Fault tolerance in robotics

This work is a contribution to illustrate the fault tolerance concepts in robotics. Every step from the analysis phase to the fault accommodation phase is presented. A fault on joint 3 is taken into account and simulated to validate the detection algorithms. The fault accommodation is thus considered and is based on the kinematic redundancy principle. The establishment of the inverse kinematic model, under some conditions of joint failure, enables the generation of an alternative trajectory to ensure the robot goes on functioning

Compliant aerial manipulation.

The aerial manipulation is a research field which proposes the integration of robotic manipulators in aerial platforms, typically multirotors – widely known as “drones” – or autonomous helicopters. The development of this technology is motivated by the convenience to reduce the time, cost and risk associated to the execution of certain operations or tasks in high altitude areas or difficult access workspaces. Some illustrative application examples are the detection and insulation of leaks in pipe structures in chemical plants, repairing the corrosion in the blades of wind turbines, the maintenance of power lines, or the installation and retrieval of sensor devices in polluted areas. Although nowadays it is possible to find a wide variety of commercial multirotor platforms with payloads from a few gramps up to several kilograms, and flight times around thirty minutes, the development of an aerial manipulator is still a technological challenge due to the strong requirements relative to the design of the manipulator in terms of very low weight, low inertia, dexterity, mechanical robustness and control. The main contribution of this thesis is the design, development and experimental validation of several prototypes of lightweight (<2 kg) and compliant manipulators to be integrated in multirotor platforms, including human-size dual arm systems, compliant joint arms equipped with human-like finger modules for grasping, and long reach aerial manipulators. Since it is expected that the aerial manipulator is capable to execute inspection and maintenance tasks in a similar way a human operator would do, this thesis proposes a bioinspired design approach, trying to replicate the human arm in terms of size, kinematics, mass distribution, and compliance. This last feature is actually one of the key concepts developed and exploited in this work. Introducing a flexible element such as springs or elastomers between the servos and the links extends the capabilities of the manipulator, allowing the estimation and control of the torque/force, the detection of impacts and overloads, or the localization of obstacles by contact. It also improves safety and efficiency of the manipulator, especially during the operation on flight or in grabbing situations, where the impacts and contact forces may damage the manipulator or destabilize the aerial platform. Unlike most industrial manipulators, where force-torque control is possible at control rates above 1 kHz, the servo actuators typically employed in the development of aerial manipulators present important technological limitations: no torque feedback nor control, only position (and in some models, speed) references, low update rates (<100 Hz), and communication delays. However, these devices are still the best solution due to their high torque to weight ratio, low cost, compact design, and easy assembly and integration. In order to cope with these limitations, the compliant joint arms presented here estimate and control the wrenches from the deflection of the spring-lever transmission mechanism introduced in the joints, measured at joint level with encoders or potentiometers, or in the Cartesian space employing vision sensors. Note that in the developed prototypes, the maximum joint deflection is around 25 degrees, which corresponds to a deviation in the position of the end effector around 20 cm for a human-size arm. The capabilities and functionalities of the manipulators have been evaluated in fixed base test-bench firstly, and then in outdoor flight tests, integrating the arms in different commercial hexarotor platforms. Frequency characterization, position/force/impedance control, bimanual grasping, arm teleoperation, payload mass estimation, or contact-based obstacle localization are some of the experiments presented in this thesis that validate the developed prototypes.La manipulación aérea es un campo de investigación que propone la integración de manipuladores robóticos in plataformas aéreas, típicamente multirotores – comúnmente conocidos como “drones” – o helicópteros autónomos. El desarrollo de esta tecnología está motivada por la conveniencia de reducir el tiempo, coste y riesgo asociado a la ejecución de ciertas operaciones o tareas en áreas de gran altura o espacios de trabajo de difícil acceso. Algunos ejemplos ilustrativos de aplicaciones son la detección y aislamiento de fugas en estructura de tuberías en plantas químicas, la reparación de la corrosión en las palas de aerogeneradores, el mantenimiento de líneas eléctricas, o la instalación y recuperación de sensores en zonas contaminadas. Aunque hoy en día es posible encontrar una amplia variedad de plataformas multirotor comerciales con cargas de pago desde unos pocos gramos hasta varios kilogramos, y tiempo de vuelo entorno a treinta minutos, el desarrollo de los manipuladores aéreos es todavía un desafío tecnológico debido a los exigentes requisitos relativos al diseño del manipulador en términos de muy bajo peso, baja inercia, destreza, robustez mecánica y control. La contribución principal de esta tesis es el diseño, desarrollo y validación experimental de varios prototipos de manipuladores de bajo peso (<2 kg) con capacidad de acomodación (“compliant”) para su integración en plataformas aéreas multirotor, incluyendo sistemas bi-brazo de tamaño humano, brazos robóticos de articulaciones flexibles con dedos antropomórficos para agarre, y manipuladores aéreos de largo alcance. Puesto que se prevé que el manipulador aéreo sea capaz de ejecutar tareas de inspección y mantenimiento de forma similar a como lo haría un operador humano, esta tesis propone un enfoque de diseño bio-inspirado, tratando de replicar el brazo humano en cuanto a tamaño, cinemática, distribución de masas y flexibilidad. Esta característica es de hecho uno de los conceptos clave desarrollados y utilizados en este trabajo. Al introducir un elemento elástico como los muelles o elastómeros entre el los actuadores y los enlaces se aumenta las capacidades del manipulador, permitiendo la estimación y control de las fuerzas y pares, la detección de impactos y sobrecargas, o la localización de obstáculos por contacto. Además mejora la seguridad y eficiencia del manipulador, especialmente durante las operaciones en vuelo, donde los impactos y fuerzas de contacto pueden dañar el manipulador o desestabilizar la plataforma aérea. A diferencia de la mayoría de manipuladores industriales, donde el control de fuerzas y pares es posible a tasas por encima de 1 kHz, los servo motores típicamente utilizados en el desarrollo de manipuladores aéreos presentan importantes limitaciones tecnológicas: no hay realimentación ni control de torque, sólo admiten referencias de posición (o bien de velocidad), y presentan retrasos de comunicación. Sin embargo, estos dispositivos son todavía la mejor solución debido al alto ratio de torque a peso, por su bajo peso, diseño compacto y facilidad de ensamblado e integración. Para suplir estas limitaciones, los brazos robóticos flexibles presentados aquí permiten estimar y controlar las fuerzas a partir de la deflexión del mecanismo de muelle-palanca introducido en las articulaciones, medida a nivel articular mediante potenciómetros o codificadores, o en espacio Cartesiano mediante sensores de visión. Tómese como referencia que en los prototipos desarrollados la máxima deflexión articular es de unos 25 grados, lo que corresponde a una desviación de posición en torno a 20 cm en el efector final para un brazo de tamaño humano. Las capacidades y funcionalidades de estos manipuladores se han evaluado en base fija primero, y luego en vuelos en exteriores, integrando los brazos en diferentes plataformas hexartor comerciales. Caracterización frecuencial, control de posición/fuerza/impedancia, agarre bimanual, teleoperación de brazos, estimación de carga, o la localización de obstáculos mediante contacto son algunos de los experimentos presentados en esta tesis para validar los prototipos desarrollados por el auto

Model-based fault detection and diagnosis of BLDC motors working at variable speed using wavelet transform

Predictive Maintenance is becoming increasingly important in the automated industry, as maintaining equipment health is essential for the smooth flow of a manufacturing process. This thesis focuses on introducing a model-based technique for the predictive maintenance of robotic motors. The outcomes of this technique, when applied to practical scenarios as well as in simulations, are shown and discussed below. The thesis aims to provide a strong theoretical justification to an idea, that was developed and tested successfully on real-life robot motor data. The idea involves applying the wavelet transform to the motor current and gathering the occurrence of frequencies relative to the central frequency (frequency ratio) to detect the presence of an anomalous frequency ratio. The enormous amount of information documented on experiments using Motor Current Signature Analysis (MCSA) for fault detection and diagnosis (FDD) is used here to diagnose the fault. Simulations of two faulty models, Stator inter-turn winding short and eccentricity fault, have been developed and tested, at variable speeds, with this technique to provide assertive results. Also, the positive results obtained while the technique was applied to the robotic motor data has been presented and explained. This idea is different and more useful that MCSA alone as it works for variable speed conditions. Lastly, the thesis provides suggestions on how to expand on the technique to develop a useful predictive maintenance tool for robotic motors.Mechanical Engineerin

Fourth Annual Workshop on Space Operations Applications and Research (SOAR 90)

The proceedings of the SOAR workshop are presented. The technical areas included are as follows: Automation and Robotics; Environmental Interactions; Human Factors; Intelligent Systems; and Life Sciences. NASA and Air Force programmatic overviews and panel sessions were also held in each technical area

Towards narrowing the reality gap in electromechanical systems: error modeling in virtual commissioning

Digital factories and smart manufacturing systems have been increasingly researched and multiple concepts were developed to cope with prevailing ever-shortening life-cycles. The ubiquitous digital twin, despite many definitions, is often praised for accurate virtual models. One key idea to improve manufacturing through such virtual models is $\textit{virtual commissioning}$ (VC), aiming at early machine code validation. VC and its virtual models are still lacking behind their real counterparts. This gap between reality and its virtual model, commonly termed $\textit{reality gap}$, increases the complexity of creating cyber-physical systems. An especially stark contrast is visible between the idealized virtual model and a real machine encountering errors. While error simulations exist in other fields of research, a thorough investigation in VC is missing. Thus, this paper addresses the task of narrowing the reality gap in VC based on two steps. First, a comprehensive body of research of possible errors encountered in virtual commissioning is analyzed. Secondly, the feasibility of error implementation is discussed. This paper lays the foundation for narrowing the reality gap and enabling test automation and digital twin-based control

Design of an intelligent embedded system for condition monitoring of an industrial robot

PhD ThesisIndustrial robots have long been used in production systems in order to improve productivity, quality and safety in automated manufacturing processes. There are significant implications for operator safety in the event of a robot malfunction or failure, and an unforeseen robot stoppage, due to different reasons, has the potential to cause an interruption in the entire production line, resulting in economic and production losses. Condition monitoring (CM) is a type of maintenance inspection technique by which an operational asset is monitored and the data obtained is analysed to detect signs of degradation, diagnose the causes of faults and thus reduce maintenance costs. So, the main focus of this research is to design and develop an online, intelligent CM system based on wireless embedded technology to detect and diagnose the most common faults in the transmission systems (gears and bearings) of the industrial robot joints using vibration signal analysis. To this end an old, but operational, PUMA 560 robot was utilized to synthesize a number of different transmission faults in one of the joints (3 - elbow), such as backlash between the gear pair, gear tooth and bearing faults. A two-stage condition monitoring algorithm is proposed for robot health assessment, incorporating fault detection and fault diagnosis. Signal processing techniques play a significant role in building any condition monitoring system, in order to determine fault-symptom relationships, and detect abnormalities in robot health. Fault detection stage is based on time-domain signal analysis and a statistical control chart (SCC) technique. For accurate fault diagnosis in the second stage, a novel implementation of a time-frequency signal analysis technique based on the discrete wavelet transform (DWT) is adopted. In this technique, vibration signals are decomposed into eight levels of wavelet coefficients and statistical features, such as standard deviation, kurtosis and skewness, are obtained at each level and analysed to extract the most salient feature related to faults; the artificial neural network (ANN) is then used for fault classification. A data acquisition system based on National Instruments (NI) software and hardware was initially developed for preliminary robot vibration analysis and feature extraction. The transmission faults induced in the robot can change the captured vibration spectra, and the robot’s natural frequencies were established using experimental modal analysis, and also the fundamental fault frequencies for the gear transmission and bearings were obtained and utilized for preliminary robot condition monitoring. In addition to simulation of different levels of backlash fault, gear tooth and bearing faults which have not been previously investigated in industrial robots, with several levels of ii severity, were successfully simulated and detected in the robot’s joint transmission. The vibration features extracted, which are related to the robot healthy state and different fault types, using the data acquisition system were subsequently used in building the SCC and ANN, which were trained using part of the measured data set that represents the robot operating range. Another set of data, not used within the training stage, was then utilized for validation. The results indicate the successful detection and diagnosis of faults using the key extracted parameters. A wireless embedded system based on the ZigBee communication protocol was designed for the application of the proposed CM algorithm in real-time, using an Arduino DUE as the core of the wireless sensor unit attached on the robot arm. A Texas Instruments digital signal processor (TMS320C6713 DSK board) was used as the base station of the wireless system on which the robot’s fault diagnosis algorithm is run. To implement the two stages of the proposed CM algorithm on the designed embedded system, software based on the C programming language has been developed. To demonstrate the reliability of the designed wireless CM system, experimental validations were performed, and high reliability was shown in the detection and diagnosis of several seeded faults in the robot. Optimistically, the established wireless embedded system could be envisaged for fault detection and diagnostics on any type of rotating machine, with the monitoring system realized using vibration signal analysis. Furthermore, with some modifications to the system’s hardware and software, different CM techniques such as acoustic emission (AE) analysis or motor current signature analysis (MCSA), can be applied.Iraqi government, represented by the Ministry of Higher Education and Scientific Research, the Iraqi Cultural Attaché in London, and the University of Technology in Baghda

Proceedings of the NASA Conference on Space Telerobotics, volume 4

Papers presented at the NASA Conference on Space Telerobotics are compiled. The theme of the conference was man-machine collaboration in space. The conference provided a forum for researchers and engineers to exchange ideas on the research and development required for the application of telerobotic technology to the space systems planned for the 1990's and beyond. Volume 4 contains papers related to the following subject areas: manipulator control; telemanipulation; flight experiments (systems and simulators); sensor-based planning; robot kinematics, dynamics, and control; robot task planning and assembly; and research activities at the NASA Langley Research Center

Proceedings of the NASA Conference on Space Telerobotics, volume 1

The theme of the Conference was man-machine collaboration in space. Topics addressed include: redundant manipulators; man-machine systems; telerobot architecture; remote sensing and planning; navigation; neural networks; fundamental AI research; and reasoning under uncertainty