Magneto-Rheological Actuators for Human-Safe Robots: Modeling, Control, and Implementation

In recent years, research on physical human-robot interaction has received considerable attention. Research on this subject has led to the study of new control and actuation mechanisms for robots in order to achieve intrinsic safety. Naturally, intrinsic safety is only achievable in kinematic structures that exhibit low output impedance. Existing solutions for reducing impedance are commonly obtained at the expense of reduced performance, or significant increase in mechanical complexity. Achieving high performance while guaranteeing safety seems to be a challenging goal that necessitates new actuation technologies in future generations of human-safe robots. In this study, a novel two degrees-of-freedom safe manipulator is presented. The manipulator uses magneto-rheological fluid-based actuators. Magneto-rheological actuators offer low inertia-to-torque and mass-to-torque ratios which support their applications in human-friendly actuation. As a key element in the design of the manipulator, bi-directional actuation is attained by antagonistically coupling MR actuators at the joints. Antagonistically coupled MR actuators at the joints allow using a single motor to drive multiple joints. The motor is located at the base of the manipulator in order to further reduce the overall weight of the robot. Due to the unique characteristic of MR actuators, intrinsically safe actuation is achieved without compromising high quality actuation. Despite these advantages, modeling and control of MR actuators present some challenges. The antagonistic configuration of MR actuators may result in limit cycles in some cases when the actuator operates in the position control loop. To study the possibility of limit cycles, describing function method is employed to obtain the conditions under which limit cycles may occur in the operation of the system. Moreover, a connection between the amplitude and the frequency of the potential limit cycles and the system parameters is established to provide an insight into the design of the actuator as well as the controller. MR actuators require magnetic fields to control their output torques. The application of magnetic field however introduces hysteresis in the behaviors of MR actuators. To this effect, an adaptive model is developed to estimate the hysteretic behavior of the actuator. The effectiveness of the model is evaluated by comparing its results with those obtained using the Preisach model. These results are then extended to an adaptive control scheme in order to compensate for the effect of hysteresis. In both modeling and control, stability of proposed schemes are evaluated using Lyapunov method, and the effectiveness of the proposed methods are validated with experimental results

Design of a Haptic Interface for Medical Applications using Magneto-Rheological Fluid based Actuators

This thesis reports on the design, construction, and evaluation of a prototype two degrees-of-freedom (DOF) haptic interface, which takes advantage of Magneto-Rheological Fluid (MRF) based clutches for actuation. Haptic information provides important cues in teleoperated systems and enables the user to feel the interaction with a remote or virtual environment during teleoperation. The two main objectives in designing a haptic interface are stability and transparency. Indeed, deficiencies in these factors in haptics-enabled telerobotic systems has the introduction of haptics in medical environments where safety and reliability are prime considerations. An actuator with poor dynamics, high inertia, large size, and heavy weight can significantly undermine the stability and transparency of a teleoperated system. In this work, the potential benefits of MRF-based actuators to the field of haptics in medical applications are studied. Devices developed with such fluids are known to possess superior mechanical characteristics over conventional servo systems. These characteristics significantly contribute to improved stability and transparency of haptic devices. This idea is evaluated and verified through both theoretical and experimental points of view. The design of a small-scale MRF-based clutch, suitable for a multi-DOF haptic interface, is discussed and its performance is compared with conventional servo systems. This design is developed into four prototype clutches. In addition, a closed-loop torque control strategy is presented. The feedback signal used in this control scheme comes from the magnetic field acquired from embedded Hall sensors in the clutch. The controller uses this feedback signal to compensate for the nonlinear behavior using an estimated model, based on Artificial Neural Networks. Such a control strategy eliminates the need for torque sensors for providing feedback signals. The performance of the developed design and the effectiveness of the proposed modeling and control techniques are experimentally validated. Next, a 2-DOF haptic interface based on a distributed antagonistic configuration of MRF-based clutches is constructed for a class of medical applications. This device is incorporated in a master-slave teleoperation setup that is used for applications involving needle insertion and soft-tissue palpation. Phantom and in vitro animal tissue were used to assess the performance of the haptic interface. The results show a great potential of MRF-based actuators for integration in haptic devices for medical interventions that require reliable, safe, accurate, highly transparent, and stable force reflection

Comparative study of actuation systems for portable upper limb exoskeletons.

During the last two decades, a large variety of upper limb exoskeletons have been developed. Out of these, majority are platform based systems which might be the reason for not being widely adopted for post-stroke rehabilitation. Despite the potential benefits of platform-based exoskeletons as being rugged and reliable, stroke patients prefer to have a portable and user-friendly device that they can take home. However, the types of actuator as well as the actuation mechanism used in the exoskeleton are the inhibiting factors why portable exoskeletons are mostly non-existent for patient use. This paper presents a quantitative analysis of the actuation systems available for developing portable upper arm exoskeletons with their specifications. Finally, it has been concluded from this research that there are not many stand-alone arm exoskeletons which can provide all forms of rehabilitation, therefore, a generic solution has been proposed as the rehabilitation strategy to get best out of the portable arm exoskeletons

A Novel Fiber Jamming Theory and Experimental Verification

This thesis developed a novel theory of fiber jamming and experimentally verified it. The theory relates the performance, which is the ratio between the stiff and soft states of a fiber jamming chamber, to three relative design parameters: the ratio of the wall thickness to the membrane inner diameter, the ratio of the fiber diameter to membrane inner diameter, and the number of fibers. These three parameters, when held constant across different chamber sizes, hold the performance constant. To test the theory, three different types of fiber jamming chambers were built in three different sizes. Each chamber was set up as a cantilever beam and deflected 10mm in both the un-jammed (soft) and jammed (stiff) states. When the three design parameters were held constant, the performance of the chamber was consistent within 10\%. In contrast, when the parameters were altered, there was a statistically significant $p \u3c .0001$ and noticeable effect on chamber performance. These two results can be used in tandem to design miniaturized fiber jamming chambers. These results also have a direct application in soft robots designed for minimally invasive surgery

DEVELOPMENT OF A KINETIC MODEL FOR STEERABLE CATHETERS FOR MINIMALLY INVASIVE SURGERY

The steerable catheters have demonstrated many advantages to overcome the limitations of the conventional catheters in the minimally invasive surgery. The motion and force transmission from the proximal end to distal tip of the catheter have significant effects to the efficiency and safety of surgery. While the force information between the catheter and the body (e.g., vessel) can be obtained by mounting sensors on the distal tip of the catheter, this would be more intrusive and less reliable than the one without the sensors, which is described in this disseration. In addition, the small diameters of the catheters may also restrict the idea of mounting sensors on the distal tip. The other approach to obtain the force information is to infer it from the information outside the body. This will demand an accurate mathematical model that describes the force and motion relation called kinetic model, and unfortunately, such a kinetic model is not available in the literature. In this dissertation, a kinetic model for steerable catheters is presented wich captures the following characteristics of the steerable catheter, namely (1) the geometrical non-linear behavior of the catheter in motion, (2) the deformable pathway, (3) the friction between the catheter and the pathyway, and (4) the contact between the catheter and pathway. A non-linear finite element system (SPACAR) was employed to capture these characteristics. A test-bed was built and an experiment was carried out to verify the developed kinetic model. The following conclusions can be drawn from this dissertation: (1) the developed kinetic model is accurte in comparison with those in literature; (2) the Dahl friction model, the LuGre friction model and the simplified LuGre friction model are able to capture the friction behavior between the catheter and the pathway but the Coulomb friction model fails (as it cannot capture the hysteresis property which has a significant influence on the behavior of the catheter); (3) the developed kinetic model has the potential of being used to optimize the design and operation of steerable catheters with several salient findings that (3a) the maximal contact force between the catheter and the pathway occurs on the tip of the distal part or the connecting part between the distal part and catheter body of the catheter and (3b) the rigidity and length of the distal part are crucial structural parameters that affect the motion and force transmission significantly. There are several contributions made by this dissertation. In the field of the steerable catheter, biomechanics and bio-instrumentation, the contributions are summarized in the following: (1) the approach to develop the kinetic model of the steerable catheter in a complex work environment is useful to model other similar compliant medical devices, such as endoscope; (2) the kinetic model of the steerable catheter can provide the force information to improve the efficiency and safety of MIS (minimally invastive surgery) and to realize the “doctor-assisted” catheter-based MIS procedure; (3) the kinetic model can provide accurate data for developing other simplified models for the steerable catheters in their corresponding work environments for realizing the robotic-based fully automated MIS procedure. (4) The kinetic model of the steerable catheter and the test-bed with the corresponding instruments and methods for the kinetic and kinematic measurements are a useful design validation in the steerable catheter technology as well as for the training of physicians to perform the catheter-based interventional procedure by adding more complex anatomic phantoms. In the field of continuum manipulator and continuum robots, the approach to develop the kinetic model is useful to model other manipulators and robots, such as snake-like robots

Elbow exoskeleton mechanism for multistage poststroke rehabilitation.

More than three million people are suffering from stroke in England. The process of post-stroke rehabilitation consists of a series of biomechanical exercises- controlled joint movement in acute phase; external assistance in the mid phase; and variable levels of resistance in the last phase. Post-stroke rehabilitation performed by physiotherapist has many limitations including cost, time, repeatability and intensity of exercises. Although a large variety of arm exoskeletons have been developed in the last two decades to substitute the conventional exercises provided by physiotherapist, most of these systems have limitations with structural configuration, sensory data acquisition and control architecture. It is still difficult to facilitate multistage post-stroke rehabilitation to patients sited around hospital bed without expert intervention. To support this, a framework for elbow exoskeleton has been developed that is portable and has the potential to offer all three types of exercises (external force, assistive and resistive) in a single structure. The design enhances torque to weight ratio compared to joint based actuation systems. The structural lengths of the exoskeleton are determined based on the mean anthropometric parameters of healthy users and the lengths of upperarm and forearm are determined to fit a wide range of users. The operation of the exoskeleton is divided into three regions where each type of exercise can be served in a specific way depending on the requirements of users. Electric motor provides power in the first region of operation whereas spring based assistive force is used in the second region and spring based resistive force is applied in the third region. This design concept provides an engineering solution of integrating three phases of post-stroke exercises in a single device. With this strategy, the energy source is only used in the first region to power the motor whereas the other two modes of exercise can work on the stored energy of springs. All these operations are controlled by a single motor and the maximum torque of the motor required is only 5 Nm. However, due to mechanical advantage, the exoskeleton can provide the joint torque up to 10 Nm. To remove the dependency on biosensor, the exoskeleton has been designed with a hardware-based mechanism that can provide assistive and resistive force. All exoskeleton components are integrated into a microcontroller-based circuit for measuring three joint parameters (angle, velocity and torque) and for controlling exercises. A user-friendly, multi-purpose graphical interface has been developed for participants to control the mode of exercise and it can be managed manually or in automatic mode. To validate the conceptual design, a prototype of the exoskeleton has been developed and it has been tested with healthy subjects. The generated assistive torque can be varied up to 0.037 Nm whereas resistive torque can be varied up to 0.057 Nm. The mass of the exoskeleton is approximately 1.8 kg. Two comparative studies have been performed to assess the measurement accuracy of the exoskeleton. In the first study, data collected from two healthy participants after using the exoskeleton and Kinect sensor by keeping Kinect sensor as reference. The mean measurement errors in joint angle are within 5.18 % for participant 1 and 1.66% for participant 2; the errors in torque measurement are within 8.48% and 7.93% respectively. In the next study, the repeatability of joint measurement by exoskeleton is analysed. The exoskeleton has been used by three healthy users in two rotation cycles. It shows a strong correction (correlation coefficient: 0.99) between two consecutive joint angle measurements and standard deviation is calculated to determine the error margin which comes under acceptable range (maximum: 8.897). The research embodied in this thesis presents a design framework of a portable exoskeleton model for providing three modes of exercises, which could provide a potential solution for all stages of post- stroke rehabilitation

Dynamic modeling and bioinspired control of a walking piezoelectric motor

Szufnarowski F. Dynamic modeling and bioinspired control of a walking piezoelectric motor. Bielefeld: Universität Bielefeld; 2013.Piezoelectric motors have increasingly extended their field of applications during recent years. Improved material properties and manufacturing techniques have led to a variety of designs which can achieve theoretically unlimited displacements for moderate voltage levels while retaining a relatively high stiffness. In practical terms, this leads to stronger and faster motors which become a viable alternative to electromagnetic drives, especially if compact size and small weight are important. The piezoelectric motor considered in this work consists of four piezoelectric bender elements which can forward a ceramic bar by means of a frictional interaction. The drive elements can be compared to "legs" walking on a movable plane. The walking motor offers outstanding force generation capabilities for a motor of its size. Despite this fact, this motor has not been used in a force control scenario before and no motor models exist in the literature which can reproduce the effect of load on its performance. In this work, two dynamic motor models are developed to address the latter issue. Both of them faithfully reproduce the non-linear motor velocity decrease under load. The first model is based on an analytic approach and describes the low-level frictional interactions between the legs and the ceramic bar by means of several physically meaningful assumptions. This analytic model explains several non-linear phenomena in the operation of the walking motor within the full bandwidth of its rated operation. Non-linear influences due to the impact dynamics of the legs, ferroelectric hysteresis and friction are identified in the motor and new insights for an improved motor design as well as an improved motor-drive strategy gained. Moreover, the analytic model finds its application in a theoretical investigation of an alternative motor-drive strategy which is based on findings in insect walking. Specifically, it is shown that the performance of the motor can be improved by a half in terms of its force generation and doubled in terms of its maximal velocity, as compared to classical drive approaches, if the bioinspired drive strategy as proposed in this work is used. The second model is based on an experimental approach and system identification. Although less general, the second model is well-suited for a practical application in a force-control scenario. In particular, the experimental model is used in this work for the development of a load compensation strategy based on force feedback which restores the linearity of motor operation for moderate levels of loading. Based on the linearized motor model, a force controller is developed whose performance is evaluated both theoretically and experimentally. The developed force controller is also used in a bioinspired control scenario. Specifically, two walking motors together with their force controllers are employed in a 1-DOF antagonistic joint as force generators. The motors are supposed to partially mimic the functionality of a muscle based on the non-linear force-length relation as derived by Hill. A simple positioning task shows the feasibility of this kind of non-standard application of a piezoelectric motor. Beside the development of motor models and bioinspired control approaches, this work addresses the issue of drive-signal generation for the walking motor. Specifically, the development of motor-drive electronics is presented which supersedes the commercially available products due to its compactness and the possibility of waveform generation at much higher drive frequencies, above 50 kHz, as compared to the nominal limit of 3 kHz and commercial products. In this context, the possibility of motor operation at ultrasonic frequencies is discussed which would benefit the motor in terms of its speed and the absence of audible noises

Robotic manipulators for in situ inspections of jet engines

Jet engines need to be inspected periodically and, in some instances, repaired. Currently, some of these maintenance operations require the engine to be removed from the wing and dismantled, which has a significant associated cost. The capability of performing some of these inspections and repairs while the engine is on-wing could lead to important cost savings. However, existing technology for on-wing operations is limited, and does not suffice to satisfy some of the needs. In this work, the problem of performing on-wing operations such as inspection and repair is analysed, and after an extensive literature review, a novel robotic system for the on-wing insertion and deployment of probes or other tools is proposed. The system consists of a fine-positioner, which is a miniature and dexterous robotic manipulator; a gross-positioner, which is a device to insert the fine-positioner to the engine region of interest; an end-effector, such as a probe; a deployment mechanism, which is a passive device to ensure correct contact between probe and component; and a feedback system that provides information about the robot state for control. The research and development work conducted to address the main challenges to create this robotic system is presented in this thesis. The work is focussed on the fine-positioner, as it is the most relevant and complex part of the system. After a literature review of relevant work, and as part of the exploration of potential robot concepts for the system, the kinematic capabilities of concentric tube robots (CTRs) are first investigated. The complete set of stable trajectories that can be traced in follow-the-leader motion is discovered. A case study involving simulations and an experiment is then presented to showcase and verify the work. The research findings indicate that CTRs are not suitable for the fine-positioner. However, they show that CTRs with non-annular cross section can be used for the gross-positioner. In addition, the new trajectories discovered show promise in minimally invasive surgery (MIS). Soft robotic manipulators with fluidic actuation are then selected as the most suitable concept for the fine-positioner. The design of soft robotic manipulators with fluidic actuation is investigated from a general perspective. A general framework for the design of these devices is proposed, and a set of design principles are derived. These principles are first applied in a MIS case study to illustrate and verify the work. Finite element (FE) simulations are then reported to perform design optimisation, and thus complete the case study. The design study is then applied to determine the most suitable design for the fine-positioner. An additional analytical derivation is developed, followed by FE simulations, which extend those of the case study. Eventually, this work yields a final design of the fine-positioner. The final design found is different from existing ones, and is shown to provide an important performance improvement with respect to existing soft robots in terms of wrenches it can support. The control of soft and continuum robots relevant to the fine-positioner is also studied. The full kinematics of continuum robots with constant curvature bending and extending capabilities are first investigated, which correspond to a preliminary design concept conceived for the fine-positioner. Closed-form solutions are derived, closing an open problem. These kinematics, however, do not exactly match the final fine-positioner design selected. Thus, an alternative control approach based on closed-loop control laws is then adopted. For this, a mechanical model is first developed. Closed-loop control laws are then derived based on this mechanical model for planar operation of a segment of the fine-positioner. The control laws obtained represent the foundation for the subsequent development of control laws for a full fine-positioner operating in 3D. Furthermore, work on path planning for nonholonomic systems is also reported, and a new algorithm is presented, which can be applied for the insertion of the overall robotic system. Solutions to the other parts of the robotic system for on-wing operations are also reported. A gross-positioner consisting of a non-annular CTR is proposed. Solutions for a deployment mechanism are also presented. Potential feedback systems are outlined. In addition, methods for the fabrication of the systems are reported, and the electronics and systems required for the assembly of the different parts are described. Finally, the use of the robotic system to perform on-wing inspections in a representative case study is studied to determine the viability. Inspection strategies are shortlisted, and simulations and experiments are used to study them. The results, however, indicate that inspection is not viable since the signal to noise ratio is excessively low. Nonetheless, the robotic system proposed, and the research conducted, are still expected to be useful to perform a range of on-wing operations that require the insertion and deployment of a probe or other end-effector. In addition, the trajectories discovered for CTRs, the design found for the fine-positioner, and the advances on control, also have significant potential in MIS, where there is an important need for miniature robotic manipulators and similar devices.Open Acces