Affordable flexible hybrid manipulator for miniaturised product assembly

Miniaturised assembly systems are capable of assembling parts of a few millimetres in size with an accuracy of a few micrometres. Reducing the size and the cost of such a system while increasing its flexibility and accuracy is a challenging issue. The introduction of hybrid manipulation, also called coarse/fine manipulation, within an assembly system is the solution investigated in this thesis. A micro-motion stage (MMS) is designed to be used as the fine positioning mechanism of the hybrid assembly system. MMSs often integrate compliant micro-motion stages (CMMSs) to achieve higher performances than the conventional MMSs. CMMSs are mechanisms that transmit an output force and displacement through the deformation of their structure. Although widely studied, the design and modelling techniques of these mechanisms still need to be improved and simplified. Firstly, the linear modelling of CMMSs is evaluated and two polymer prototypes are fabricated and characterised. It is found that polymer based designs have a low fabrication cost but not suitable for construction of a micro-assembly system. A simplified nonlinear model is then derived and integrated within an analytical model, allowing for the full characterisation of the CMMS in terms of stiffness and range of motion. An aluminium CMMS is fabricated based on the optimisation results from the analytical model and is integrated within an MMS. The MMS is controlled using dual-range positioning to achieve a low-cost positioning accuracy better than 2µm within a workspace of 4.4×4.4mm2. Finally, a hybrid manipulator is designed to assemble mobile-phone cameras and sensors automatically. A conventional robot manipulator is used to pick and place the parts in coarse mode while the aluminium CMMS based MMS is used for fine alignment of the parts. A high-resolution vision system is used to locate the parts on the substrate and to measure the relative position of the manipulator above MMS using a calibration grid with square patterns. The overall placement accuracy of the assembly system is ±24µm at 3σ and can reach 2µm, for a total cost of less than £50k, thus demonstrating the suitability of hybrid manipulation for desktop-size miniaturised assembly systems. The precision of the existing system could be significantly improved by making the manipulator stiffer (i.e. preloaded bearings…) and adjustable to compensate for misalignment. Further improvement could also be made on the calibration of the vision system. The system could be either scaled up or down using the same architecture while adapting the controllers to the scale.Engineering and Physical Sciences Research Council (EPSRC

Nonlinear Control Strategies for Outdoor Aerial Manipulators

In this thesis, the design, validation and implementation of nonlinear control strategies for aerial manipulators {i.e. aerial robots equipped with manipulators{ is studied, with special emphasis on the internal coupling of the system and its resilience against external disturbances. For the rst, di erent decentralised control strategies {i.e. using di erent control typologies for each one of the subsystems{ that indirectly take into account this coupling have been analysed. As a result, a nonlinear strategy composed of two controllers is proposed. A higher priority is given to the manipulation accuracy, relaxing the platform tracking, and hence obtaining a solution improving the manipulation capabilities with the surrounding environment. To validate these results, thorough stability and robustness analyses are provided, both theoretically and in simulation. On the other hand, a signi cant e ort has been devoted to improving the response and applicability of robot manipulators used in ight via control. In particular, the design of controllers for lightweight exible manipulators {that reduce the consequences of incidents involving unforeseen contacts{ is analysed. Although their inherent nature perfectly ts for aerial manipulation applications, the added exibility produces unwanted behaviours, such as second-order modes and uncertainties. To cope with them, an adaptable position nonlinear control strategy is proposed. To validate this contribution, the stability of the approach is studied in theory and its capabilities are proven in several experimental scenarios. In these, the robustness of the solution against unforeseen impacts and contact with uncharacterised interfaces is demonstrated. Subsequently, this strategy has been enriched with {multiaxis{ force control capabilities thanks to the inclusion of an outer control loop modifying the manipulator reference. Accordingly, this additional applicationfocused capability is added to the controlled system without loosing the modulated response of the inner-loop position strategy. It is also worth noting that, thanks to the cascade-like nature of the modi cation, the transition between position and force control modes is inherently smooth and automatic. The stability of this expanded strategy has been theoretically analysed and the results validated in a set of experimental scenarios. To validate the rst nonlinear approach with realistic outdoor simulations before its implementation, a computational uid dynamics analysis has been performed to obtain an explicit model of the aerodynamic forces and torques applied to the blunt-body of the aerial platform in ight. The results of this study have been compared to the most common alternative nowadays, being highlighted that the proposed model signi cantly surpasses this option in terms of accuracy. Moreover, it is worth underscoring that this characterisation could be also employed in the future to develop control solutions with enhanced rejection capabilities against wind conditions. Finally, as the focus of this thesis is on the use of novel control strategies on real aerial manipulation outdoors to improve their accuracy while performing complex tasks, a modular autopilot solution to be able to implement them has been also developed. This general-purpose autopilot allows the implementation of new algorithms, and facilitates their theory-to-experimentation transition. Taking into account this perspective, the proposed tool employs the simple and widely-known MAS interface and the highly reliable PX4 autopilot as backup, thus providing a redundant approach to handle unexpected incidents in ight.En esta tesis se ha estudiado el diseño, validación e implementación de estrategias de control no lineales para robots manipuladores aéreos –esto es, robots aéreos equipados con un sistema de manipulación robótica–, dándose especial énfasis a las interacciones internas del sistema y a su resiliencia frente a efectos externos. Para lo primero, se han analizado diferentes estrategias de control descentralizado –es decir, que usan tipologías de control diferentes para cada uno de los subsistemas–, pero que tienen indirectamente en consideración la interacción entre manipulación y vuelo. Como resultado de esta línea, se propone una estretegia de control conformada por dos controladores. Estos se coordinan de tal forma que se le da prioridad a la manipulación sobre el seguimiento de posiciones del vehículo, produciéndose un sistema de control que mejora la precisión de las interacciones entre el sistema manipulador y el entorno. Para validar estos resultados, se ha analizado su estabilidad y robustez tanto teóricamente como mediante simulaciones numéricas. Por otro lado, se ha buscado mejorar la respuesta y aplicabilidad de los manipuladores que se usan en vuelo mediante su control. Dentro de esta tendencia, la tesis se ha centrado en el diseño de controladores para manipuladores ligeros flexibles, ya que estos permiten reducir el peso del sistema completo y reducen el riesgo de incidentes debidos a contactos inesperados. Sin embargo, la flexibilidad de estos produce comportamientos indeseados durante la operación, como la aparición de modos de segundo orden y cierta incentidumbre en su comportamiento. Para reducir su impacto en la precisión de las tareas de manipulación, se ha desarrollado un controlador no lineal adaptable. Para validar estos resultados, se ha analizado la estabilidad del sistema teóricamente y se han desarrollado una serie de experimentos. En ellos, se ha comprobado su robustez ante impactos inesperados y contactos con elementos no caracterizados. Posteriormente, esta estrategia para manipuladores flexibles ha sido ampliada al añadir un bucle externo que posibilita el control en fuerzas en varias direcciones. Esto permite, mediante un único controlador, mantener la suave respuesta de la estrategia. Además cabe destacar que, al contar esta estrategia con un diseño en cascade, la transición entre los segmentos de desplazamiento del brazo y de aplicación de fuerzas es fluida y automática. La estabilidad de esta estrategia ampliada ha sido analizada teóricamente y los resultados han sido validados experimentalmente. Para validar la primera estrategia mediante simulaciones que representen fielmente las condiciones en exteriores antes de su implementación, ha sido necesario realizar un estudio mediante mecánica de fluidos computacional para obtener un modelo explícito de las fuerzas y momentos aerodinámicos a los que se efrenta la plataforma en vuelo. Los resultados de este estudio han sido comparados con la alternativa más empleada actualmente, mostrándose que los avances del método propuesto son sustanciales. Asimismo, es importante destacar que esta caracterización podría también usarse en el futuro para desarrollar controladores con una respuesta mejorada ante perturbaciones aerodinámicas, como en el caso de volar con viento. Finalmente, al ser esta una tesis centrada en las estrategias de control novedosas en sistemas reales para la mejora de su rendimiento en misiones complejas, se ha desarrollado un autopiloto modular fácilmente modificable para implementarlas. Este permite validar experimentalmente nuevos algoritmos y facilita la transición entre teoría y práctica. Para ello, esta herramienta se basa en una interfaz sencilla ampliamente conocida por los investigadores de robótica, Simulink®, y cuenta con un autopiloto de respaldo, PX4, para enfrentarse a los incidentes inesperados que pudieran surgir en vuelo

Simulation of the thermoforming process of UD fiber-reinforced thermoplastic tape laminates

Einer der entscheidendsten Prozessschritte bei der Herstellung von kontinuierlich faserverstärkten Kunstoffen ist die Umformung von zweidimensionalen Halbzeugen in komplexe Geometrien. Hierbei spielt das nicht-isotherme Stempelumformverfahren von unidirektional (UD) faserverstärkten thermoplastischen Tape-Laminaten aufgrund geringer Zykluszeiten, Materialeffizienz und Recyclingfähigkeit insbesondere in der Automobilindustrie eine immer größer werdende Rolle. Durch die Umformsimulation kann die Herstellbarkeit einer bestimmten Geometrie virtuell abgesichert und hierfür notwendige Prozessparameter bestimmt werden, wodurch eine zeit- und kostenintensive "Trial and Error" Prozessauslegung vermieden werden kann. In dieser Arbeit werden initial anhand einer experimentellen Umformstudie und Materialcharakterisierungen die Anforderungen an die Umformsimulation von teilkristallinen thermoplastischen UD-Tapes abgeleitet. Hierbei zeigt sich, dass ein thermomechanischer Ansatz, unter Berücksichtigung der raten- und temperaturabhängigen Materialeigenschaften, als auch der Kristallisationskinetik, erstrebenswert ist. Darauf aufbauend wird mit der kommerziellen Finite Elemente (FE) Software Abaqus, in Kombination mit mehreren sogenannten User-Subroutinen, ein entsprechender Simulationsansatz entwickelt. Zunächst werden hypo- und hyperelastischen Materialmodellierungsansätze untersucht, sowie ratenabhängige intra-ply Materialmodellierungsansätze vorgestellt. Dabei liegt ein Schwerpunkt auf dem ratenabhängigen Biegeverhalten, da diese Materialeigenschaft üblicherweise nicht berücksichtigt wird, weshalb hierfür hypoviskoelastische Modellierungsansätze auf Basis eines nichtlinearen Voigt-Kelvin- sowie eines nichtlinearen generalisierten Maxwell-Ansatzes vorgestellt werden. Unter Anwendung dieser Ansätze zeigt sich im Vergleich mit experimentellen Umformergebnissen eine gute Übereinstimmung. Darüber hinaus wird ein Einfluss der ratenabhängigen Biegeeigenschaften auf die Vorhersage der Faltenbildung beobachtet. Im nächsten Schritt wird der Ansatz um eine "Discrete Kirchhoff Triangle" (DKT) Schalenformulierung erweitert, welche in Abaqus als User-Element implementiert ist. Dies ermöglicht im Gegensatz zu dem im vorherigen Kapitel vorgestellten Ansatz die hyperviskoelastische Modellierung des Membran- und des Biegeverhaltens. Darauf aufbauend werden ein nichtlinearer Voigt-Kelvin-, sowie ein nichtlinearer generalisierter Maxwell-Ansatz, welcher auf einer multiplikativen Zerlegung des Deformationsgradienten basiert, vorgestellt. In der Umformsimulation zeigt sich eine gute Übereinstimmung mit experimentellen Umformergebnissen. Darüber hinaus wird beobachtet, dass ein nichtlinearer Voigt-Kelvin-Ansatz für die Modellierung des Membranverhaltens ausreichend ist. Neben intra-ply werden auch inter-ply Modellierungsansätze untersucht. Hierfür wird ein erweiterter Ansatz vorgestellt, der neben den üblicherweise berücksichtigten Zustandsgrößen Abgleitgeschwindigkeit und Transversaldruck auch die Relativorientierung zwischen den abgleitenden Schichten berücksichtigt. Bei der Anwendung dieses Ansatzes in der Umformsimulation werden jedoch nur geringe Unterschiede gegenüber einem herkömmlichen Ansatz beobachtet. Der präsentierte Ansatz für die Umformsimulation von thermoplastischen UD-Tapes wird final zu einem gekoppelten thermomechanischen Ansatz erweitert. Die entsprechende thermische Modellierung berücksichtigt Strahlung, Konvektion und Wärmeleitung, sowie die Kristallisationskinetik, wobei das mechanische Verhalten über die Temperatur und die relative Kristallinität an das thermische Verhalten gekoppelt ist. Hiermit wird der Übergang vom schmelzflüssigen zum Festkörperzustand vorhergesagt und in der Modellierung des Umformverhaltens berücksichtigt. Hierdurch wird eine verbesserte Übereinstimmung mit den experimentellen Umformergebnissen erzielt und auch die lokale Temperaturentwicklung akkurat vorhergesagt. Darüber hinaus zeigt sich, dass bei einer ungünstigen Wahl der Prozessparameter eine starke Kristallisation schon während der Umformung auftritt. Da außerdem nur der thermomechanische Ansatz den Einfluss aller relevanten Prozessparameter berücksichtigen kann, wird geschlussfolgert, dass die Berücksichtigung thermischer Effekte sowie der Kristallisationskinetik vorteilhaft für die virtuelle Prozessauslegung nicht-isothermer Stempelumformverfahren mit teilkristallinen Thermoplasten ist

Lateral Capacity of Piles and Caissons in Cohesive Soils

Upper bound plastic limit analysis (PLA) solutions have been widely used to assess maximum capacity of laterally loaded piles and caissons. However, for the specific case of short piles and caissons with aspect ratios generally ranging from one to three, the current solutions tend to over-estimate capacities. Furthermore, these over predictions seem to be significantly influenced by eccentricity of loading. This dissertation presents a unified upper bound plastic limit analysis solution aiming to improve predictions of capacity for the aforementioned cases. In addition, a simplified upper bound method is proposed for cases in which computational efficiency is needed. Both solutions are compared to results from three dimensional finite element studies. Towards this end, most of the existing simplified predictive methods typically apply to idealized soil strength profiles that are either constant or linearly increasing with depth. However, site investigations often reveal complex strength profiles that deviate significantly from simple linear profiles. One example is the case in which a superficial stiff layer overlays a thicker layer of very soft soil. The work herein presented also includes analyses of pile and caisson performance in stratified soils based on a three dimensional upper bound PLA with a collapse mechanism comprising a surface failure wedge, a flow-around region and a spherical base failure surface. An introductory discussion on the influence of soil stratigraphy and geology for design purposes is included. Selected strength distributions are representative from field data obtained through cone penetration testing. Finally, the installation of driven piles and suction caissons in clayey soils generates excess pore pressures that temporarily reduce load capacity due to side resistance. Time dependent dissipation of these excess pore pressures leads to recovery of side resistance, a process known as ‘setup’. Since many facilities cannot be put into operation until sufficient pile load capacity has been mobilized, realistic predictions of setup time can be important. A simplified method of analysis for calculation of the setup time following open ended pile penetration is also presented

Lateral Capacity of Piles and Caissons in Cohesive Soils

Upper bound plastic limit analysis (PLA) solutions have been widely used to assess maximum capacity of laterally loaded piles and caissons. However, for the specific case of short piles and caissons with aspect ratios generally ranging from one to three, the current solutions tend to over-estimate capacities. Furthermore, these over predictions seem to be significantly influenced by eccentricity of loading. This dissertation presents a unified upper bound plastic limit analysis solution aiming to improve predictions of capacity for the aforementioned cases. In addition, a simplified upper bound method is proposed for cases in which computational efficiency is needed. Both solutions are compared to results from three dimensional finite element studies. Towards this end, most of the existing simplified predictive methods typically apply to idealized soil strength profiles that are either constant or linearly increasing with depth. However, site investigations often reveal complex strength profiles that deviate significantly from simple linear profiles. One example is the case in which a superficial stiff layer overlays a thicker layer of very soft soil. The work herein presented also includes analyses of pile and caisson performance in stratified soils based on a three dimensional upper bound PLA with a collapse mechanism comprising a surface failure wedge, a flow-around region and a spherical base failure surface. An introductory discussion on the influence of soil stratigraphy and geology for design purposes is included. Selected strength distributions are representative from field data obtained through cone penetration testing. Finally, the installation of driven piles and suction caissons in clayey soils generates excess pore pressures that temporarily reduce load capacity due to side resistance. Time dependent dissipation of these excess pore pressures leads to recovery of side resistance, a process known as ‘setup’. Since many facilities cannot be put into operation until sufficient pile load capacity has been mobilized, realistic predictions of setup time can be important. A simplified method of analysis for calculation of the setup time following open ended pile penetration is also presented

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

Industrial Robotics

This book covers a wide range of topics relating to advanced industrial robotics, sensors and automation technologies. Although being highly technical and complex in nature, the papers presented in this book represent some of the latest cutting edge technologies and advancements in industrial robotics technology. This book covers topics such as networking, properties of manipulators, forward and inverse robot arm kinematics, motion path-planning, machine vision and many other practical topics too numerous to list here. The authors and editor of this book wish to inspire people, especially young ones, to get involved with robotic and mechatronic engineering technology and to develop new and exciting practical applications, perhaps using the ideas and concepts presented herein