Model-Based Iterative Learning Control Applied to an Industrial Robot with Elasticity

In this paper model-based Iterative Learning Control (ILC) is applied to improve the tracking accuracy of an industrial robot with elasticity. The ILC algorithm iteratively updates the reference trajectory for the robot such that the predicted tracking error in the next iteration is minimised. The tracking error is predicted by a model of the closed-loop dynamics of the robot. The model includes the servo resonance frequency, the first resonance frequency caused by elasticity in the mechanism and the variation of both frequencies along the trajectory. Experimental results show that the tracking error of the robot can be reduced, even at frequencies beyond the first elastic resonance frequency

Learning for Advanced Motion Control

Iterative Learning Control (ILC) can achieve perfect tracking performance for mechatronic systems. The aim of this paper is to present an ILC design tutorial for industrial mechatronic systems. First, a preliminary analysis reveals the potential performance improvement of ILC prior to its actual implementation. Second, a frequency domain approach is presented, where fast learning is achieved through noncausal model inversion, and safe and robust learning is achieved by employing a contraction mapping theorem in conjunction with nonparametric frequency response functions. The approach is demonstrated on a desktop printer. Finally, a detailed analysis of industrial motion systems leads to several shortcomings that obstruct the widespread implementation of ILC algorithms. An overview of recently developed algorithms, including extensions using machine learning algorithms, is outlined that are aimed to facilitate broad industrial deployment.Comment: 8 pages, 15 figures, IEEE 16th International Workshop on Advanced Motion Control, 202

Iterative Learning Control for Milling with Industrial Robots in Advanced Manufacturing

The demand of today for advanced manufactured parts with high precision is due to the increasing complexity of technologies. The parts are typically made by CNC (Computer Numerical Control) machines, which are expensive and comparably big. By using industrial robots that are significantly cheaper, reduced costs can be achieved, which is particularly beneficial for small and medium enterprises. Robots are, however, less stiff and strong and are less accurate compared to the CNC machines. In this thesis, the idea was that by designing a controller, this could be compensated for so that the robot could perform machining with high precision. The research made in this thesis was part of the EU co-funded research project COMET. The robot task was to repeatedly mill parts with improved results. Iterative Learning Control (ILC) was therefore chosen as a suitable control strategy for this task. It uses the position error from previous iterations and adds it to the control signal to converge the output to successful results. Results showed that when using ILC for tracking paths, the position error could be reduced with approximately 11-20% in x, y, and z directions after one iteration

Improving the Accuracy of Industrial Robots by offline Compensation of Joints Errors

The use of industrial robots in many fields of industry like prototyping, pre-machining and end milling is limited because of their poor accuracy. Robot joints are mainly responsible for this poor accuracy. The flexibility of robots joints and the kinematic errors in the transmission systems produce a significant error of position in the level of the end-effector. This paper presents these two types of joint errors. Identification methods are presented with experimental validation on a 6 axes industrial robot, STAUBLI RX 170 BH. An offline correction method used to improve the accuracy of this robot is validated experimentally

Benchmarking Cerebellar Control

Cerebellar models have long been advocated as viable models for robot dynamics control. Building on an increasing insight in and knowledge of the biological cerebellum, many models have been greatly refined, of which some computational models have emerged with useful properties with respect to robot dynamics control. Looking at the application side, however, there is a totally different picture. Not only is there not one robot on the market which uses anything remotely connected with cerebellar control, but even in research labs most testbeds for cerebellar models are restricted to toy problems. Such applications hardly ever exceed the complexity of a 2 DoF simulated robot arm; a task which is hardly representative for the field of robotics, or relates to realistic applications. In order to bring the amalgamation of the two fields forwards, we advocate the use of a set of robotics benchmarks, on which existing and new computational cerebellar models can be comparatively tested. It is clear that the traditional approach to solve robotics dynamics loses ground with the advancing complexity of robotic structures; there is a desire for adaptive methods which can compete as traditional control methods do for traditional robots. In this paper we try to lay down the successes and problems in the fields of cerebellar modelling as well as robot dynamics control. By analyzing the common ground, a set of benchmarks is suggested which may serve as typical robot applications for cerebellar models

Adaptation and Learning for Manipulators and Machining

This thesis presents methods for improving the accuracy and efficiency of tasks performed using different kinds of industrial manipulators, with a focus on the application of machining. Industrial robots offer a flexible and cost-efficient alternative to machine tools for machining, but cannot achieve as high accuracy out of the box. This is mainly caused by non-ideal properties in the robot joints such as backlash and compliance, in combination with the strong process forces that affect the robot during machining operations. In this thesis, three different approaches to improving the robotic machining accuracy are presented. First, a macro/micro-manipulator approach is considered, where an external compensation mechanism is used in combination with the robot, for compensation of high-frequency Cartesian errors. Two different milling scenarios are evaluated, where a significant increase in accuracy was obtained. The accuracy specification of 50 μm was reached for both scenarios. Because of the limited workspace and the higher bandwidth of the compensation mechanism compared to the robot, two different mid-ranging approaches for control of the relative position between the robot and the compensator are developed and evaluated. Second, modeling and identification of robot joints is considered. The proposed method relies on clamping the manipulator end effector and actuating the joints, while measuring joint motor torque and motor position. The joint stiffness and backlash can subsequently be extracted from the measurements, to be used for compensation of the deflections that occur during machining. Third, a model-based iterative learning control (ILC) approach is proposed, where feedback is provided from three different sensors of varying investment costs. Using position measurements from an optical tracking system, an error decrease of up to 84 % was obtained. Measurements of end-effector forces yielded an error decrease of 55 %, and a force-estimation method based on joint motor torques decreased the error by 38 %. Further investigation of ILC methods is considered for a different kind of manipulator, a marine vibrator, for the application of marine seismic acquisition. A frequency-domain ILC strategy is proposed, in order to attenuate undesired overtones and improve the tracking accuracy. The harmonics were suppressed after approximately 20 iterations of the ILC algorithm, and the absolute tracking error was r educed by a factor of approximately 50. The final problem considered in this thesis concerns increasing the efficiency of machining tasks, by minimizing cycle times. A force-control approach is proposed to maximize the feed rate, and a learning algorithm for path planning of the machining path is employed for the case of machining in non-isotropic materials, such as wood. The cycle time was decreased by 14 % with the use of force control, and on average an additional 28 % decrease was achieved by use of a learning algorithm. Furthermore, by means of reinforcement learning, the path-planning algorithm is refined to provide optimal solutions and to incorporate an increased number of machining directions