Affordable flexible hybrid manipulator for miniaturised product assembly

Miniaturised assembly systems are capable of assembling parts of a few millimetres in size with an accuracy of a few micrometres. Reducing the size and the cost of such a system while increasing its flexibility and accuracy is a challenging issue. The introduction of hybrid manipulation, also called coarse/fine manipulation, within an assembly system is the solution investigated in this thesis. A micro-motion stage (MMS) is designed to be used as the fine positioning mechanism of the hybrid assembly system. MMSs often integrate compliant micro-motion stages (CMMSs) to achieve higher performances than the conventional MMSs. CMMSs are mechanisms that transmit an output force and displacement through the deformation of their structure. Although widely studied, the design and modelling techniques of these mechanisms still need to be improved and simplified. Firstly, the linear modelling of CMMSs is evaluated and two polymer prototypes are fabricated and characterised. It is found that polymer based designs have a low fabrication cost but not suitable for construction of a micro-assembly system. A simplified nonlinear model is then derived and integrated within an analytical model, allowing for the full characterisation of the CMMS in terms of stiffness and range of motion. An aluminium CMMS is fabricated based on the optimisation results from the analytical model and is integrated within an MMS. The MMS is controlled using dual-range positioning to achieve a low-cost positioning accuracy better than 2µm within a workspace of 4.4×4.4mm2. Finally, a hybrid manipulator is designed to assemble mobile-phone cameras and sensors automatically. A conventional robot manipulator is used to pick and place the parts in coarse mode while the aluminium CMMS based MMS is used for fine alignment of the parts. A high-resolution vision system is used to locate the parts on the substrate and to measure the relative position of the manipulator above MMS using a calibration grid with square patterns. The overall placement accuracy of the assembly system is ±24µm at 3σ and can reach 2µm, for a total cost of less than £50k, thus demonstrating the suitability of hybrid manipulation for desktop-size miniaturised assembly systems. The precision of the existing system could be significantly improved by making the manipulator stiffer (i.e. preloaded bearings…) and adjustable to compensate for misalignment. Further improvement could also be made on the calibration of the vision system. The system could be either scaled up or down using the same architecture while adapting the controllers to the scale.Engineering and Physical Sciences Research Council (EPSRC

Precise control of flexible manipulators

The design and experimental testing of end point position controllers for a very flexible one link lightweight manipulator are summarized. The latest upgraded version of the experimental set up, and the basic differences between conventional joint angle feedback and end point position feedback are described. A general procedure for application of modern control methods to the problem is outlined. The relationship between weighting parameters and the bandwidth and control stiffness of the resulting end point position closed loop system is shown. It is found that joint rate angle feedback in addition to the primary end point position sensor is essential for adequate disturbance rejection capability of the closed loop system. The use of a low order multivariable compensator design computer code; called Sandy is documented. A solution to the problem of control mode switching between position sensor sets is outlined. The proof of concept for endpoint position feedback for a one link flexible manipulator was demonstrated. The bandwidth obtained with the experimental end point position controller is about twice as fast as the beam's first natural cantilevered frequency, and comes within a factor of four of the absolute physical speed limit imposed by the wave propagation time of the beam

Controlled motion in an elastic world. Research project: Manipulation strategies for massive space payloads

The flexibility of the drives and structures of controlled motion systems are presented as an obstacle to be overcome in the design of high performance motion systems, particularly manipulator arms. The task and the measure of performance to be applied determine the technology appropriate to overcome this obstacle. Included in the technologies proposed are control algorithms (feedback and feed forward), passive damping enhancement, operational strategies, and structural design. Modeling of the distributed, nonlinear system is difficult, and alternative approaches are discussed. The author presents personal perspectives on the history, status, and future directions in this area

Dynamic analysis and control system design of a deployable space robotic manipulator

This thesis presents a dynamic analysis and a control system for a flexible space manipulator, the Deployable Robotic Manipulator or DRM, which has a deployable/retractable link. The link extends (or retracts) from the containing slewing link of the manipulator to change the DRM's length and hence its workspace. This makes the system dynamics time varying and therefore any control strategy has to adapt to this fact. The aim of the control system developed is to slew the manipulator through a predetermined angle given a maximum angular acceleration, to reduce flexural vibrations of the manipulator and to have a certain degree of robustness, all of this while carrying a payload and while the length of the manipulator is changing. The control system consists of a slewing motor that rotates the manipulator using the open-loop assumed torque method and two reaction wheel actuators, one at the base and one at the tip of the manipulator, which are driven by a closed-loop damping control law. Two closed-loop control laws are developed, a linear control law and a Lyapunov based control law. The linear control law is based on collocated output feedback. The Lyapunov control law is developed for each of the actuators using Lyapunov stability theory to produce vibration control that can achieve the objectives stated above for different payloads, while the manipulator is rotating and deploying or retracting. The response of the system is investigated by computer simulation for two-dimensional vibrations of the deployable manipulator. Both the linear and Lyapunov based feedback control laws are found to eliminate vibrations for a range of payloads, and to increase the robustness of the slewing mechanism to deal with uncertain payload characteristics

Dynamics and Control of Flexible Composite Robotic Manipulators Based on Finite Element Method

The robotic manipulator is a device to carry out the various tasks according to the requirements without any human intervention. Vibration analysis of flexible manipulators has been an important area of research in order to model and control of such systems. In the present analysis, the Timoshenko beam theory based single and double link flexible manipulators made up of advanced composite material have been analyzed using finite element method. A three noded beam element has been implemented for modelling and analysis of the flexible composite manipulators under different input torques. The effects of hybridization of the different composite materials on the positions and residuals of the end effectors have also been studied. The input shaping has also been carried out in order to reduce the residual vibration of the end effector by adjusting the amplitude and time delay. The influences of the taper angles of the tapered flexible composite manipulators on the end effector movement and vibration have also been presented. The linear quadratic regulator control (LQR) scheme has been applied in order to further reduce the residual vibration of the end effector. Various results have been obtained based on the different analyses. The results reveal that the tapered hollow flexible composite manipulators give the better performances in terms of end effector positions and residual vibration. The obtained results based on the LQR control scheme show that residual vibration can be controlled without compromising the end effector movement

Direct model reference adaptive control of a flexible robotic manipulator

Quick, precise control of a flexible manipulator in a space environment is essential for future Space Station repair and satellite servicing. Numerous control algorithms have proven successful in controlling rigid manipulators wih colocated sensors and actuators; however, few have been tested on a flexible manipulator with noncolocated sensors and actuators. In this thesis, a model reference adaptive control (MRAC) scheme based on command generator tracker theory is designed for a flexible manipulator. Quicker, more precise tracking results are expected over nonadaptive control laws for this MRAC approach. Equations of motion in modal coordinates are derived for a single-link, flexible manipulator with an actuator at the pinned-end and a sensor at the free end. An MRAC is designed with the objective of controlling the torquing actuator so that the tip position follows a trajectory that is prescribed by the reference model. An appealing feature of this direct MRAC law is that it allows the reference model to have fewer states than the plant itself. Direct adaptive control also adjusts the controller parameters directly with knowledge of only the plant output and input signals

Technology for large space systems: A special bibliography with indexes (supplement 04)

This bibliography lists 259 reports, articles, and other documents introduced into the NASA scientific and technical information system between July 1, 1980 and December 31, 1980. Its purpose is to provide information to the researcher, manager, and designer in technology development and mission design in the area of the Large Space Systems Technology Program. Subject matter is grouped according to systems, interactive analysis and design. Structural concepts, control systems, electronics, advanced materials, assembly concepts, propulsion, solar power satellite systems, and flight experiments

Analysis and design of large space structures with nonlinear joints

Issued as Final report, Project no. E-25-62

Numerical modelling of rotorcraft aeroelastic stability

Imperial Users onl

A steady state tip control strategy for long reach robots

The work presented in this thesis describes the development of a novel strategy for the steady state tip position control of a single link flexible robot arm. Control is based upon a master/slave relationship. Arm trajectory is defined by through 'master' positioning head which moves a laser through a programmed path. Tip position is detected by an optical system which produces an error signal proportional to the displacement of the tip from the demand laser spot position. The error signal and its derivative form inputs to the arm 'slave' controller so enabling direct tip control with simultaneous correction for arm bending. Trajectory definition is not model-based as it is defined optically through movement of the positioning head alone. A critical investigation of vacuum tube and solid state sensing methods is undertaken leading to the development of a photodiode quadrant detector beam tracking system. The effect of varying the incident light parameters on the beam tracker performance are examined from which the optimum illumination characteristics are determined. Operational testing of the system on a dual-axis prototype robot using the purpose-built beam tracker has shown that successful steady state tip control can be achieved through a PD based slave controller. Errors of less than 0.05 mm and settling times of 0.2 s are obtained. These results compare favourably with those for the model-based tip position correction strategies where tracking errors of ± 0.6 mm are recorded