EFFICIENCY OF FLEXIBLE FIXTURES: DESIGN AND CONTROL

The manufacturing industries have been using flexible production technologies to meet the demand for customisation. As a part of production, fixtures have remained limited to dedicated technologies, even though numerous flexible fixtures have been studied and proposed by both academia and industry. The integration of flexible fixtures has shown that such efforts did not yield the anticipated performance and resulted in inefficiencies of cost and time. The fundamental formulation of this thesis addresses this issue and aims to increase the efficiency of flexible fixtures.To realise this aim, the research in this thesis poses three research questions. The first research question investigates the efficiency description of flexible fixtures in terms of the criteria. Relative to this, the second research question investigates the use of efficiency metrics to integrate efficiency criteria into a design procedure. Once the efficiency and design aspects have been established, the third research question investigates the active control of flexible fixtures to increase their efficiency. The results of this thesis derive from the outcome of seven studies investigating the automotive and aerospace industries. The results that answer the first research question use five criteria to establish the efficiency of flexible fixtures. These are: fundamental, flexibility, cost, time and quality. By incorporating design characteristics in respect of production system paradigms, each criterion is elaborated upon using relevant sub-criteria and metrics. Moreover, a comparative design procedure is presented for the second research question and comprising four stages (including mechanical, control and software aspects). Initially, the design procedure proposes conceptual design and verification stages to determine the most promising flexible fixture for a target production system. By executing detailed design and verification, the design procedure enables a fixture designer to finalise the flexible fixture and determine its efficiency. Furthermore, a novel parallel kinematics machine is presented to demonstrate the applicability of the design procedure’s analytical steps and illustrate how appropriate kinematic structures can facilitate the efficiency-orientated design of flexible fixtures.Based on the correlation established by the controller software’s design procedure, the active control of flexible fixtures directly affects the quality criterion of flexible fixture efficiency. This provides the answer to the third research question, on general control strategies for active control of flexible fixtures. The introduction of a system model and manipulator dynamics proposes force and position control strategies. It is shown that any flexible fixture using a kinematic class can be controlled, to regulate the force and position of a workpiece and ensure that process nominals are preserved. Moreover, using both direct and indirect force control strategies, a flexible fixture’s role in active control can be expanded into a system of actively controlled fixtures that are useful in various processes. Finally, a position controller is presented which has the capacity to regulate both periodic and non-periodic signals. This controller uses an additional feedforward scheme (based on the Hilbert transform) in parallel with a feedback mechanism. Thus, the position controller enables flexible fixtures to regulate the position of a workpiece in respect of any kind of disturbance

Robot manipulator prototyping (Complete Design Review)

Journal ArticlePrototyping is an important activity in engineering. Prototype development is a good test for checking the viability of a proposed system. Prototypes can also help in determining system parameters, ranges, or in designing better systems. The interaction between several modules (e.g., S/W, VLSI, CAD, CAM, Robotics, and Control) illustrates an interdisciplinary prototyping environment that includes radically different types of information, combined in a coordinated way. Developing an environment that enables optimal and flexible design of robot manipulators using reconfigurable links, joints, actuators, and sensors is an essential step for efficient robot design and prototyping. Such an environment should have the right "mix" of software and hardware components for designing the physical parts and the controllers, and for the algorithmic control of the robot modules (kinematics, inverse kinematics, dynamics, trajectory planning, analog control and digital computer control). Specifying object-based communications and catalog mechanisms between the software modules, controllers, physical parts, CAD designs, and actuator and sensor components is a necessary step in the prototyping activities. We propose a flexible prototyping environment for robot manipulators with the required subsystems and interfaces between the different components of this environment

Kinematics and Robot Design I, KaRD2018

This volume collects the papers published on the Special Issue “Kinematics and Robot Design I, KaRD2018” (https://www.mdpi.com/journal/robotics/special_issues/KARD), which is the first issue of the KaRD Special Issue series, hosted by the open access journal “MDPI Robotics”. The KaRD series aims at creating an open environment where researchers can present their works and discuss all the topics focused on the many aspects that involve kinematics in the design of robotic/automatic systems. Kinematics is so intimately related to the design of robotic/automatic systems that the admitted topics of the KaRD series practically cover all the subjects normally present in well-established international conferences on “mechanisms and robotics”. KaRD2018 received 22 papers and, after the peer-review process, accepted only 14 papers. The accepted papers cover some theoretical and many design/applicative aspects

Parallel robots with unconventional joints to achieve under-actuation and reconfigurability

The aim of the thesis is to define, analyze, and verify through simulations and practical implementations, parallel robots with unconventional joints that allow them to be under-actuated and/or reconfigurable. The new designs will be derived from the: * 6SPS robot (alternatively 6UPS or 6SPU, depending on the implementation) when considering the spatial case (i.e., robots with 3 degrees of freedom of rotation and 3 degrees of freedom of translation). * S-3SPS robot (alternatively S-3UPS or S-3SPU, depending on the implementation) when considering spherical robots (i.e., robots with 3 degrees of freedom of rotation). In both cases, we will see how, through certain geometric transformations, some of the standard joints can be replaced by lockable or non-holonomic joints. These substitutions permit reducing the number of legs (and hence the number of actuators needed to control the robot), without losing the robot's ability to bring its mobile platform to any position and orientation (in case of a spatial robot), or to any orientation (in case of a spherical robot), within its workspace. The expected benefit of these new designs is to obtain parallel robots with: * larger working spaces because the possibility of collisions between legs is reduced, and the number of joints (with their intrinsic range limitations) is also reduced; * lower weight because the number of actuators and joints is reduced; and * lower cost because the number of actuators and controllers is also reduced. The elimination of an actuator and the introduction of a motion constraint reduces in one the dimension of the space of allowed velocities attainable from a given configuration. As a result, it will be necessary, in general, to plan maneuvers to reach the desired configuration for the moving platform. Therefore, the obtained robots will only be suitable for applications where accuracy is required in the final position and a certain margin of error is acceptable in the generated trajectories.El objetivo de esta tesis es definir, analizar y verificar, mediante simulaciones e implementaciones prácticas, robots paralelos con articulaciones no-convencionales con el fin de incorporarles propiedades de sub-actuación y reconfigurabilidad. Los nuevos diseños se basaran en robots paralelos tipo: * 6SPS (alternativamente 6UPS o 6SPU, dependiendo de la implementación) para el caso de robot espacial (es decir, robots con 3 grados de libertad de rotación y de 3 grados de libertad de la traducción). * S-3SPS (alternativamente S-3UPS o S-3SPU, dependiendo de la implementación) para el caso de robot esférico (es decir, robots con 3 grados de libertad de rotación). En ambos casos, veremos cómo, a través de ciertas transformaciones geométricas, algunas de la articulaciones convencionales pueden ser sustituidas por articulaciones bloqueables o no holonómicos. Estas sustituciones permiten la reducción de la número de patas (y por tanto el número de actuadores necesarios para controlar el robot), sin perder la capacidad del robot para llevar su plataforma móvil a cualquier posición y orientación (en el caso de un robot espacial), o para cualquier orientación (en el caso de un robot esférico), dentro de su espacio de trabajo. El beneficio esperado de estos nuevos diseños es la obtención de robots paralelos con: * Espacios de trabajo mayores debido a que la posibilidad de colisiones entre las patas se reduce, y el número de articulaciones (con sus limitaciones intrínsecas de rango) también se reduce; * Menor peso debido a que el número de actuadores y de articulaciones se reduce; y * Un menor coste debido a que el número de actuadores y controladores también se reduce. La eliminación de un actuador y la introducción de una restricción de movimiento reduce, en uno, la dimensión del espacio de velocidades alcanzables para una configuración dada. Como resultado, será necesario, en general, planificar maniobras para llegar a la configuración deseada de la plataforma móvil. Por lo tanto, los robots obtenidos sólo serán adecuados para aplicaciones donde la precisión se requiera en la posición final y exista un cierto margen de error aceptable en las trayectorias generadasPostprint (published version

Parallel robots with unconventional joints to achieve under-actuation and reconfigurability

The aim of the thesis is to define, analyze, and verify through simulations and practical implementations, parallel robots with unconventional joints that allow them to be under-actuated and/or reconfigurable. The new designs will be derived from the: * 6SPS robot (alternatively 6UPS or 6SPU, depending on the implementation) when considering the spatial case (i.e., robots with 3 degrees of freedom of rotation and 3 degrees of freedom of translation). * S-3SPS robot (alternatively S-3UPS or S-3SPU, depending on the implementation) when considering spherical robots (i.e., robots with 3 degrees of freedom of rotation). In both cases, we will see how, through certain geometric transformations, some of the standard joints can be replaced by lockable or non-holonomic joints. These substitutions permit reducing the number of legs (and hence the number of actuators needed to control the robot), without losing the robot's ability to bring its mobile platform to any position and orientation (in case of a spatial robot), or to any orientation (in case of a spherical robot), within its workspace. The expected benefit of these new designs is to obtain parallel robots with: * larger working spaces because the possibility of collisions between legs is reduced, and the number of joints (with their intrinsic range limitations) is also reduced; * lower weight because the number of actuators and joints is reduced; and * lower cost because the number of actuators and controllers is also reduced. The elimination of an actuator and the introduction of a motion constraint reduces in one the dimension of the space of allowed velocities attainable from a given configuration. As a result, it will be necessary, in general, to plan maneuvers to reach the desired configuration for the moving platform. Therefore, the obtained robots will only be suitable for applications where accuracy is required in the final position and a certain margin of error is acceptable in the generated trajectories.El objetivo de esta tesis es definir, analizar y verificar, mediante simulaciones e implementaciones prácticas, robots paralelos con articulaciones no-convencionales con el fin de incorporarles propiedades de sub-actuación y reconfigurabilidad. Los nuevos diseños se basaran en robots paralelos tipo: * 6SPS (alternativamente 6UPS o 6SPU, dependiendo de la implementación) para el caso de robot espacial (es decir, robots con 3 grados de libertad de rotación y de 3 grados de libertad de la traducción). * S-3SPS (alternativamente S-3UPS o S-3SPU, dependiendo de la implementación) para el caso de robot esférico (es decir, robots con 3 grados de libertad de rotación). En ambos casos, veremos cómo, a través de ciertas transformaciones geométricas, algunas de la articulaciones convencionales pueden ser sustituidas por articulaciones bloqueables o no holonómicos. Estas sustituciones permiten la reducción de la número de patas (y por tanto el número de actuadores necesarios para controlar el robot), sin perder la capacidad del robot para llevar su plataforma móvil a cualquier posición y orientación (en el caso de un robot espacial), o para cualquier orientación (en el caso de un robot esférico), dentro de su espacio de trabajo. El beneficio esperado de estos nuevos diseños es la obtención de robots paralelos con: * Espacios de trabajo mayores debido a que la posibilidad de colisiones entre las patas se reduce, y el número de articulaciones (con sus limitaciones intrínsecas de rango) también se reduce; * Menor peso debido a que el número de actuadores y de articulaciones se reduce; y * Un menor coste debido a que el número de actuadores y controladores también se reduce. La eliminación de un actuador y la introducción de una restricción de movimiento reduce, en uno, la dimensión del espacio de velocidades alcanzables para una configuración dada. Como resultado, será necesario, en general, planificar maniobras para llegar a la configuración deseada de la plataforma móvil. Por lo tanto, los robots obtenidos sólo serán adecuados para aplicaciones donde la precisión se requiera en la posición final y exista un cierto margen de error aceptable en las trayectorias generada

Industrial Robotics

This book covers a wide range of topics relating to advanced industrial robotics, sensors and automation technologies. Although being highly technical and complex in nature, the papers presented in this book represent some of the latest cutting edge technologies and advancements in industrial robotics technology. This book covers topics such as networking, properties of manipulators, forward and inverse robot arm kinematics, motion path-planning, machine vision and many other practical topics too numerous to list here. The authors and editor of this book wish to inspire people, especially young ones, to get involved with robotic and mechatronic engineering technology and to develop new and exciting practical applications, perhaps using the ideas and concepts presented herein

Locomotion Control of Hexapod Walking Robot with Four Degrees of Freedom per Leg

V této práci představujeme nového šestinohého robota jménem HAntR, kterého jsme vytvořili dle potřeb Laboratoře výpočetní robotiky Centra umělé inteligence fakulty Elektrotechnické Českého vysokého učení technického v Praze. Jeho hlavním účelem jest vylepšit schopnosti pohybu v těžkém terénu původního robotu přidáním čtvrtého stupně volnosti každé noze. Na základě nově navržené nohy jsme také přepracovali celé tělo robotu tak, aby splnilo i další požadavky, jako například menší rozměry, či možnost osazení alespoň šesti Lithium-Iontovými monočlánky. V práci pečlivě popisujeme motivace a úvahy, které nás k výslednému návrhu vedly. Uvádíme řešení přímé i inverzní kinematické úlohy řešené pomocí podmínky na ideální orientaci konce nohy a uvažující i důležité kinematické singularity. Navržený robot byl vyzkoušen v několika experimentech, při kterých byl použit námi navržený řídicí systém napsaný v jazyce C++. Ukázalo se, že HAntR vydrží díky zvýšené energetické hustotě a lepšímu rozkladu sil v končetinách autonomně fungovat přes hodinu. Robot je také schopen jít rychlostí až 0.42m/s, což předčí mnohé srovnatelné roboty. Při experimentu, kdy robot stál na nakloněné rovině, bylo prokázáno zlepšení oproti předchozímu robotu. A také jsme dle pokynů této práce potvrdili, že i HAntR je schopen adaptivní chůze spoléhající pouze na poziční zpětnou vazbu.In this thesis a novel six-legged robot called HAntR is presented. The robot was developed according to needs of the Robotics Laboratory, at the Artificial Intelligent Center, Faculty of Electrical Engineering, Czech Technical University in Prague. Its main purpose is enhancing rough-terrain movement capabilities by upgrading a former design by adding fourth degree of freedom to each leg. We also revised robot torso to fit new leg design and incorporate other requirements such as smaller dimensions with space for at least six Lithium-Ion cells. We thoroughly describe motivations and considerations that led us to the presented particular solution. Further, the solutions of forward and inverse kinematic tasks with partial orientation constraint and important singularities avoidance are presented. The proposed design has been evaluated in several experimental deployments, which utilised developed software controller written in C++. Endurance tests showed, that HAntR is able to remotely operate for over an hour thanks to increased energy density. Maximal speed test resulted to 0.42m/s during tripod gait, which outpaces most of the comparable robotic platforms. Experiment where HAntR stood on platform with varying inclination showed qualitative improvement against former robot. Finally, in accord with the thesis assignment, we proved that HAntR is able to perform walking with adaptive gait using positional feedback only

Addressing Tasks Through Robot Adaptation

Developing flexible, broadly capable systems is essential for robots to move out of factories and into our daily lives, functioning as responsive agents that can handle whatever the world throws at them. This dissertation focuses on two kinds of robot adaptation. Modular self-reconfigurable robots (MSRR) adapt to the requirements of their task and environments by transforming themselves. By rearranging the connective structure of their component robot modules, these systems can assume different morphologies: for example, a cluster of modules might configure themselves into a car to maneuver on flat ground, a snake to climb stairs, or an arm to pick and place objects. Conversely, environment augmentation is a strategy in which the robot transforms its environment to meet its own needs, adding physical structures that allow it to overcome obstacles. In both areas, the presented work includes elements of hardware design, algorithms, and integrated systems, with the common goal of establishing these methods of adaptation as viable strategies to address tasks. The research takes a systems-level view of robotics, placing particular emphasis on experimental validation in hardware

Part clamping and fixture geometric adaptability for reconfigurable assembly systems.

Masters of Science in Mechanical Engineering. University of KwaZulu-Natal. Durban, 2017.The Fourth Industrial Revolution is leading towards cyber-physical systems which justified research efforts in pursuing efficient production systems incorporating flexible grippers. Due to the complexity of assembly processes, reconfigurable assembly systems have received considerable attention in recent years. The demand for the intricate task and complicated operations, demands the need for efficient robotic manipulators that are required to manoeuvre and grasp objects effectively. Investigations were performed to understand the requirements of efficient gripping systems and existing gripping methods. A biologically inspired robotic gripper was investigated to establish conformity properties for the performance of a robotic gripper system. The Fin Ray Effect® was selected as a possible approach to improve effective gripping and reduce slippage of component handling with regards to pick and place procedures of assembly processes. As a result, the study established the optimization of self-adjusting end-effectors. The gripper system design was simulated and empirically tested. The impact of gripping surface compliance and geometric conformity was investigated. The gripper system design focused on the response of load applied to the conformity mechanism called the Fin Ray Effect®. The appendages were simulated to determine the deflection properties and stress distribution through a finite element analysis. The simulation proved that the configuration of rib structures of the appendages affected the conformity to an applied force representing an object in contact. The system was tested in real time operation and required a control system to produce an active performance of the system. A mass loading test was performed on the gripper system. The repeatability and mass handling range was determined. A dynamic operation was tested on the gripper to determine force versus time properties throughout the grasping movement for a pick and place procedure. The fluctuating forces generated through experimentation was related to the Lagrangian model describing forces experienced by a moving object. The research promoted scientific contribution to the investigation, analysis, and design of intelligent gripping systems that can potentially be implemented in the operational processes of on-demand production lines for reconfigurable assembly systems