Visual Calibration, Identification and Control of 6-RSS Parallel Robots

Parallel robots present some outstanding advantages in high force-to-weight ratio, better stiffness and theoretical higher accuracy compared with serial manipulators. Hence parallel robots have been utilized increasingly in various applications. However, due to the manufacturing tolerances and defections in the robot structure, the positioning accuracy of parallel robots is basically equivalent with that of serial manipulators according to previous researches on the accuracy analysis of the Stewart Platform [1], which is difficult to meet the precision requirement of many potential applications. In addition, the existence of closed-chain mechanism yields difficulties in designing control system for practical applications, due to its highly coupled dynamics. Visual sensor is a good choice for providing non-contact measurement of the end-effector pose (position and orientation) with simplicity in operation and low cost compared to other measurement methods such as the coordinate measurement machine (CMM) [2] and the laser tracker [3]. In this research, a series of solutions including kinematic calibration, dynamic identification and visual servoing are proposed to improve the positioning and tracking performance of the parallel robot based on the visual sensor. The main contributions of this research include three parts. In the first part, a relative pose-based algorithm (RPBA) is proposed to solve the kinematic calibration problem of a six-revolute-spherical-spherical (6-RSS) parallel robot by using the optical CMM sensor. Based on the relative poses between the candidate and the initial configurations, a calibration algorithm is proposed to determine the optimal error parameters of the robot kinematic model and external parameters introduced by the optical sensor. The experimental results demonstrate that the proposal RPBA using optical CMM is an implementable and effective method for the parallel robot calibration. The second part focuses on the dynamic model identification of the 6-RSS parallel robots. A visual closed-loop output-error identification method based on an optical CMM sensor is proposed for the purpose of the advanced model-based visual servoing control design of parallel robots. By using an outer loop visual servoing controller to stabilize both the parallel robot and the simulated model, the visual closed-loop output-error identification method is developed and the model parameters are identified by using a nonlinear optimization technique. The effectiveness of the proposed identification algorithm is validated by experimental tests. In the last part, a dynamic sliding mode control (DSMC) scheme combined with the visual servoing method is proposed to improve the tracking performance of the 6-RSS parallel robot based on the optical CMM sensor. By employing a position-to-torque converter, the torque command generated by DSMC can be applied to the position controlled industrial robot. The stability of the proposed DSMC has been proved by using Lyapunov theorem. The real-time experiment tests on a 6-RSS parallel robot demonstrate that the developed DSMC scheme is robust to the modeling errors and uncertainties. Compared with the classical kinematic level controllers, the proposed DSMC exhibits the superiority in terms of tracking performance and robustness

Controlo e execução de estampagem incremental com cinemática paralela

Mestrado em Engenharia MecânicaO projeto SPIF-A é um verdadeiro desa o de engenharia: desenvolver uma má- quina totalmente nova e inovadora para conformação plástica de chapa. Trata-se principalmente de um trabalho de equipa, que abrange varias áreas da engenharia mecânica, desde análise estrutural até automação e controlo, passando pela termodin âmica e cinemática, entre outras. Esta dissertação sendo mais uma peça no puzzle, vai-se focar no seu desenvolvimento, principalmente no estudo da cinemática inversa e directa da plataforma de Stewart, assim como no desenvolvimento do primeiro sistema de controlo de posição. O referido sistema é um controlador de lógica difusa e será implementado através de software num computador de processamento em tempo real. Durante o desenvolvimento destes componentes também foram optimizados e/ou actualizados os sistemas hidráulicos, eléctricos e mecânicos da máquina assim como se implementou e calibrou um sistema de medição de forças de trabalho recorrendo ao uso de células de carga.The SPIF-A project is a true engineering challenge: to develop an entirely new and innovative machine for sheet metal forming. It is mostly a team e ort, covering various engineering subjects from structural analysis to automation and control but also thermodynamics, kinematics, among others. This dissertation being another piece of that puzzle, will focus on machine development, namely on de ning the machine's Stewart platform inverse kinematics, proposing a solution for the forward kinematics and devising its rst position control system. The referred system will be a fuzzy logic controller and will be implemented via software on a real time targeting machine. During this work several components like from its hydraulic, electrical and mechanical systems were updated and a force measuring system, using load cells was installed and calibrated

DEVELOPMENT OF A POST-FABRICATION STIFFNESS CHARACTERIZATION TOOL FOR MEMS

Micro-Electromechanical Systems (MEMS) manufacturers face difficulties in characterizing material properties of MEMS post production. Properties such as stiffness can be obtained from simultaneous force and displacement measurements in full-field. We developed a prototype MEMS metrology system that uses a sub-micro Newton resolution force probe operating under a nanometer resolution interferometer to characterize MEMS mechanical properties. FEA simulations and analytical calculations were performed to help determine system constraints and validate results. Precision actuators were integrated and controlled from a developed graphical user interface. The system was tested on an Analog Devices ADXL202 accelerometer

Design and control of a 6-degree-of-freedom precision positioning system

This paper presents the design and test of a6-degree-of-freedom (DOF) precision positioning system, which is assembledby two different 3-DOF precision positioning stages each driven by three piezoelectric actuators (PEAs). Based on the precision PEAs and flexure hinge mechanisms, high precision motion is obtained.The design methodology and kinematic characteristics of the6-DOF positioning system areinvestigated. According to an effective kinematic model, the transformation matrices are obtained, which is used to predict the relationship between the output displacement from the system arrangement and the amountof PEAsexpansion. In addition, the static and dynamic characteristics of the 6-DOF system have been evaluated by finite element method (FEM) simulation andexperiments. The design structure provides a high dynamic bandwidth withthe first naturalfrequency of 586.3 Hz.Decoupling control is proposed to solve the existing coupling motion of the 6-DOF system. Meanwhile, in order to compensate for the hysteresis of PEAs, the inverse Bouc-Wen model was applied as a feedforward hysteresis compensator in the feedforward/feedback hybrid control method. Finally, extensive experiments were performed to verify the tracking performance of the developed mechanism

Calibration of high-precision flexure parallel robots

Over the last decades, calibration techniques have been widely used in robotics since they represent a cost-effective solution for improving the accuracy of robots and machine-tools. They only involve software modification without the necessity of revising the robot design or tightening the manufacturing tolerances. The goal of this thesis is to propose a procedure that guides the engineer through the calibration of a given multi-DOF flexure parallel robot within sub-µm accuracy. Two robots having 3 and 6 degrees of freedom have been considered as a case-study throughout the work. As in any calibration procedure, the work has been conducted on three different fronts: measurement, data processing and validation. The originality of this thesis in respect to published material lies in these three points. Measurements were carried out in a chamber inside which the measuring environment was protected against mechanical and thermal perturbations. In particular, the temperature variations experienced by the different parts of the measuring loop during a typical measurement session were stabilized within less than ± 0.1 °C. Proposed procedures allow the collection of reliable sets of data on the two robots. Delicate aspects of practical implementation are discussed. In particular, the problem of collecting a complete set of 6D data within accuracies in the nanometre range, for which there is still a lack of standard equipment, is solved using a procedure comprising several steps and making use of existing instrumentation. Suggestions for future investigations are given, regarding either long-term research problems or short-term industrial implementation issues. Data processing was performed using two different techniques in order to reach absolute accuracies after calibration better than ± 100 nm for translations and ± 3 arcsec for rotations (± 0.3 arcsec inside a more restricted range of ± 0.11°). The first method is called the "model-based approach" and requires the use of a known analytical relationship between the motor and operational coordinates of the robot. This relationship involves a certain number of parameters that can be related to the geometry of the robot (physical models) or simply mathematical coefficients of an approximating mathematical function (behavioural models). In the case of high-precision multi-DOF flexure parallel robots, we show that polynomial-based behavioural models are preferable to physical models in terms of accuracy for data processing tasks. In the second method, called the "model-free approach", the user does not need to model explicitly the main error sources (or their effect) affecting the robot accuracy. A model-free approach has been implemented using Artificial Neural Networks. We show that, using a heuristic search based on a decision-tree, the architecture of a network with satisfactory prediction capability can be found systematically. In particular, this algorithm can find a network able to predict the direct correspondence between the motor and operational coordinates (within the desired accuracy) without the help of the Inverse Geometric Model of the robot, i.e. even if the nominal geometry of the robot being calibrated remains unknown. This result contradicts conclusions reported by previous researchers. It is claimed that any robot (not necessarily a high-precision flexure parallel mechanism) can be calibrated by means of a "neural approach" in which the architecture of an appropriate network is determined with the help of our algorithm. Two examples (other than the robots measured in this thesis) are given to illustrate this universality. In the last part of this work, we provide a feasibility study on the use of indentation, a technique traditionally used for material testing, as a validation procedure to assess the accuracy of the calibrated degrees of freedom. The industrial interest of this technique lies in the fact that the robot is asked to execute similar motions to those involved in a real micro-machining operation

Synthetic biology and microdevices : a powerful combination

Recent developments demonstrate that the combination of microbiology with micro-and nanoelectronics is a successful approach to develop new miniaturized sensing devices and other technologies. In the last decade, there has been a shift from the optimization of the abiotic components, for example, the chip, to the improvement of the processing capabilities of cells through genetic engineering. The synthetic biology approach will not only give rise to systems with new functionalities, but will also improve the robustness and speed of their response towards applied signals. To this end, the development of new genetic circuits has to be guided by computational design methods that enable to tune and optimize the circuit response. As the successful design of genetic circuits is highly dependent on the quality and reliability of its composing elements, intense characterization of standard biological parts will be crucial for an efficient rational design process in the development of new genetic circuits. Microengineered devices can thereby offer a new analytical approach for the study of complex biological parts and systems. By summarizing the recent techniques in creating new synthetic circuits and in integrating biology with microdevices, this review aims at emphasizing the power of combining synthetic biology with microfluidics and microelectronics

Design and validation of a system for controlling a robot for 3D ultrasound scanning of the lower limbs

Peripheral arterial disease (PAD) is a common circulatory problem featured by arterial narrowing or stenosis, usually in the lower limbs (i.e. legs). Without sufficient blood supply, in the case of PAD, the patient may suffer from intermittent claudication, or even require an amputation. Due to the PAD’s high prevalence yet low public awareness in the early stages, its diagnosis becomes very important. Among the most common medical imaging technologies in PAD diagnosis, the ultrasound probe has the advantages of lower cost and non-radiation. Traditional ultrasound scanning is conducted by sonographers and it causes musculoskeletal disorders in the operators. In addition, the data obtained from the manual operation are unable for the three-dimensional reconstruction of the artery needed for further study. Medical ultrasound robots release sonographers from routine lifting strain and provide accurate data for three-dimensional reconstruction. However, most existing medical ultrasound robots are designed for other purposes, and are unsuited to PAD diagnosis in the lower limbs. In this study, we present a novel medical ultrasound robot designed for PAD diagnosis in the lower limbs. The robot platform and the system setup are illustrated. Its forward and inverse kinematic models are solved by decomposing a complex parallel robot into several simple assemblies. Singularity issues and workspace are also discussed. Robots need to meet certain accuracy requirements to perform dedicated tasks. Our robot is calibrated by direct measurement with a laser tracker. The calibration method used is easy to implement without requiring knowledge of advanced calibration or heavy computation. The calibration result shows that, as an early prototype, the robot has noticeable errors in manufacturing and assembling. The implemented calibration method greatly improves the robot's accuracy. A force control design is essential when the robot needs to interact with an object/environment. Variable admittance controllers are implemented to adapt the variable stiffness encountered in human-robot interaction. An intuitive implementation of the passivity theory is proposed to ensure that the admittance model possesses a passivity property. Finally, experiments involving human interaction demonstrate the effectiveness of the proposed control design

Modeling, Stability Analysis, and Testing of a Hybrid Docking Simulator

A hybrid docking simulator is a hardware-in-the-loop (HIL) simulator that includes a hardware element within a numerical simulation loop. One of the goals of performing a HIL simulation at the European Proximity Operation Simulator (EPOS) is the verification and validation of the docking phase in an on-orbit servicing mission.....Comment: 30 papge

Parallel Platform-Based Robot for Operation in Active Water Pipes

This thesis presents a novel design for a pipe inspection robot. The main aim of the design has been to allow the robot to operate in a water pipe while it is still in service. Water pipes form a very crucial part of the infrastructure of the world we live in today. Despite their importance, water leakage is a major problem suffered by water companies worldwide, costing them billions of dollars every year. There are a wide variety of different techniques used for leak detection and localisation, but no one method is capable of accurately pinpointing the leak location and severity in all pipe conditions with minimal labour. A survey of existing pipe inspection robots showed that there have been many designs implemented that are capable of navigating the pipeline environment. However, none of these were capable of fully autonomous control in a live water pipe. It was concluded that an autonomous pipe inspection robot capable of working in active pipelines would be of great industrial benefit as it would be able to carry a wide range of sensors directly to the source of the leak with minimal, if any, human intervention. An inchworm robot prototype was constructed based on a Gough-Stewart parallel platform. The robot’s inverse kinematics equations were derived and a simulation model of the robot was constructed. These were verified using a motion capture suite, confirming that they are valid representations of the robot. The simulation was used to determine the robot’s movement limitations and minimum bend radius it could navigate. Several CFD simulations were carried out in order to estimate the maximum fluid force exerted on the robot. It was found that the robot’s design successfully minimised the fluid force such that off-the-shelf actuators had the capability to overcome it. The prototype was successfully tested in both a straight and bent pipe, demonstrating its ability to navigate a dry pipe environment. Overall, the robot prototype served as a successful proof of concept for a design of pipe inspection robot that would be capable of operating in active pipelines

Controller Design Methodology for Sustainable Local Energy Systems

Commercial Buildings and complexes are no longer just national heat and power network energy loads, but they are becoming part of a smarter grid by including their own dedicated local heat and power generation. They do this by utilising both heat and power networks/micro-grids. A building integrated approach of Combined Heat and Power (CHP) generation with photovoltaic power generation (PV) abbreviated as CHPV is emerging as a complementary energy supply solution to conventional (i.e. national grid based) gas and electricity grid supplies in the design of sustainable commercial buildings and communities. The merits for the building user/owner of this approach are: to reduce life time energy running costs; reduce carbon emissions to contribute to UK’s 2020/2030 climate change targets; and provide a more flexible and controllable local energy system to act as a dynamic supply and/or load to the central grid infrastructure. The energy efficiency and carbon dioxide (CO2) reductions achievable by CHP systems are well documented. The merits claimed by these solutions are predicated on the ability of these systems being able to satisfy: perfect matching of heat and power supply and demand; ability at all times to maintain high quality power supply; and to be able to operate with these constraints in a highly dynamic and unpredictable heat and power demand situation. Any circumstance resulting in failure to guarantee power quality or matching of supply and demand will result in a degradation of the achievable energy efficiency and CO2 reduction. CHP based local energy systems cannot rely on large scale diversity of demand to create a relatively easy approach to supply and demand matching (i.e. as in the case of large centralised power grid infrastructures). The diversity of demand in a local energy system is both much greater than the centralised system and is also specific to the local system. It is therefore essential that these systems have robust and high performance control systems to ensure supply and demand matching and high power quality can be achieved at all times. Ideally this same control system should be able to make best use of local energy system energy storage to enable it to be used as a flexible, highly responsive energy supply and/or demand for the centralised infrastructure. In this thesis, a comprehensive literature survey has identified that there is no scientific and rigorous method to assess the controllability or the design of control systems for these local energy systems. Thus, the main challenge of the work described in this thesis is that of a controller design method and modelling approach for CHP based local energy systems. Specifically, the main research challenge for the controller design and modelling methodology was to provide an accurate and stable system performance to deliver a reliable tracking of power drawn/supplied to the centralised infrastructure whilst tracking the require thermal comfort in the local energy systems buildings. In the thesis, the CHPV system has been used as a case study. A CHPV based solution provides all the benefits of CHP combined with the near zero carbon building/local network integrated PV power generation. CHPV needs to be designed to provide energy for the local buildings’ heating, dynamic ventilating system and air-conditioning (HVAC) facilities as well as all electrical power demands. The thesis also presents in addition to the controller design and modelling methodology a novel CHPV system design topology for robust, reliable and high-performance control of building temperatures and energy supply from the local energy system. The advanced control system solution aims to achieve desired building temperatures using thermostatic control whilst simultaneously tracking a specified national grid power demand profile. The theory is innovative as it provides a stability criterion as well as guarantees to track a specified dynamic grid connection demand profile. This research also presents: design a dynamic MATLAB simulation model for a 5-building zone commercial building to show the efficacy of the novel control strategy in terms of: delivering accurate thermal comfort and power supply; reducing the amount of CO2 emissions by the entire energy system; reducing running costs verses national rid/conventional approaches. The model was developed by inspecting the functional needs of 3 local energy system case studies which are also described in the thesis. The CHPV system is combined with supplementary gas boiler for additional heating to guarantee simultaneous tracking of all the zones thermal comfort requirements whilst simultaneously tracking a specified national grid power demand using a Photovoltaics array to supply the system with renewable energy to reduce amount of CO2 emission. The local energy system in this research can operate in any of three modes (Exporting, Importing, Island). The emphasise of the thesis modelling method has been verified to be applicable to a wide range of case studies described in the thesis chapter 3. This modelling framework is the platform for creating a generic controlled design methodology that can be applied to all these case studies and beyond, including Local Energy System (LES) in hotter climates that require a cooling network using absorption chillers. In the thesis in chapter 4 this controller design methodology using the modelling framework is applied to just one case study of Copperas Hill. Local energy systems face two types of challenges: technical and nontechnical (such as energy economics and legislation). This thesis concentrates solely on the main technical challenges of a local energy system that has been identified as a gap in knowledge in the literature survey. The gap identified is the need for a controller design methodology to allow high performance and safe integration of the local energy system with the national grid infrastructure and locally installed renewables. This integration requires the system to be able to operate at high performance and safely in all different modes of operation and manage effectively the multi-vector energy supply system (e.g. simultaneous supply of heat and power from a single system)