A hyper-redundant manipulator

“Hyper-redundant” manipulators have a very large number of actuatable degrees of freedom. The benefits of hyper-redundant robots include the ability to avoid obstacles, increased robustness with respect to mechanical failure, and the ability to perform new forms of robot locomotion and grasping. The authors examine hyper-redundant manipulator design criteria and the physical implementation of one particular design: a variable geometry truss

Kinematically optimal hyper-redundant manipulator configurations

“Hyper-redundant” robots have a very large or infinite degree of kinematic redundancy. This paper develops new methods for determining “optimal” hyper-redundant manipulator configurations based on a continuum formulation of kinematics. This formulation uses a backbone curve model to capture the robot's essential macroscopic geometric features. The calculus of variations is used to develop differential equations, whose solution is the optimal backbone curve shape. We show that this approach is computationally efficient on a single processor, and generates solutions in O(1) time for an N degree-of-freedom manipulator when implemented in parallel on O(N) processors. For this reason, it is better suited to hyper-redundant robots than other redundancy resolution methods. Furthermore, this approach is useful for many hyper-redundant mechanical morphologies which are not handled by known methods

Modeling, Control and Estimation of Reconfigurable Cable Driven Parallel Robots

The motivation for this thesis was to develop a cable-driven parallel robot (CDPR) as part of a two-part robotic device for concrete 3D printing. This research addresses specific research questions in this domain, chiefly, to present advantages offered by the addition of kinematic redundancies to CDPRs. Due to the natural actuation redundancy present in a fully constrained CDPR, the addition of internal mobility offers complex challenges in modeling and control that are not often encountered in literature. This work presents a systematic analysis of modeling such kinematic redundancies through the application of reciprocal screw theory (RST) and Lie algebra while further introducing specific challenges and drawbacks presented by cable driven actuators. It further re-contextualizes well-known performance indices such as manipulability, wrench closure quality, and the available wrench set for application with reconfigurable CDPRs. The existence of both internal redundancy and static redundancy in the joint space offers a large subspace of valid solutions that can be condensed through the selection of appropriate objective priorities, constraints or cost functions. Traditional approaches to such redundancy resolution necessitate computationally expensive numerical optimization. The control of both kinematic and actuation redundancies requires cascaded control frameworks that cannot easily be applied towards real-time control. The selected cost functions for numerical optimization of rCDPRs can be globally (and sometimes locally) non-convex. In this work we present two applied examples of redundancy resolution control that are unique to rCDPRs. In the first example, we maximize the directional wrench ability at the end-effector while minimizing the joint torque requirement by utilizing the fitness of the available wrench set as a constraint over wrench feasibility. The second example focuses on directional stiffness maximization at the end-effector through a variable stiffness module (VSM) that partially decouples the tension and stiffness. The VSM introduces an additional degrees of freedom to the system in order to manipulate both reconfigurability and cable stiffness independently. The controllers in the above examples were designed with kinematic models, but most CDPRs are highly dynamic systems which can require challenging feedback control frameworks. An approach to real-time dynamic control was implemented in this thesis by incorporating a learning-based frameworks through deep reinforcement learning. Three approaches to rCDPR training were attempted utilizing model-free TD3 networks. Robustness and safety are critical features for robot development. One of the main causes of robot failure in CDPRs is due to cable breakage. This not only causes dangerous dynamic oscillations in the workspace, but also leads to total robot failure if the controllability (due to lack of cables) is lost. Fortunately, rCDPRs can be utilized towards failure tolerant control for task recovery. The kinematically redundant joints can be utilized to help recover the lost degrees of freedom due to cable failure. This work applies a Multi-Model Adaptive Estimation (MMAE) framework to enable online and automatic objective reprioritization and actuator retasking. The likelihood of cable failure(s) from the estimator informs the mixing of the control inputs from a bank of feedforward controllers. In traditional rigid body robots, safety procedures generally involve a standard emergency stop procedure such as actuator locking. Due to the flexibility of cable links, the dynamic oscillations of the end-effector due to cable failure must be actively dampened. This work incorporates a Linear Quadratic Regulator (LQR) based feedback stabilizer into the failure tolerant control framework that works to stabilize the non-linear system and dampen out these oscillations. This research contributes to a growing, but hitherto niche body of work in reconfigurable cable driven parallel manipulators. Some outcomes of the multiple engineering design, control and estimation challenges addressed in this research warrant further exploration and study that are beyond the scope of this thesis. This thesis concludes with a thorough discussion of the advantages and limitations of the presented work and avenues for further research that may be of interest to continuing scholars in the community

Waveform based Inverse Kinematics Algorithm of Kinematically Redundant 3-DOF Manipulator

This paper presents a new approach to the problem of inverse kinematics by modelling robot arm movements as signals generated from algebra-based solutions. The inverse kinematics of point P(xP,yP) are modelled as sinusoidal functions with mechanical constraints. Unique wave forms occur at each point in the workspace. There are four types of inverse kinematic waves depending on how sinusoidal waves cross the value of mechanical constraints. In terms of tracking the path, the robot's arm produces complex waves that produce the desired movement. Due to mechanical constraints, many points in the workspace have the bandwidth where the signal is produced only at limited intervals from the angular domain. Tracks must be stored at these appropriate intervals, which build bandwidth tunnels, completely from the initial configuration to the final configuration. Simulations will be carried out using 3-DOF series planar robots to track highly complex mathematical curves. With a wave-based approach, the solution of the IK problem can benefit from wave characteristics such as the superposition principle

Determining Singularity-Free Inner Workspace through Offline Conversion of Assembly Modes for a 3-RRR PPM

The existing singularity avoidance methods have deficiencies, such as the conditionality of the online conversion of the assembly modes (AMs) and the kinematically redundant manipulator with the predicament of the prototype design and added complexity of the mechanism. To address these issues, a method to determine a singularity-free inner workspace through offline conversion of the AMs of the 3-RRR planar parallel manipulator (PPM) is presented. Based on the geometric relations among rods of the manipulator during the occurrence of singularity, and the singular points at or near the boundary of the workspace are permitted, the AMs and ranges of the orientation angle of the moving platform corresponding to the inner singularity-free workspace are determined through a three-dimensional search method. The simulation and experimental comparisons indicate that singular-free paths related to the constant or variable orientation angle of the moving platform can be planned on the singularity-free inner workspace