two tasks, incorporating once the force and once the velocity extrema of a human subject's extremities, were implemented: a simulator with 3-DOF highly dynamic force feedback and a 3-DOF setup optimized to perform dynamic movements. In addition, a 6-DOF platform capable of lifting a human subject off the ground was realized. For these three applications, a position controller was implemented, adapted to each task, and tested. In the controller tests with highly different, task-specific trajectories, the three robot configurations fulfilled the demands on the application-specific accuracy which illustrates and confirms the versatility of the developed haptic interfac

Improving robotic machining accuracy through experimental error investigation and modular compensation

Machining using industrial robots is currently limited to applications with low geometrical accuracies and soft materials. This paper analyzes the sources of errors in robotic machining and characterizes them in amplitude and frequency. Experiments under different conditions represent a typical set of industrial applications and allow a qualified evaluation. Based on this analysis, a modular approach is proposed to overcome these obstacles, applied both during program generation (offline) and execution (online). Predictive offline compensation of machining errors is achieved by means of an innovative programming system, based on kinematic and dynamic robot models. Real-time adaptive machining error compensation is also provided by sensing the real robot positions with an innovative tracking system and corrective feedback to both the robot and an additional high-dynamic compensation mechanism on piezo-actuator basis

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

Modeling and Control of Flexible Link Manipulators

Autonomous maritime navigation and offshore operations have gained wide attention with the aim of reducing operational costs and increasing reliability and safety. Offshore operations, such as wind farm inspection, sea farm cleaning, and ship mooring, could be carried out autonomously or semi-autonomously by mounting one or more long-reach robots on the ship/vessel. In addition to offshore applications, long-reach manipulators can be used in many other engineering applications such as construction automation, aerospace industry, and space research. Some applications require the design of long and slender mechanical structures, which possess some degrees of flexibility and deflections because of the material used and the length of the links. The link elasticity causes deflection leading to problems in precise position control of the end-effector. So, it is necessary to compensate for the deflection of the long-reach arm to fully utilize the long-reach lightweight flexible manipulators. This thesis aims at presenting a unified understanding of modeling, control, and application of long-reach flexible manipulators. State-of-the-art dynamic modeling techniques and control schemes of the flexible link manipulators (FLMs) are discussed along with their merits, limitations, and challenges. The kinematics and dynamics of a planar multi-link flexible manipulator are presented. The effects of robot configuration and payload on the mode shapes and eigenfrequencies of the flexible links are discussed. A method to estimate and compensate for the static deflection of the multi-link flexible manipulators under gravity is proposed and experimentally validated. The redundant degree of freedom of the planar multi-link flexible manipulator is exploited to minimize vibrations. The application of a long-reach arm in autonomous mooring operation based on sensor fusion using camera and light detection and ranging (LiDAR) data is proposed.publishedVersio

Correction of Force Errors for Flexible Manipulators in Quasi-Static Conditions

This paper deals with the problem of controlling the interactions of flexible manipulators with their environment. For executing a force control task, a manipulator with intrinsic (mechanical) compliance has some advantages over the rigid manipulators commonly employed in position control tasks. In particular, stability margins of the force control loop are increased, and robustness to uncertainties in the model of the environment is improved for compliant arms. On the other hand, the deformations of the arm under the applied load give rise to errors, that ultimately reflect in force control errors. This paper addresses the problem of evaluating these errors, and of compensating for them with suitable joint angle corrections. A solution to this problem is proposed in the simplifying assumptions that an accurate model of the arm flexibility is known, and that quasi-static corrections are of interest.MIT Artificial Intelligence Laborator