Magneto-Rheological Actuators for Human-Safe Robots: Modeling, Control, and Implementation

In recent years, research on physical human-robot interaction has received considerable attention. Research on this subject has led to the study of new control and actuation mechanisms for robots in order to achieve intrinsic safety. Naturally, intrinsic safety is only achievable in kinematic structures that exhibit low output impedance. Existing solutions for reducing impedance are commonly obtained at the expense of reduced performance, or significant increase in mechanical complexity. Achieving high performance while guaranteeing safety seems to be a challenging goal that necessitates new actuation technologies in future generations of human-safe robots. In this study, a novel two degrees-of-freedom safe manipulator is presented. The manipulator uses magneto-rheological fluid-based actuators. Magneto-rheological actuators offer low inertia-to-torque and mass-to-torque ratios which support their applications in human-friendly actuation. As a key element in the design of the manipulator, bi-directional actuation is attained by antagonistically coupling MR actuators at the joints. Antagonistically coupled MR actuators at the joints allow using a single motor to drive multiple joints. The motor is located at the base of the manipulator in order to further reduce the overall weight of the robot. Due to the unique characteristic of MR actuators, intrinsically safe actuation is achieved without compromising high quality actuation. Despite these advantages, modeling and control of MR actuators present some challenges. The antagonistic configuration of MR actuators may result in limit cycles in some cases when the actuator operates in the position control loop. To study the possibility of limit cycles, describing function method is employed to obtain the conditions under which limit cycles may occur in the operation of the system. Moreover, a connection between the amplitude and the frequency of the potential limit cycles and the system parameters is established to provide an insight into the design of the actuator as well as the controller. MR actuators require magnetic fields to control their output torques. The application of magnetic field however introduces hysteresis in the behaviors of MR actuators. To this effect, an adaptive model is developed to estimate the hysteretic behavior of the actuator. The effectiveness of the model is evaluated by comparing its results with those obtained using the Preisach model. These results are then extended to an adaptive control scheme in order to compensate for the effect of hysteresis. In both modeling and control, stability of proposed schemes are evaluated using Lyapunov method, and the effectiveness of the proposed methods are validated with experimental results

Control algorithm implementation for a redundant degree of freedom manipulator

This project's purpose is to develop and implement control algorithms for a kinematically redundant robotic manipulator. The manipulator is being developed concurrently by Odetics Inc., under internal research and development funding. This SBIR contract supports algorithm conception, development, and simulation, as well as software implementation and integration with the manipulator hardware. The Odetics Dexterous Manipulator is a lightweight, high strength, modular manipulator being developed for space and commercial applications. It has seven fully active degrees of freedom, is electrically powered, and is fully operational in 1 G. The manipulator consists of five self-contained modules. These modules join via simple quick-disconnect couplings and self-mating connectors which allow rapid assembly/disassembly for reconfiguration, transport, or servicing. Each joint incorporates a unique drive train design which provides zero backlash operation, is insensitive to wear, and is single fault tolerant to motor or servo amplifier failure. The sensing system is also designed to be single fault tolerant. Although the initial prototype is not space qualified, the design is well-suited to meeting space qualification requirements. The control algorithm design approach is to develop a hierarchical system with well defined access and interfaces at each level. The high level endpoint/configuration control algorithm transforms manipulator endpoint position/orientation commands to joint angle commands, providing task space motion. At the same time, the kinematic redundancy is resolved by controlling the configuration (pose) of the manipulator, using several different optimizing criteria. The center level of the hierarchy servos the joints to their commanded trajectories using both linear feedback and model-based nonlinear control techniques. The lowest control level uses sensed joint torque to close torque servo loops, with the goal of improving the manipulator dynamic behavior. The control algorithms are subjected to a dynamic simulation before implementation

Remote robot manipulator coupled with remote-controlled guide vehicle for soil sampling in hazardous waste sites

The important initial step for remediation of hazardous waste is contaminant analysis since the cleanup operation can not begin until the contaminants in hazardous waste sites have been clearly identified. Ames Laboratory, one of the U.S. Department of Energy sites, has developed a robotic sampling system for automation of real-time contaminant analysis in situ which will provide the advantage of lowering the cost per sample, eliminating personnel exposure to hazardous environments, and allowing quicker results. Successful accomplishment of real-time contaminant analysis will require a remote manipulator to perform the sampling tasks in remote and unstructured surroundings, and a remote-controlled guide vehicle to move a remote manipulator into the desired sampling location;This thesis focuses on the design and construction of a remote-controlled guide vehicle to move the robotic sampling system into the contaminated field to obtain soil samples at the desired locations, the development of an integrated dynamic model of a remote manipulator, the identification of dynamic parameters in the integrated dynamic model, and the design of a mobile robotic sampling system. A four-wheeled vehicle prototype has been constructed and its performance tested manually in the field to verify the design requirements. To remotely control the vehicle, mechanical requirements to activate the brake, throttle, transmission, and steering linkages were determined based on experimental results. A teleoperated control utilizing hundred feet long umbilical cords was first employed to remotely control the vehicle. Next, the vehicle was modified to remotely operate in the field by radio control without the aid of long umbilical cords, satisfying all the design specifications;To reduce modeling error in the robotic system, the integrated dynamic system comprised of a remote manipulator (located on a trailer pulled by the remote-controlled guide vehicle) and its drive system has been modeled. The friction model as a function of velocity is included. The dynamic parameters such as velocity-dependent friction and gravity torque in the integrated dynamic model have been determined based on experimental results;Finally, a robotic arm, a sampling tool, and a soil recovery fixture for a mobile robotic sampling system to be mounted on the remote-controlled guide vehicle have been designed and analyzed. The integrated dynamic model for the robotic arm (mounted on the remote-controlled guide vehicle) and its drive system has also been developed

Improving Automated Operations of Heavy-Duty Manipulators with Modular Model-Based Control Design

The rapid development of robotization and automation in mobile working machines aims to increase productivity and safety in many industrial sectors. In heavy-duty applications, hydraulically actuated manipulators are the common solution due to their large power-to-weight ratio. As hydraulic systems can exhibit nonlinear dynamic behavior, automated operations with closed-loop control become challenging. In industrial applications, the dexterity of operations for manipulators is ensured by providing interfaces to equip product variants with different tool attachments. By considering these domain-specific tool attachments for heavy-duty hydraulic manipulators (HHMs), the autonomous robotic operating development for all product variants might be a time-consuming process. This thesis aims to develop a modular nonlinear model-based (NMB) control method for HHMs to enable systematic NMB model reuse and control system modularity across different HHM product variants with actuators and tool attachments. Equally importantly, the properties of NMB control are used to improve the high-performance control for multi degrees-of-freedom robotic HHMs, as rigorously stability-guaranteed control systems have been shown to provide superior performance. To achieve these objectives, four research problems (RPs) on HHM controls are addressed. The RPs are focused on damping control methods in underactuated tool attachments, compensating for static actuator nonlinearities, and, equally significantly, improving overall control performance. The fourth RP is introduced for hydraulic series elastic actuators (HSEAs) in HHM applications, which can be regarded as supplementing NMB control with the aim of improving force controllability. Six publications are presented to investigate the RPs in this thesis. The control development focus was on modular NMB control design for HHMs equipped with different actuators and tool attachments consisting of passive and actuated joints. The designed control methods were demonstrated on a full-size HHM and a novel HSEA concept in a heavy-duty experimental setup. The results verified that modular control design for HHM systems can be used to decrease the modifications required to use the manipulator with different tool attachments and floating-base environments

A flexible access platform for robot-assisted minimally invasive surgery

Advances in Minimally Invasive Surgery (MIS) are driven by the clinical demand to reduce the invasiveness of surgical procedures so patients undergo less trauma and experience faster recoveries. These well documented benefits of MIS have been achieved through parallel advances in the technology and instrumentation used during procedures. The new and evolving field of Flexible Access Surgery (FAS), where surgeons access the operative site through a single incision or a natural orifice incision, is being promoted as the next potential step in the evolution of surgery. In order to achieve similar levels of success and adoption as MIS, technology again has its role to play in developing new instruments to solve the unmet clinical challenges of FAS. As procedures become less invasive, these instruments should not just address the challenges presented by the complex access routes of FAS, but should also build on the recent advances in pre- and intraoperative imaging techniques to provide surgeons with new diagnostic and interventional decision making capabilities. The main focus of this thesis is the development and applications of a flexible robotic device that is capable of providing controlled flexibility along curved pathways inside the body. The principal component of the device is its modular mechatronic joint design which utilises an embedded micromotor-tendon actuation scheme to provide independently addressable degrees of freedom and three internal working channels. Connecting multiple modules together allows a seven degree-of-freedom (DoF) flexible access platform to be constructed. The platform is intended for use as a research test-bed to explore engineering and surgical challenges of FAS. Navigation of the platform is realised using a handheld controller optimised for functionality and ergonomics, or in a "hands-free" manner via a gaze contingent control framework. Under this framework, the operator's gaze fixation point is used as feedback to close the servo control loop. The feasibility and potential of integrating multi-spectral imaging capabilities into flexible robotic devices is also demonstrated. A force adaptive servoing mechanism is developed to simplify the deployment, and improve the consistency of probe-based optical imaging techniques by automatically controlling the contact force between the probe tip and target tissue. The thesis concludes with the description of two FAS case studies performed with the platform during in-vivo porcine experiments. These studies demonstrate the ability of the platform to perform large area explorations within the peritoneal cavity and to provide a stable base for the deployment of interventional instruments and imaging probes

Design, implementation, control, and user evaluations of assiston-arm self-aligning upper-extremity exoskeleton

Physical rehabilitation therapy is indispensable for treating neurological disabilities. The use of robotic devices for rehabilitation holds high promise, since these devices can bear the physical burden of rehabilitation exercises during intense therapy sessions, while therapists are employed as decision makers. Robot-assisted rehabilitation devices are advantageous as they can be applied to patients with all levels of impairment, allow for easy tuning of the duration and intensity of therapies and enable customized, interactive treatment protocols. Moreover, since robotic devices are particularly good at repetitive tasks, rehabilitation robots can decrease the physical burden on therapists and enable a single therapist to supervise multiple patients simultaneously; hence, help to lower cost of therapies. While the intensity and quality of manually delivered therapies depend on the skill and fatigue level of therapists, high-intensity robotic therapies can always be delivered with high accuracy. Thanks to their integrated sensors, robotic devices can gather measurements throughout therapies, enable quantitative tracking of patient progress and development of evidence-based personalized rehabilitation programs. In this dissertation, we present the design, control, characterization and user evaluations of AssistOn-Arm, a powered, self-aligning exoskeleton for robotassisted upper-extremity rehabilitation. AssistOn-Arm is designed as a passive back-driveable impedance-type robot such that patients/therapists can move the device transparently, without much interference of the device dynamics on natural movements. Thanks to its novel kinematics and mechanically transparent design, AssistOn-Arm can passively self-align its joint axes to provide an ideal match between human joint axes and the exoskeleton axes, guaranteeing ergonomic movements and comfort throughout physical therapies. The self-aligning property of AssistOn-Arm not only increases the usable range of motion for robot-assisted upper-extremity exercises to cover almost the whole human arm workspace, but also enables the delivery of glenohumeral mobilization (scapular elevation/depression and protraction/retraction) and scapular stabilization exercises, extending the type of therapies that can be administered using upper-extremity exoskeletons. Furthermore, the self-alignment property of AssistOn-Arm signi cantly shortens the setup time required to attach a patient to the exoskeleton. As an impedance-type device with high passive back-driveability, AssistOn- Arm can be force controlled without the need of force sensors; hence, high delity interaction control performance can be achieved with open-loop impedance control. This control architecture not only simpli es implementation, but also enhances safety (coupled stability robustness), since open-loop force control does not su er from the fundamental bandwidth and stability limitations of force-feedback. Experimental characterizations and user studies with healthy volunteers con- rm the transparency, range of motion, and control performance of AssistOn- Ar

Modelling, Control and Performance Evaluation of a Single-Axis Compliant Nano-Positioning System

This thesis presents the results from a preliminary activity devoted to the implementation of high-performance controller for a single axis compliant nano-positioning system. Preliminarily, this work discusses the mechanical design of the system, its peculiar features, and presents a system transfer function. After a detailed description of the design, the thesis discusses both theoretical and practical aspects of three control techniques used and the experimental results obtaine

Parallel Manipulators

In recent years, parallel kinematics mechanisms have attracted a lot of attention from the academic and industrial communities due to potential applications not only as robot manipulators but also as machine tools. Generally, the criteria used to compare the performance of traditional serial robots and parallel robots are the workspace, the ratio between the payload and the robot mass, accuracy, and dynamic behaviour. In addition to the reduced coupling effect between joints, parallel robots bring the benefits of much higher payload-robot mass ratios, superior accuracy and greater stiffness; qualities which lead to better dynamic performance. The main drawback with parallel robots is the relatively small workspace. A great deal of research on parallel robots has been carried out worldwide, and a large number of parallel mechanism systems have been built for various applications, such as remote handling, machine tools, medical robots, simulators, micro-robots, and humanoid robots. This book opens a window to exceptional research and development work on parallel mechanisms contributed by authors from around the world. Through this window the reader can get a good view of current parallel robot research and applications