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

A Controllable Flexible Micropump and a Semi-Active Vibration Absorber Using Magnetorheological Elastomers

This study is focused on magneto-fluid-solid interaction analysis of a soft magnetorheological elastomer (MRE) controllable flexible micropump. In addition, material characterizations of MRE, modeling, fabrication and testing of a MRE-based vibration absorber system are investigated.Theoretical modeling and analysis of a controllable flexible magnetically-actuated fluid transport system (CFMFTS) is presented. For the first time, soft magnetorheological elastomer (MRE) is proposed as an actuation element in a fluid transport system (micropump). The flexible micropump can propel fluid under a fluctuating magnetic field. Magnetic-fluid-solid interaction analysis is performed to determine deflection in the solid domain and velocity of the fluid under a magnetic field. The effects of key material and geometric system parameters are examined on the micropump performance. Two- and three-dimensional analyses are performed to model the asymmetric deflection of the channel under a magnetic field. It is successfully demonstrated that the proposed system can propel the fluid in one direction.In addition, a novel semi-active variable stiffness and damping absorber (VSDA) is modeled, built and tested. Magnetically induced mechanical properties of MRE and their controllability are investigated by quasi-static and dynamic experiments. The VSDA is modeled, using springs, dashpots and the Bouc-Wen hysteresis element, fabricated and implemented in a scaled building to assess performance. Experiments are performed on a single VSDA, integrated system of four VSDAs, and a scaled building supported by four VSDAs. To demonstrate feasibility, a scaled, two-story building is constructed and installed on a shake table supported by four prototype VSDAs. The properties of VSDAs are regulated in real time by varying the applied magnetic field through the controller. A scaled earthquake excitation is applied to the system, and the vibration mode is controlled by a Lyapunov-based control strategy. The control system is used to control displacement and acceleration of the floors. Results demonstrate that the proposed VSDA significantly reduces acceleration and relative displacement of the structure

Smart materials and vehicle efficiency. Design and experimentation of new devices.

In this dissertation the activities carried out during the PhD are comprehensively described. The research mainly focused on the development of novel smart devices aimed at disengaging auxiliaries in internal combustion engine vehicles. In particular, the activities dealt with modeling, design, manufacturing and testing different fail-safe magnetorheological clutch prototypes, in the framework of a project funded by Regione Toscana, which involved two departments of the University of Pisa and Pierburg Pump Technology - Stabilimento di Livorno. After an extended literature review, several concepts of the clutch were proposed, which led to the design of the first magnetorheological prototype. An intensive experimental campaign was conducted, which involved several prototypes. A particular attention was focused on the measurement and analysis of the torque transmitted by the clutch in different operating conditions and new indices were proposed to objectively analyze the performances of magnetorheological clutches in general. On the basis of the results of the first experimental phase, the limits of the first design were analyzed and a novel prototype was developed, which succeeded in fulfilling all the design specifications. Further analyses were carried out in order to develop a clutch model starting from the experimental results. The effect of clutch heating was considered and a complete model of the clutch based on neural networks was proposed. The model was capable of taking into account the effect of the main parameters influencing the torque characteristic and may be used in a vehicle simulator or in a hardware-in-the-loop bench. Finally, an additional component to be connected to the clutch, which made use of shape memory alloys, was developed and tested during the visiting period at the University of Toledo (OH), USA

磁性流体を用いたバックドライブ可能な油圧アクチュエータの開発

早大学位記番号:新7478早稲田大

An innovative multi-gap clutch based on magneto-rheological fluids and electrodynamic effects: magnetic design and experimental characterization

In this paper an innovative multi-gap magnetorheological clutch is described. It is inspired by a device previously developed by the author’s research group and contains a novel solution based on electrodynamic effects, capable to considerably improve the transmissible torque during the engagement phase. Since this (transient) phase is characterized by a non-zero angular speed between the two clutch shafts, the rotation of a permanent magnets system, used to excite the fluid, induces eddy currents on some conductive material strategically positioned in the device. As a consequence, an electromagnetic torque is produced which is added to the torque transmitted by the magnetorheological fluid only. Once the clutch is completely engaged and the relative speed between the two shafts is zero, the electrodynamic effects vanish and the device operates like a conventional magnetorheological clutch. The system is investigated and designed by means a 3D FEM model and the performance of the device is experimentally validated on a prototype

Design and Development of Magneto-Rheological Actuators with Application in Mobile Robotics

In recent years, Magneto-Rheological (MR) fluids devices are widely studied and used for various purposes. Among these MR fluids devices, the MR actuator has attracted increasing attention for last two decades. An MR actuator is usually made of an active component (motor) and MR clutches. Compared with the regular actuators, the MR actuator features compliance due to the existence of MR fluids, which is commonly consider as benefits at the aspect of safety. On the other hand, the MR actuator has advantages on controllable bandwidth, torque-mass and torque-inertia ratios compared with the other compliant actuators. In this study, a new closed-loop, Field-Programable-Gate-Array (FPGA) based control scheme to linearize an MR clutch\u27s input-output relationship is presented. The feedback signal used in this control scheme is the magnetic field acquired from hall sensors within the MR clutch. The FPGA board uses this feedback signal to compensate for the nonlinear behavior of the MR clutch using an estimated model of the clutch magnetic field. The local use of an FPGA board will dramatically simplify the use of MR clutches for torque actuation. The effectiveness of the proposed technique is validated using an experimental platform that includes an MR clutch as part of a compliant actuation mechanism. The results clearly demonstrate that the use of the FPGA based closed-loop control scheme can effectively eliminate hysteretic behaviors of the MR clutch, allowing to have linear actuators with predictable behaviors. Moreover, a novel optimization design of MR clutches is proposed. Based on the optimization, the characteristics of MR clutches in three common configurations are discussed and compared. People can select suitable configuration of MR clutch before design. Lastly, a lightweight mobile robot is developed by using MR actuators. This mobile robot also has large driving force and can stop at any positions without running the motor

MR Fluid Damper and Its Application to Force Sensorless Damping Control System

Vibration suppression is considered as a keyresearch field in civil engineering to ensure the safety and comfort of their occupants and users of mechanical structures. To reduce the system vibration, an effective vibration control with isolation is necessary. Vibration control techniques have classically been categorized into two areas, passive and active controls. For a long time, efforts were made to make the suspension system work optimally by optimizing its parameters, but due to the intrinsic limitations of a passive suspension system, improvements were effective only in a certain frequency range. Compared with passive suspensions, active suspensions can improve the performance of the suspension system over a wide range of frequencies. Semi-active suspensions were proposed in the early 1970s [1], and can be nearly as effective as active suspensions. When the control system fails, the semi-active suspension can still work under passive conditions. Compared with active and passive suspension systems, the semi-active suspension system combines the advantages of both active and passive suspensions because it provides better performance when compared with passive suspensions and is economical, safe and does not require either higher-power actuators or a large power supply as active suspensions do [2]

Hybrid Magneto-Rheological Actuators for Human Friendly Robotic Manipulators

In recent years, many developments in the field of the physical human robot interaction (pHRI) have been witnessed and significant attentions have been given to the subject of safety within the interactive environments. Ensuring the safety has led to the design of the robots that are physically unable to hurt humans. However, Such systems commonly suffer from the safety-performance trade-off. Magneto-Rheological (MR) fluids are a special class of fluids that exhibit variable yield stress with respect to an applied magnetic field. Devices developed with such fluids are known to provide the prerequisite requirements of intrinsic safe actuation while maintaining the dynamical performance of the actuator. In this study, a new concept for generating magnetic field in Magneto-Rheological (MR) clutches is presented. The main rationale behind this concept is to divide the magnetic field generation into two parts using an electromagnetic coil and a permanent magnet. The main rationale behind this concept is to utilize a hybrid combination of electromagnetic coil and a permanent magnet. The combination of permanent magnets and electromagnetic coils in Hybrid Magneto-Rheological (HMR) clutches allows to distribute the magnetic field inside an MR clutch more uniformly. Moreover, The use of a permanent magnet dramatically reduces the mass of MR clutches for a given value of the nominal torque that results in developing higher torque-to-mass ratio. High torque-to-mass and torque-to-inertia ratios in HMR clutches promotes the use of these devices in human-friendly actuation

Mechanical characterization, constitutive modeling and applications of ultra-soft magnetorheological elastomers

Mención Internacional en el título de doctorSmart materials are bringing sweeping changes in the way humans interact with engineering devices. A myriad of state-of-the-art applications are based on novel ways to actuate on structures that respond under different types of stimuli. Among them, materials that respond to magnetic fields allow to remotely modify their mechanical properties and macroscopic shape. Ultra-soft magnetorheological elastomers (MREs) are composed of a highly stretchable soft elastomeric matrix in the order of 1 kPa and magnetic particles embedded in it. This combination allows large deformations with small external actuations. The type of the magnetic particles plays a crucial role as it defines the reversibility or remanence of the material magnetization. According to the fillers used, MREs are referred to as soft-magnetic magnetorheological elastomers (sMREs) and hard-magnetic magnetorheological elastomers (hMREs). sMREs exhibit strong changes in their mechanical properties when an external magnetic field is applied, whereas hMREs allow sustained magnetic effects along time and complex shape-morphing capabilities. In this regard, end-of-pipe applications of MREs in the literature are based on two major characteristics: the modification of their mechanical properties and macrostructural shape changes. For instance, smart actuators, sensors and soft robots for bioengineering applications are remotely actuated to perform functional deformations and autonomous locomotion. In addition, hMREs have been used for industrial applications, such as damping systems and electrical machines. From the analysis of the current state of the art, we identified some impediments to advance in certain research fields that may be overcome with new solutions based on ultrasoft MREs. On the mechanobiology area, we found no available experimental methodologies to transmit complex and dynamic heterogeneous strain patterns to biological systems in a reversible manner. To remedy this shortcoming, this doctoral research proposes a new mechanobiology experimental setup based on responsive ultra-soft MRE biological substrates. Such an endeavor requires deeper insights into the magneto-viscoelastic and microstructural mechanisms of ultra-soft MREs. In addition, there is still a lack of guidance for the selection of the magnetic fillers to be used for MREs and the final properties provided to the structure. Eventually, the great advances on both sMREs and hMREs to date pose a timely question on whether the combination of both types of particles in a hybrid MRE may optimize the multifunctional response of these active structures. To overcome these roadblocks, this thesis provides an extensive and comprehensive experimental characterization of ultra-soft sMREs, hMREs and hybrid MREs. The experimental methodology uncovers magneto-mechanical rate dependences under numerous loading and manufacturing conditions. Then, a set of modeling frameworks allows to delve into such mechanisms and develop three ground-breaking applications. Therefore, the thesis has lead to three main contributions. First and motivated on mechanobiology research, a computational framework guides a sMRE substrate to transmit complex strain patterns in vitro to biological systems. Second, we demonstrate the ability of remanent magnetic fields in hMREs to arrest cracks propagations and improve fracture toughness. Finally, the combination of soft- and hard-magnetic particles is proved to enhance the magnetorheological and magnetostrictive effects, providing promising results for soft robotics.Los materiales inteligentes están generando cambios radicales en la forma que los humanos interactúan con dispositivos ingenieriles. Distintas aplicaciones punteras se basan en formas novedosas de actuar sobre materiales que responden a diferentes estímulos. Entre ellos, las estructuras que responden a campos magnéticos permiten la modificación de manera remota tanto de sus propiedades mecánicas como de su forma. Los elastómeros magnetorreológicos (MREs) ultra blandos están compuestos por una matriz elastomérica con gran ductilidad y una rigidez en torno a 1 kPa, reforzada con partículas magnéticas. Esta combinación permite inducir grandes deformaciones en el material mediante la aplicación de campos magnéticos pequeños. La naturaleza de las partículas magnéticas define la reversibilidad o remanencia de la magnetización del material compuesto. De esta manera, según el tipo de partículas que contengan, los MREs pueden presentar magnetización débil (sMRE) o magnetización fuerte (hMRE). Los sMREs experimentan grandes cambios en sus propiedades mecánicas al aplicar un campo magnético externo, mientras que los hMREs permiten efectos magneto-mecánicos sostenidos a lo largo del tiempo, así como programar cambios de forma complejos. En este sentido, las aplicaciones de los MREs se basan en dos características principales: la modificación de sus propiedades mecánicas y los cambios de forma macroestructurales. Por ejemplo, los campos magnéticos pueden emplearse para inducir deformaciones funcionales en actuadores y sensores inteligentes, o en robótica blanda para bioingeniería. Los hMREs también se han aplicado en el ámbito industrial en sistemas de amortiguación y máquinas eléctricas. A partir del análisis del estado del arte, se identifican algunas limitaciones que impiden el avance en ciertos campos de investigación y que podrían resolverse con nuevas soluciones basadas en MREs ultra blandos. En el área de la mecanobiología, no existen metodologías experimentales para transmitir patrones de deformación complejos y dinámicos a sistemas biológicos de manera reversible. En esta investigación doctoral se propone una configuración experimental novedosa basada en sustratos biológicos fabricados con MREs ultra blandos. Dicha solución requiere la identificación de los mecanismos magneto-viscoelásticos y microestructurales de estos materiales, según el tipo de partículas magnéticas, y las consiguientes propiedades macroscópicas del material. Además, investigaciones recientes en sMREs y hMREs plantean la pregunta sobre si la combinación de distintos tipos de partículas magnéticas en un MRE híbrido puede optimizar su respuesta multifuncional. Para superar estos obstáculos, la presente tesis proporciona una caracterización experimental completa de sMREs, hMREs y MREs híbridos ultra blandos. Estos resultados muestran las dependencias del comportamiento multifuncional del material con la velocidad de aplicación de cargas magneto-mecánicas. El desarrollo de un conjunto de modelos teórico-computacionales permite profundizar en dichos mecanismos y desarrollar aplicaciones innovadoras. De este modo, la tesis doctoral ha dado lugar a tres bloques de aportaciones principales. En primer lugar, este trabajo proporciona un marco computacional para guiar el diseño de sustratos basados en sMREs para transmitir patrones de deformación complejos in vitro a sistemas biológicos. En segundo lugar, se demuestra la capacidad de los campos magnéticos remanentes en los hMRE para detener la propagación de grietas y mejorar la tenacidad a la fractura. Finalmente, se establece que la combinación de partículas magnéticas de magnetización débil y fuerte mejora el efecto magnetorreológico y magnetoestrictivo, abriendo nuevas posibilidades para el diseño de robots blandos.I want to acknowledge the support from the Ministerio de Ciencia, Innovación y Universidades, Spain (FPU19/03874), and the European Research Council (ERC) under the European Union’s Horizon 2020 research and innovation programme (grant agreement No. 947723, project: 4D-BIOMAP).Programa de Doctorado en Ingeniería Mecánica y de Organización Industrial por la Universidad Carlos III de MadridPresidente: Ramón Eulalio Zaera Polo.- Secretario: Abdón Pena Francesch.- Vocal: Laura de Lorenzi