Instationary modal Analysis for Impulse-type stimulated structures

In order to determine modal parameters, classical experimental modal analysis can be used in engineering application. This method finds a system frequency response function using fast Fourier Transform (FFT). The Fourier Transform is one type of global data analysis method. The frequency resolution is equal to the reciprocal of the total sample time. So applying the FFT is not suitable for any transient signal to reveal local characteristics. However, in modern manufacturing industries, processing forces are rapidly changing. The dynamic behavior may vary rapidly in a short time due to variations in the machining parameters and changes in boundary conditions. These nonlinear and non-stationary dynamic parameters are not constant during machining operations identification using FFT. In this research, an innovative transient signal analysis approach has been developed, which is based on an application of the least squares estimation. The proposed method provides transient information with high resolution and to identify the time-varying modal parameters during machining. Least squares estimation can be augmented with a sliding-window operation (SWLSE) to reveal the actual system dynamic behavior at any moment. The accuracy of this method depends on the window size, the noise ratio and the sampling rate etc. The estimation accuracy of modal parameters is discussed in this work. To examine the efficiency of the SWLSE method experimental tests are performed on a laboratory beam system and the results are compared with the classical experimental modal analysis (CEMA) method. The laboratory beam system is designed and assembled that the stiffness and damping ratio of the structure can be adjusted. Additionally, the proposed method is applied to the identification of the actual modal parameters of machine tools during machining operations. In another application, the proposed method provides also the process varied damping information in a process monitoring

Dynamic Modeling and Identification of Joint Drive with Load-Dependent Friction Model

International audienceFriction modeling is essential for joint dynamic identification and control. Joint friction is composed of a viscous and a dry friction force. According to Coulomb law, dry friction depends linearly on the load in the transmission. However, in robotics field, a constant dry friction is frequently used to simplify modeling, identification and control. That is not accurate enough for joints with large payload or inertial and gravity variations and actuated with transmissions as speed reducer, screw-nut or worm gear. A new joint friction model taking dynamic and external forces into account is proposed in this paper. A new identification process is proposed, merging all the joint data collected while the mechanism is tracking exciting trajectories and with different payloads, to get a global LS estimation in one step. An experimental validation is carried out with a prismatic joint composed of a Star high precision ball screw drive positioning unit

High-performance series elastic actuation

textMobile legged robots have the potential to restructure many aspects of our lives in the near future. Whether for applications in household care, entertainment, or disaster response, these systems depend on high-performance actuators to improve their basic capabilities. The work presented here focuses on developing new high-performance actuators, specifically series elastic actuators, to address this need. We adopt a system-wide optimization approach, dealing with factors which influence performance at the levels of mechanical design, electrical system design, and control. Using this approach and based on a set of performance metrics, we produce an actuator, the UT-SEA, which achieves leading empirical results in terms of power-to-weight, force control, size, and system efficiency. We also develop general high-performance control techniques for both force- and position-controlled actuators, some of which were adopted for use on NASA-JSC's Valkyrie Humanoid robot and were used during DARPA's DRC Trials 2013 robotics competition.Electrical and Computer Engineerin

Performance and manufacturing considerations for series elastic actuators

Robots are becoming an integral part of our lives. We are already physically connected with them through many robotic applications such as exoskeletons in military, orthosis devices in health care, collaborative robots in industry, etc. While the integration of robots improves the quality of human life, it still poses a safety concern during the physical human-robot interaction. Series Elastic Actuators (SEAs) play an important role in improving the safety of human-robot interaction and collaboration. Considering the fast expansion of robotic applications in our lives and the safety benefits of SEAs, it is conceivable that SEAs are going to play an important role in robotic applications in every aspect of human life. This dissertation focuses on reducing the cost, simplifying the use and improving the performance of SEAs. The first research focus in this dissertation is to reduce the cost of SEAs. Robots are successful in reducing production and service costs when used but the capital cost of robot installations are very high. As robotics research shifts to safe robotic applications, reducing the cost of SEAs will greatly help to deploy this technology in more robotic applications and to increase their accessibility to a broader range of researchers and educators. With this motivation, I present a case study on reducing the cost of a SEA while maintaining high force and position control performance and industrial grade service life. The second research focus in this dissertation is to simplify the laborious gain selection process of the cascaded controllers of SEAs. In order to simplify the gain selection process of the impedance controllers of SEAs, an optimal feedback gain selection methodology was developed. Using this method, the feedback gains of the cascaded PD-type impedance controllers of SEAs can easily be calibrated. The developed method allows the users to find the highest feedback gains for a desired phase-margin. Beyond the low-cost realization and simple controller tuning of SEAs, performance improvements on SEAs are possible utilizing the series elasticity in these actuators. As the third research focus in this dissertation, a sequential convex optimization-based motion planning technique is developed in order to improve the joint velocity capabilities of SEAs with nonlinearities. By using this method, higher joint velocities, that are not achievable with the rigid counterparts of SEAs can be achievedMechanical Engineerin

Highly redundant and fault tolerant actuator system: control, condition monitoring and experimental validation

This thesis is concerned with developing a control and condition monitoring system for a class of fault tolerant actuators with high levels of redundancy. The High Redundancy Actuator (HRA) is a concept inspired by biomimetics that aims to provide fault tolerance using relatively large numbers of actuation elements which are assembled in parallel and series configurations to form a single actuator. Each actuation element provides a small contribution to the overall force and displacement of the system. Since the capability of each actuation element is small, the effect of faults within the individual element of the overall system is also small. Hence, the HRA will gracefully degrade instead of going from fully functional to total failure in the presence of faults. Previous research on HRA using electromechanical technology has focused on a relatively low number of actuation elements (i.e. 4 elements), which were controlled with multiple loop control methods. The objective of this thesis is to expand upon this, by considering an HRA with a larger number of actuation elements (i.e. 12 elements). First, a mathematical model of a general n-by-m HRA is derived from first principles. This method can be used to represent any size of electromechanical HRA with actuation elements arranged in a matrix form. Then, a mathematical model of a 4-by-3 HRA is obtained from the general n-by-m model and verified experimentally using the HRA test rig. This actuator model is then used as a foundation for the controller design and condition monitoring development. For control design, two classical and control method-based controllers are compared with an H_infinity approach. The objective for the control design is to make the HRA track a position demand signal in both health and faulty conditions. For the classical PI controller design, the first approach uses twelve local controllers (1 per actuator) and the second uses only a single global controller. For the H_infinity control design, a mixed sensitivity functions is used to obtain good tracking performance and robustness to modelling uncertainties. Both of these methods demonstrate good tracking performance, with a slower response in the presence of faults. As expected, the H_infinity control method's robustness to modelling uncertainties, results in a smaller performance degradation in the presence of faults, compared with the classical designs. Unlike previous work, the thesis also makes a novel contribution to the condition monitoring of HRA. The proposed algorithm does not require the use of multiple sensors. The condition monitoring scheme is based on least-squares parameter estimation and fuzzy logic inference. The least-squares parameter estimation estimates the physical parameters of the electromechanical actuator based on input-output data collected from real-time experiments, while the fuzzy logic inference determines the health condition of the actuator based on the estimated physical parameters. Hence, overall, a new approach to both control and monitoring of an HRA is proposed and demonstrated on a twelve elements HRA test rig

Control Methods for Improving Tracking Accuracy and Disturbance Rejection in Ball Screw Feed Drives

This thesis studies in detail the dynamics of ball screw feed drives and expands understanding of the factors that impose limitations on their performance. This knowledge is then used for developing control strategies that provide adequate command following and disturbance rejection. High performance control strategies proposed in this thesis are designed for, and implemented on, a custom-made ball screw drive. A hybrid Finite Element (FE) model for the ball screw drive is developed and coded in Matlab programming language. This FE model is employed for prediction of natural frequencies, mode shapes, and Frequency Response Functions (FRFs) of the ball screw setup. The accuracy of FRFs predicted for the ball screw mechanism alone is validated against the experimental measurements obtained through impact hammer testing. Next, the FE model for the entire test setup is validated. The dynamic characteristics of the actuator current controller are also modeled. In addition, the modal parameters of the mechanical structure are extracted from measured FRFs, which include the effects of current loop dynamics. To ensure adequate command following and disturbance rejection, three motion controllers with active vibration damping capability are developed. The first is based on the sensor averaging concept which facilitates position control of the rigid body dynamics. Active damping is added to suppress vibrations. To achieve satisfactory steady state response, integral action over the tracking error is included. The stability analysis and tuning procedure for this controller is presented together with experimental results that prove the effectiveness of this method in high-speed tracking and cutting applications. The second design uses the pole placement technique to move the real component of two of the oscillatory poles further to the left along the real axis. This yields a faster rigid body response with less vibration. However, the time delay from the current loop dynamics imposes a limitation on how much the poles can be shifted to the left without jeopardizing the system’s stability. To overcome this issue, a lead filter is designed to recover the system phase at the crossover frequency. When designing the Pole Placement Controller (PPC) and the lead filter concurrently, the objective is to minimize the load side disturbance response against the disturbances. This controller is also tested in high-speed tracking and cutting experiments. The third control method is developed around the idea of using the pole placement technique for active damping of not only the first mode of vibration, but also the second and third modes as well. A Kalman filter is designed to estimate a state vector for the system, from the control input and the position measurements obtained from the rotary and linear encoders. The state estimates are then fed back to the PPC controller. Although for this control design, promising results in terms of disturbance rejection are obtained in simulations, the Nyquist stability analysis shows that the closed loop system has poor stability margins. To improve the stability margins, the McFarlane-Glover robustness optimization method is attempted, and as a result, the stability margins are improved, but at the cost of degraded performance. The practical implementation of the third controller, was, unfortunately, not successful. This thesis concludes by addressing the problem of harmonic disturbance rejection in ball screw drives. It is shown that for cases where a ball screw drive is subject to high-frequency disturbances, the dynamic positioning accuracy of the ball screw drive can be improved significantly by adopting an additional control scheme known as Adaptive Feedforward Cancellation (AFC). Details of parameter tuning and stability analysis for AFC are presented. At the end, successful implementation and effectiveness of AFC is demonstrated in applications involving time periodic or space periodic disturbances. The conclusions drawn about the effectiveness of the AFC are based on results obtained from the high-speed tracking and end-milling experiments

Linear motor motion control using a learning feedforward controller

The design and realization of an online learning motion controller for a linear motor is presented, and its usefulness is evaluated. The controller consists of two components: (1) a model-based feedback component, and (2) a learning feedforward component. The feedback component is designed on the basis of a simple second-order linear model, which is known to have structural errors. In the design, an emphasis is placed on robustness. The learning feedforward component is a neural-network-based controller, comprised of a one-hidden-layer structure with second-order B-spline basis functions. Simulations and experimental evaluations show that, with little effort, a high-performance motion system can be obtained with this approach

Mechatronic development and dynamic control of a 3-DOF parallel manipulator

This is an Author's Accepted Manuscript of an article published in Mechanics Based Design of Structures and Machines: An International Journal, 40:4, 434-452 [September 2012] [copyright Taylor & Francis], available online at: http://www.tandfonline.com/10.1080/15397734.2012.687292The aim of this article is to develop, from the mechatronic point of view, a low-cost parallel manipulator (PM) with 3-degrees of freedom (DOF). The robot has to be able to generate and control one translational motion (heave) and two rotary motions (rolling and pitching). Applications for this kind of parallel manipulator can be found at least in driving-motion simulation and in the biomechanical field. An open control architecture has been developed for this manipulator, which allows implementing and testing different dynamic control schemes for a PM with 3-DOF. Thus, the robot developed can be used as a test bench where control schemes can be tested. In this article, several control schemes are proposed and the tracking control responses are compared. The schemes considered are based on passivity-based control and inverse dynamic control. The control algorithm considers point-to-point control or tracking control. When the controller considers the system dynamics, an identified model has been used. The control schemes have been tested on a virtual robot and on the actual prototype. © 2012 Taylor & Francis Group, LLC.The authors wish to express their gratitude to the Plan Nacional de I+D, Comision Interministerial de Ciencia y Tecnologia (FEDER-CICYT) for the partial financing of this study under the projects DPI2009-13830-C02-01 and DPI2010-20814-C02-(01, 02). This work was also supported in part by the CDCHT-ULA Grant I-1286-11-02-B.Vallés Miquel, M.; Díaz-Rodríguez, M.; Valera Fernández, Á.; Mata Amela, V.; Page Del Pozo, AF. (2012). Mechatronic development and dynamic control of a 3-DOF parallel manipulator. 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