Pneumatic Artificial Muscle Driven Trailing Edge Flaps For Active Rotors

This research focuses on the development of an active rotor system capable of primary control and vibration reduction for rotorcraft. The objective is to investigate the feasibility of a novel Trailing Edge Flap (TEF) actuation system driven by Pneumatic Artificial Muscles (PAMs). A significant design effort led to a series of experimental apparatuses which tested various aspects of the performance of the actuators themselves and of TEF systems driven by them. Analytical models were developed in parallel to predict the quasistatic and dynamic behavior of these systems. Initial testing of a prototype blade section with an integrated PAM driven TEF proved the viability of the concept through successful benchtop testing under simulated M = 0.3 loading and open jet wind tunnel tests under airspeeds up to M = 0.13. This prototype showed the ability of PAM actuators to generate significant flap deflections over the bandwidth of interest for primary control and vibration reduction on a rotorcraft. It also identified the importance of high pneumatic system mass flow rate for maintaining performance at higher operating frequencies. Research into the development and improvement of PAM actuators centered around a new manufacturing technique which was invented to directly address the weaknesses of previous designs. Detailed finite element model (FEM) analysis of the design allowed for the mitigation of stress concentrations, leading to increased strength. Tensile testing of the swaged actuators showed a factor of safety over 5, and burst pressure testing showed a factor of safety of 3. Over 120,000,000 load cycles were applied to the actuators without failure. Characterization testing before, during, and after the fatigue tests showed no reduction in PAM performance. Wind tunnel testing of a full scale Bell 407 blade retrofitted with a PAM TEF system showed excellent control authority. At the maximum wind tunnel test speed of M = 0.3 and a derated PAM operating pressure of 28 psi, 18.8° half-peak-to-peak flap deflections were achieved at 1/rev (7 Hz), and 17.1° of half-peak-to-peak flap deflection was still available at 5/rev (35 Hz). A quasistatic system model was developed which combined PAM forces, kinematics and flap aerodynamics to predict flap deflection amplitudes. This model agreed well with experimental data. Whirl testing of a sub-span whirl rig under full scale loading conditions showed the ability of PAM TEF systems to operate under full scale levels of centrifugal (CF), aerodynamic, and inertia loading. A commercial pneumatic rotary union was used to provide air in the rotating frame. Extrapolation of the results to 100% of CF acceleration predicts 15.4° of half-peak-to-peak flap deflection at 1/rev (7 Hz), and 7.7° of half-peak-to-peak flap deflection at 5/rev (35 Hz). A dynamic model was developed which successfully predicted the time domain behavior of the PAM actuators and PAM TEF system. This model includes control valve dynamics, frictional tubing losses, pressure dynamics, PAM forces, mechanism kinematics, aerodynamic hinge moments, system stiffness, damping, and inertia to solve for the rotational dynamics of the flap. Control system development led to a closed loop control system for PAM TEF systems capable of tracking complex, multi-sinusoid flap deflections representative of a combined primary control and vibration reduction flap actuation scheme. This research shows the promise that PAM actuators have as drivers for trailing edge flaps on active helicopter rotors. The robustness, ease of integration, control authority and tracking accuracy of these actuators have been established, thereby motivating further research

High Fidelity Dynamic Modeling and Nonlinear Control of Fluidic Artificial Muscles

A fluidic artificial muscle is a type of soft actuator. Soft actuators transmit power with elastic or hyper-elastic bladders that are deformed with a pressurized fluid. In a fluidic artificial muscle a rubber tube is encompassed by a helical fiber braid with caps on both ends. One of the end caps has an orifice, allowing the control of fluid flow in and out of the device. As the actuator is pressurized, the rubber tube expands radially and is constrained by the helical fiber braid. This constraint results in a contractile motion similar to that of biological muscles. Although artificial muscles have been extensively studied, physics-based models do not exist that predict theirmotion.This dissertation presents a new comprehensive lumped-parameter dynamic model for both pneumatic and hydraulic artificial muscles. It includes a tube stiffness model derived from the theory of large deformations, thin wall pressure vessel theory, and a classical artificial muscle force model. Furthermore, it incorporates models for the kinetic friction and braid deformation. The new comprehensive dynamic model is able to accurately predict the displacement of artificial muscles as a function of pressure. On average, the model can predict the quasi-static position of the artificial muscles within 5% error and the dynamic displacement within 10% error with respect to the maximum stroke. Results show the potential utility of the model in mechanical system design and control design. Applications include wearable robots, mobile robots, and systems requiring compact, powerful actuation.The new model was used to derive sliding mode position and impedance control laws. The accuracy of the controllers ranged from ± 6 µm to ± 50 µm, with respect to a 32 mm and 24 mm stroke artificial muscles, respectively. Tracking errors were reduced by 59% or more when using the high-fidelity model sliding mode controller compared to classical methods. The newmodel redefines the state-of-the-art in controller performance for fluidic artificial muscles

Pneumatic motion control systems for modular robots

This thesis describes a research study in the design, implementation, evaluation and commercialisation of pneumatic motion control systems for modular robots. The research programme was conducted as part of a collaborative study, sponsored by the Science and Engineering Research Council, between Loughborough University and Martonair (UK) Limited. Microprocessor based motion control strategies have been used to produce low cost pneumatic servo-drives which can be used for 'point-to-point' positioning of payloads. Software based realtime control strategies have evolved which accomplish servo-controlled positioning while compensating for drive system non-linearities and time delays. The application of novel compensation techniques has resulted in a significant improvement in both the static and dynamic performance of the drive. A theoretical foundation is presented based on a linearised model of a pneumatic actuator, servo-valve, and load system. The thesis describes the design and evolution of microprocessor based hardware and software for motion control of pneumatic drives. A British Standards based test-facility has allowed control strategies to be evaluated with reference to standard performance criteria. It is demonstrated in this research study that the dynamic and static performance characteristics of a pneumatic motion control system can be dramatically improved by applying appropriate software based realtime control strategies. This makes the application of computer controlled pneumatic servos in manufacturing very attractive with cost performance ratios which match or better alternative drive technologies. The research study has led to commercial products (marketed by Martonair Ltd), in which realtime control algorithms implementing these control strategy designs are executed within a microprocessor based motion controller

Development of a Hybrid Powered 2D Biped Walking Machine Designed for Rough Terrain Locomotion

Biped robots hold promise as terrestrial explorers because they require a single discrete foothold to place their next step. However, biped robots are multi-input multi-output dynamically unstable machines. This makes walking on rough terrain difficult at best. Progress has been made with non-periodic rough terrain like stairs or inclines with fully active walking machines. Terrain that requires the walker to change its gait pattern from a standard walk is still problematic. Most walking machines have difficulty detecting or responding to the small perturbations induced by this type of terrain. These small perturbations can lead to unstable gait cycles and possibly a fall. The Intelligent Systems and Automation Lab at the University of Kansas has built a three legged 2D biped walking machine to be used as a test stand for studying rough terrain walking. The specific aim of this research is to investigate how biped walkers can best maintain walking stability when acted upon by small perturbations caused by periodic rough terrain. The first walking machine prototype, referred to as Jaywalker has two main custom actuation systems. The first is the hip ratchet system. It allows the walker to have either a passive or active hip swing. The second is the hybrid parallel ankle actuator. This new actuator uses a pneumatic ram and stepper motor in parallel to produce an easily controlled high torque output. In open loop control it has less than a 1° tracking error and 0.065 RPM velocity error compared to a standard stepper motor. Step testing was conducted using the Jaywalker, with a passive hip, to determine if a walker with significant leg mass could walk without full body actuation. The results of testing show the Jaywalker is ultimately not capable of walking with a passive hip. However, the walking motion is fine until the terminal stance phase. At this point the legs fall quickly towards the ground as the knee extends the shank. This quick step phenomenon is caused by increased speeds and forces about the leg and hip caused by the extension of the shank. This issue can be overcome by fully actuating the hip, or by adding counterbalances to the legs about the hip

Modelling of servo-controlled pneumatic drives: a generalised approach to pneumatic modelling and applications in servo-drive design

The primary objective of this research is to develop a general modelling facility for modular pneumatic servo-drives. The component-oriented approach has been adopted as the modelling technique to provide the flexibility of modelling a wide variety of components and the segmentation of the non-linear system to less complex uncoupled component modules. A significant part of the research work has been devoted to identify a series of component modules of the single axis linear pneumatic servomechanism with standardised linking variables. The mathematical models have been implemented in a simulation software which produces time domain responses for design evaluation purposes. Alternative components for different servomechanism design were modelled as mutually exclusive modules which could be selected for assembly as if they were real physical entities. The philosophy of the approach was validated by tests on prototype servo-drives with matching components. Design analysis could be performed by simulating and comparing the performance of alternative system structures. [Continues.

Rapid acceleration of legged robots: a pneumatic approach

For robotics to be useful to the public in a multifaceted manner, they need to be both legged and agile. The legged constraint arises as many environments and systems in our world are tailored to ablebodied adults. Therefore, a practically useful robot would need to have the same morphology for maximum efficacy. For robots to be useful in these environments, they need to perform at least as well as humans, therefore presenting the agility constraint. These requirements have been out of reach of the field until recently. The aim of this thesis was to design a planar monopod robot for rapid acceleration manoeuvres, that could later be expanded to a planar quadruped robot. This was achieved through a hybrid electric and pneumatic actuation system. To this end, modelling schemes for the pneumatic cylinder were investigated and verified with physical experiments. This was done to develop accurate models of the pneumatic system that were later used in simulation to aid in the design of the platform. The design of the platform was aided through the use of Simulink to conduct iterative testing and multivariate evaluations using Monte Carlo simulation methods. Once the topology of the leg was set, the detail design was conducted in Solidworks and validated with its built in simulation functions. In addition to the mechanical design of the platform, a specialist boom was designed. The design needed to compensate for the forces the robot exerts on the boom as well as the material constraints on the boom. This resulted in the development of a cable-stayed, four bar mechanism boom system. An embedded operating system was created to control the robot and take in and fuse sensor inputs. This was run using multiple sensors, sub-controllers and microcontrollers. Sensor fusion for the system was done using a Kalman Filter to improve readings and estimate unmeasured states of the robot. This Kalman Filter took LiDAR and accelerometer readings as inputs to the system to produce a subcentimetre accurate position measure for the system. Finally, the completed platform was validated using fixed-body forward hopping tests. These tests showed a significant degree of similarity to the simulated results and therefore validated the design process

A Comparative Study Between Convolution and Optimal Backstepping Controller for Single Arm Pneumatic Artificial Muscles

This study was based on the dynamic modeling and parameter characterization of the one-link robot arm driven by pneumatic artificial muscles. This work discusses an up-to-date control design based on the notion of a conventional and optimal backstepping controller for regulating a one-link robot arm with conflicting biceps and triceps positions supplied by pneumatic artificial muscles. The main problems found in systems that utilize pneumatic artificial muscle as actuators are primarily the large uncertainties, non-linearities, and time-varying features that severely impede movement performance in tracking control. In consideration of the uncertainty, high nonlinearity, and external disturbances that can exist during the motion. Lyapunov-based backstepping control technique was utilized to assure the stability of the system with improved dynamic performance. The bat algorithm optimization method is utilized in order to modify the variables used in the design of the controller to enhance the efficiency of the suggested controller. According to the conclusions, a quantitative comparison of the response in the PAM actuated the arm model in the current study and earlier investigations with the Backstepping controlled system revealed fair agreement with a variation of 37.5% from the optimal classical synergetic controller. In addition, computer simulations were utilized in order to compare the effectiveness of the proposed conventional controls and the optimal background. It has been proven that an optimal controller can control the uncertainties and maintain the controlled system’s stability