Calibration of UR10 robot controller through simple auto-tuning approach

This paper presents a calibration approach of a manipulator robot controller using an auto-tuning technique. Since the industry requires machines to run with increasing speed and precision, an optimal controller is too demanding. Even though the robots make use of an internal controller, usually, this controller does not fulfill the user specification with respect to their applications. Therefore, in order to overcome the user requirements, an auto-tuning method based on a single sine test is employed to obtain the optimal parameters of the proportional-integral-derivative PID controller. This approach has been tested, validated and implemented on a UR10 robot. The experimental results revealed that the performances of the robot increased when the designed controller, using the auto-tuning technique, was employed

The application of a new PID autotuning method for the steam/water loop in large scale ships

In large scale ships, the most used controllers for the steam/water loop are still the proportional-integral-derivative (PID) controllers. However, the tuning rules for the PID parameters are based on empirical knowledge and the performance for the loops is not satisfying. In order to improve the control performance of the steam/water loop, the application of a recently developed PID autotuning method is studied. Firstly, a 'forbidden region' on the Nyquist plane can be obtained based on user-defined performance requirements such as robustness or gain margin and phase margin. Secondly, the dynamic of the system can be obtained with a sine test around the operation point. Finally, the PID controller's parameters can be obtained by locating the frequency response of the controlled system at the edge of the 'forbidden region'. To verify the effectiveness of the new PID autotuning method, comparisons are presented with other PID autotuning methods, as well as the model predictive control. The results show the superiority of the new PID autotuning method

Universal direct tuner for loop control in industry

This paper introduces a direct universal (automatic) tuner for basic loop control in industrial applications. The direct feature refers to the fact that a first-hand model, such as a step response first-order plus dead time approximation, is not required. Instead, a point in the frequency domain and the corresponding slope of the loop frequency response is identified by single test suitable for industrial applications. The proposed method has been shown to overcome pitfalls found in other (automatic) tuning methods and has been validated in a wide range of common and exotic processes in simulation and experimental conditions. The method is very robust to noise, an important feature for real life industrial applications. Comparison is performed with other well-known methods, such as approximate M-constrained integral gain optimization (AMIGO) and Skogestad internal model controller (SIMC), which are indirect methods, i.e., they are based on a first-hand approximation of step response data. The results indicate great similarity between the results, whereas the direct method has the advantage of skipping this intermediate step of identification. The control structure is the most commonly used in industry, i.e., proportional-integral-derivative (PID) type. As the derivative action is often not used in industry due to its difficult choice, in the proposed method, we use a direct relation between the integral and derivative gains. This enables the user to have in the tuning structure the advantages of the derivative action, therefore much improving the potential of good performance in real life control applications

Robust controller design: Recent emerging concepts for control of mechatronic systems

The recent industrial revolution puts competitive requirements on most manufacturing and mechatronic processes. Some of these are economic driven, but most of them have an intrinsic projection on the loop performance achieved in most of closed loops across the various process layers. It turns out that successful operation in a globalization context can only be ensured by robust tuning of controller parameter as an effective way to deal with continuously changing end-user specs and raw product properties. Still, ease of communication in non-specialised process engineering vocabulary must be ensured at all times and ease of implementation on already existing platforms is preferred. Specifications as settling time, overshoot and robustness have a direct meaning in terms of process output and remain most popular amongst process engineers. An intuitive tuning procedure for robustness is based on linear system tools such as frequency response and bandlimited specifications thereof. Loop shaping remains a mature and easy to use methodology, although its tools such as Hinf remain in the shadow of classical PID control for industrial applications. Recently, next to these popular loop shaping methods, new tools have emerged, i.e. fractional order controller tuning rules. The key feature of the latter group is an intrinsic robustness to variations in the gain, time delay and time constant values, hence ideally suited for loop shaping purpose. In this paper, both methods are sketched and discussed in terms of their advantages and disadvantages. A real life control application used in mechatronic applications illustrates the proposed claims. The results support the claim that fractional order controllers outperform in terms of versatility the Hinf control, without losing the generality of conclusions. The paper pleads towards the use of the emerging tools as they are now ready for broader use, while providing the reader with a good perspective of their potential

Neural network-enhanced fault diagnosis of robot joints

Industrial robots play an indispensable role in flexible production lines, and the faults caused by degradation of equipment, motors, mechanical system joints, and even task diversity affect the efficiency of production lines and product quality. Aiming to achieve high-precision multiple size of fault diagnosis of robotic arms, this study presents a back propagation (BP) multiclassification neural network-based method for robotic arm fault diagnosis by taking feature fusion of position, attitude and acceleration of UR10 robotic arm end-effector to establish the database for neural network training. The new algorithm achieves an accuracy above 95% for fault diagnosis of each joint, and a diagnostic accuracy of up to 0.1 degree. It should be noted that the fault diagnosis algorithm can detect faults effectively in time, while avoiding complex mathematical operations

Calibration of UR10 Robot Controller through Simple Auto-Tuning Approach

This paper presents a calibration approach of a manipulator robot controller using an auto-tuning technique. Since the industry requires machines to run with increasing speed and precision, an optimal controller is too demanding. Even though the robots make use of an internal controller, usually, this controller does not fulfill the user specification with respect to their applications. Therefore, in order to overcome the user requirements, an auto-tuning method based on a single sine test is employed to obtain the optimal parameters of the proportional–integral–derivative PID controller. This approach has been tested, validated and implemented on a UR10 robot. The experimental results revealed that the performances of the robot increased when the designed controller, using the auto-tuning technique, was employed