CAD enabled trajectory optimization and accurate motion control for repetitive tasks

As machine users generally only define the start and end point of the movement, a large trajectory optimization potential rises for single axis mechanisms performing repetitive tasks. However, a descriptive mathematical model of the mecha- nism needs to be defined in order to apply existing optimization techniques. This is usually done with complex methods like virtual work or Lagrange equations. In this paper, a generic technique is presented to optimize the design of point-to-point trajectories by extracting position dependent properties with CAD motion simulations. The optimization problem is solved by a genetic algorithm. Nevertheless, the potential savings will only be achieved if the machine is capable of accurately following the optimized trajectory. Therefore, a feedforward motion controller is derived from the generic model allowing to use the controller for various settings and position profiles. Moreover, the theoretical savings are compared with experimental data from a physical set-up. The results quantitatively show that the savings potential is effectively achieved thanks to advanced torque feedforward with a reduction of the maximum torque by 12.6% compared with a standard 1/3-profil

Trajectory Synthesis for Fisher Information Maximization

Estimation of model parameters in a dynamic system can be significantly improved with the choice of experimental trajectory. For general, nonlinear dynamic systems, finding globally "best" trajectories is typically not feasible; however, given an initial estimate of the model parameters and an initial trajectory, we present a continuous-time optimization method that produces a locally optimal trajectory for parameter estimation in the presence of measurement noise. The optimization algorithm is formulated to find system trajectories that improve a norm on the Fisher information matrix. A double-pendulum cart apparatus is used to numerically and experimentally validate this technique. In simulation, the optimized trajectory increases the minimum eigenvalue of the Fisher information matrix by three orders of magnitude compared to the initial trajectory. Experimental results show that this optimized trajectory translates to an order of magnitude improvement in the parameter estimate error in practice.Comment: 12 page

On the trajectory planning for energy efficiency in industrial robotic systems

In this paper, we present an approach for the minimum-energy trajectory planning in industrial robotic systems. The method is based on the dynamic and electro-mechanical modeling of one-degree-of-freedom systems and the derivation of the energy formulation for standard point-to-point trajectories, as, for instance, trapezoidal and cycloidal speed profiles. The proposed approach is experimentally validated on two robotic systems, namely a linear axis of a Cartesian manipulator built in the 1990\u2019s, and a test bench composed of two servomotors directly connected or coupled by means of a planetary gear. During the tests, the electrical power expended by the systems is measured and integrated over time to compute the energy consumption for each trajectory. Despite the limitations of the energy measurement systems, the results reveal a trend in agreement with the theoretical calculations, showing the possibility of applying the method for enhancing the performance of industrial robotic systems in terms of energy consumption in point-to-point motions

Experimental Validation of a Real-Time Optimal Controller for Coordination of CAVs in a Multi-Lane Roundabout

Roundabouts in conjunction with other traffic scenarios, e.g., intersections, merging roadways, speed reduction zones, can induce congestion in a transportation network due to driver responses to various disturbances. Research efforts have shown that smoothing traffic flow and eliminating stop-and-go driving can both improve fuel efficiency of the vehicles and the throughput of a roundabout. In this paper, we validate an optimal control framework developed earlier in a multi-lane roundabout scenario using the University of Delaware's scaled smart city (UDSSC). We first provide conditions where the solution is optimal. Then, we demonstrate the feasibility of the solution using experiments at UDSSC, and show that the optimal solution completely eliminates stop-and-go driving while preserving safety.Comment: 6 Pages, 4 Figures, 1 tabl

Study and Development of Mechatronic Devices and Machine Learning Schemes for Industrial Applications

Obiettivo del presente progetto di dottorato è lo studio e sviluppo di sistemi meccatronici e di modelli machine learning per macchine operatrici e celle robotizzate al fine di incrementarne le prestazioni operative e gestionali. Le pressanti esigenze del mercato hanno imposto lavorazioni con livelli di accuratezza sempre più elevati, tempi di risposta e di produzione ridotti e a costi contenuti. In questo contesto nasce il progetto di dottorato, focalizzato su applicazioni di lavorazioni meccaniche (e.g. fresatura), che includono sistemi complessi quali, ad esempio, macchine a 5 assi e, tipicamente, robot industriali, il cui utilizzo varia a seconda dell’impiego. Oltre alle specifiche problematiche delle lavorazioni, si deve anche considerare l’interazione macchina-robot per permettere un’efficiente capacità e gestione dell’intero impianto. La complessità di questo scenario può evidenziare sia specifiche problematiche inerenti alle lavorazioni (e.g. vibrazioni) sia inefficienze più generali che riguardano l’impianto produttivo (e.g. asservimento delle macchine con robot, consumo energetico). Vista la vastità della tematica, il progetto si è suddiviso in due parti, lo studio e sviluppo di due specifici dispositivi meccatronici, basati sull’impiego di attuatori piezoelettrici, che puntano principalmente alla compensazione di vibrazioni indotte dal processo di lavorazione, e l’integrazione di robot per l’asservimento di macchine utensili in celle robotizzate, impiegando modelli di machine learning per definire le traiettorie ed i punti di raggiungibilità del robot, al fine di migliorarne l’accuratezza del posizionamento del pezzo in diverse condizioni. In conclusione, la presente tesi vuole proporre soluzioni meccatroniche e di machine learning per incrementare le prestazioni di macchine e sistemi robotizzati convenzionali. I sistemi studiati possono essere integrati in celle robotizzate, focalizzandosi sia su problematiche specifiche delle lavorazioni in macchine operatrici sia su problematiche a livello di impianto robot-macchina. Le ricerche hanno riguardato un’approfondita valutazione dello stato dell’arte, la definizione dei modelli teorici, la progettazione funzionale e l’identificazione delle criticità del design dei prototipi, la realizzazione delle simulazioni e delle prove sperimentali e l’analisi dei risultati.The aim of this Ph.D. project is the study and development of mechatronic systems and machine learning models for machine tools and robotic applications to improve their performances. The industrial demands have imposed an ever-increasing accuracy and efficiency requirement whilst constraining the cost. In this context, this project focuses on machining processes (e.g. milling) that include complex systems such as 5-axes machine tool and industrial robots, employed for various applications. Beside the issues related to the machining process itself, the interaction between the machining centre and the robot must be considered for the complete industrial plant’s improvement. This scenario´s complexity depicts both specific machining problematics (e.g. vibrations) and more general issues related to the complete plant, such as machine tending with an industrial robot and energy consumption. Regarding the immensity of this area, this project is divided in two parts, the study and development of two mechatronic devices, based on piezoelectric stack actuators, for the active vibration control during the machining process, and the robot machine tending within the robotic cell, employing machine learning schemes for the trajectory definition and robot reachability to improve the corresponding positioning accuracy. In conclusion, this thesis aims to provide a set of solutions, based on mechatronic devices and machine learning schemes, to improve the conventional machining centre and the robotic systems performances. The studied systems can be integrated within a robotic cell, focusing on issues related to the specific machining process and to the interaction between robot-machining centre. This research required a thorough study of the state-of-the-art, the formulation of theoretical models, the functional design development, the identification of the critical aspects in the prototype designs, the simulation and experimental campaigns, and the analysis of the obtained results

Motion planning with dynamics awareness for long reach manipulation in aerial robotic systems with two arms

Human activities in maintenance of industrial plants pose elevated risks as well as significant costs due to the required shutdowns of the facility. An aerial robotic system with two arms for long reach manipulation in cluttered environments is presented to alleviate these constraints. The system consists of a multirotor with a long bar extension that incorporates a lightweight dual arm in the tip. This configuration allows aerial manipulation tasks even in hard-to-reach places. The objective of this work is the development of planning strategies to move the aerial robotic system with two arms for long reach manipulation in a safe and efficient way for both navigation and manipulation tasks. The motion planning problem is addressed considering jointly the aerial platform and the dual arm in order to achieve wider operating conditions. Since there exists a strong dynamical coupling between the multirotor and the dual arm, safety in obstacle avoidance will be assured by introducing dynamics awareness in the operation of the planner. On the other hand, the limited maneuverability of the system emphasizes the importance of energy and time efficiency in the generated trajectories. Accordingly, an adapted version of the optimal Rapidly-exploring Random Tree algorithm has been employed to guarantee their optimality. The resulting motion planning strategy has been evaluated through simulation in two realistic industrial scenarios, a riveting application and a chimney repairing task. To this end, the dynamics of the aerial robotic system with two arms for long reach manipulation has been properly modeled, and a distributed control scheme has been derived to complete the test bed. The satisfactory results of the simulations are presented as a first validation of the proposed approach.Unión Europea H2020-644271Ministerio de Ciencia, Innovación y Universidades DPI2014-59383-C2-1-