Redundant Hybrid Cable-Driven Robots: Modeling, Control, and Analysis

Serial and Cable-Driven Parallel Robots (CDPRs) are two types of robots that are widely used in industrial applications. Usually, the former offers high position accuracy at the cost of high motion inertia and small workspace envelope. The latter has a large workspace, low motion inertia, and high motion accelerations, but low accuracy. In this thesis, redundant Hybrid Cable-Driven Robots (HCDRs) are proposed to harness the strengths and benefits of serial and CDPRs. Although the study has been directed at warehousing applications, the developed techniques are general and can be applied to other applications. The main goal of this research is to develop integrated control systems to reduce vibrations and improve the position accuracy of HCDRs. For the proposed HCDRs, the research includes system modeling, redundancy resolution, optimization problem formulation, integrated control system development, and simulation and experimental validation. In this thesis, first, a generalized HCDR is proposed for the step-by-step derivation of a generic model, and it can be easily extended to any HCDRs. Then, based on an in-plane configuration, three types of control architecture are proposed to reduce vibrations and improve the position accuracy of HCDR. Their performance is evaluated using several well-designed case studies. Furthermore, a stiffness optimization algorithm is developed to overcome the limitations of existing approaches. Decoupled system modeling is studied to reduce the complexity of HCDRs. Control design, simulations, and experiments are developed to validate the models and control strategies. Additionally, state estimation algorithms are proposed to overcome the inaccurate limitation of Inertial Measurement Unit (IMU). Based on these state observers, experiments are conducted in different cases to evaluate the control performance. An Underactuated Mobile Manipulator (UMM) is proposed to address the tracking and vibration- and balance-control problems. Out-of-plane system modeling, disturbance analysis, and model validation are also investigated. Besides, a simple but effective strategy is developed to solve the equilibrium point and balancing problem. Based on the dynamic model, two control architectures are proposed. Compared to other Model Predictive Control (MPC)-based control strategies, the proposed controllers require less effort to implement in practice. Simulations and experiments are also conducted to evaluate the model and control performance. Finally, redundancy resolution and disturbance rejection via torque optimization in HCDRs are proposed: joint-space Torque Optimization for Actuated Joints (TOAJ) and joint-space Torque Optimization for Actuated and Unactuated Joints (TOAUJ). Compared to TOAJ, TOAUJ can solve the redundancy resolution problem as well as disturbance rejection. The algorithms are evaluated using a Three-Dimensional (3D) coupled HCDR and can also be extended to other HCDRs

Integrated Trajectory-Tracking and Vibration Control of Kinematically-Constrained Warehousing Cable Robots

With the explosion of e-commerce in recent years, there is a strong desire for automated material handling solutions including warehousing robots. Cable driven parallel robots (CDPRs) are a relatively new concept which has yet to be explored for high-speed pick-&-place applications in the industry. Compared to rigid-link parallel robots, a CDPR possesses significant advantages including: large workspace, low moving inertia, high-speed motion, low power consumption, and incurring minimal maintenance cost. On the other hand, the main disadvantages of the CDPRs are the cable’s unilateral force exerting capability and low rigidity which is resulting in undesired vibrations of their moving platform. Kinematically-constrained CDPRs (KC-CDPRs) include a special class of CDPRs which provide a considerably higher level of stiffness in undesired degrees of freedom (DOFs) via connecting a set of constrained cables to the same actuator. Nevertheless, undesired vibrations of the moving platform are still their main problem which request more attention and investigation. Dynamic modeling, stiffness optimization, vibration and trajectory-tracking control, and stiffness-based trajectory-planning of redundant KC-CDPRs are studied in this thesis. As a new technique, we separate the moving platform’s vibration equations from its desired (nominal) equations of motion. The obtained vibration model forms a linear parametric variable (LPV) dynamic system which is based for the following contributions: 1) Proposing a new tension optimization approach to minimize undesired perturbations under external disturbances in a desired direction; and demonstrating the effectiveness of kinematically-constrained actuation method in vibration attenuation of CDPRs in undesired DOFs. 2) Providing the opportunity of using a wide class of well-established robust and optimal LPV-based control methods, such as H∞ control techniques, for trajectory-tracking control of CDPRs to minimize the effect of disturbances on the robot operation; and showing the effectiveness of kinematically-constrained actuation method in control design simplification of such robots. 3) Proposing the concept of stiffness-based trajectory-planning to find the stiffness-optimum geometry of trajectories for KC-CDPRs; and designing a time-optimal zero-to-zero continuous-jerk motion to track such trajectories. All the proposed concepts are developed for a generic KC-CDPR and verified via numerical analysis and experimental tests of a real planar warehousing KC-CDPR

Développement d'un mécanisme parallèle entraîné par câbles utilisé comme interface à retour haptique visant la réadaptation physique en environnement immersif

Les robots parallèles à câbles sont de plus en plus utilisés et étudiés, particulièrement dans le domaine de la recherche. Une des applications d'intérêts est leur usage en tant qu'interface haptique. Leur grand espace de travail et leur faible inertie en font de bons candidats pour en faire des interfaces de taille humaine. Une des applications intéressantes serait d'utiliser ce type d'interfaces dans le domaine de la santé, plus spécifiquement en réadaptation physique. Comme ces interfaces sont capables de reproduire des efforts à l'utilisateur, celles-ci peuvent être utilisées pour faire travailler les muscles. C'est dans cette optique que les recherches rapportées dans cette thèse ont été accomplies. Cette thèse présente donc premièrement des avancées plus générales aux mécanismes parallèles à câbles permettant leur utilisation en tant qu'interface haptique, pour ensuite se spécialiser dans la création d'un prototype d'interface haptique entraîné par câble combiné à un retour visuel immersif comme un casque de réalité virtuelle par exemple. La thèse se termine avec l'évaluation préliminaire du prototype développé qui est installé dans un centre de recherche en réadaptation physique et qui, dans un avenir rapproché, pourra servir à l'avancement de la recherche dans le domaine de la réadaptation physique.Cable driven parallel robots are studied and used more every day, especially in the research community. One interesting application is their use as haptic interfaces. Their big workspace and relatively low inertia makes them great candidates for human scale interfaces. One application of haptic interfaces of this scale is in health and physical readaptation. Since those interfaces are able to render forces, they can be used to train or evaluate physical capabilities. Research presented in this thesis aims at furthering knowledge in this domain. Some more general advances needed to make cable driven parallel mechanisms suitable haptic interfaces are presented first and then more specific developments toward the creation of a prototype haptic interface combined with a visual feedback are presented. The thesis ends with preliminary studies on the developed prototype installed in a research facility on physical readaptation