Linear Macro-Micro Positioning System Using a Shape Memory Alloy Actuator

The use of high-precision automated equipment is steadily increasing due in part to the progressively smaller sizes of electronic circuits. Currently, piezoelectric transducers (piezos) dominate as the actuation device for high precision machines, but shape memory alloys (SMA) may be a viable alternative to reduce monetary costs. This work explores the implementation of a low-cost linear macro-micro positioning system. The system consists of a modified printer carriage to provide long range, macro scale linear motion (approximately 200 mm range and 200 µm precision) and a micro scale system (approximately 4 mm range and 5 µm target precision) that uses an SMA actuator. A detailed description of the design and implementation of the system is given in this research. A model of the macro-stage is then generated by first identifying and inverting a simple friction model to linearize the system, thereby allowing for modified least squares (MLS) identification of a linear model. Various controllers are attempted for the macro-stage and compared with an experimentally tuned nonlinear PD controller that is implemented in the final design. A model of the micro-stage is derived through analysis of the SMA actuator. The model for the actuator is separated into two portions, an electro-thermal model, and a hysteresis model. The hysteresis model is derived using the Preisach model, and the electro-thermal model through MLS identification. To control the micro-stage, a PI controller with antiwindup is developed experimentally. The two stages are then executed together in closed loop and the resulting coupling between the two stages is briefly examined. Experimental data used for the modelling and design is presented, along with results of the final macro-micro linear positioning system

Design of a shape memory alloy actuator for soft wearable robots

Soft robotics represents a paradigm shift in the design of conventional robots; while the latter are designed as monolithic structures, made of rigid materials and normally composed of several stiff joints, the design of soft robots is based on the use of deformable materials such as polymers, fluids or gels, resulting in a biomimetic design that replicates the behavior of organic tissues. The introduction of this design philosophy into the field of wearable robots has transformed them from rigid and cumbersome devices into something we could call exo-suits or exo-musculatures: motorized, lightweight and comfortable clothing-like devices. If one thinks of the ideal soft wearable robot (exoskeleton) as a piece of clothing in which the actuation system is fully integrated into its fabrics, we consider that that existing technologies currently used in the design of these devices do not fully satisfy this premise. Ultimately, these actuation systems are based on conventional technologies such as DC motors or pneumatic actuators, which due to their volume and weight, prevent a seamless integration into the structure of the soft exoskeleton. The aim of this thesis is, therefore, to design of an actuator that represents an alternative to the technologies currently used in the field of soft wearable robotics, after having determined the need for an actuator for soft exoskeletons that is compact, flexible and lightweight, while also being able to produce the force required to move the limbs of a human user. Since conventional actuation technologies do not allow the design of an actuator with the required characteristics, the proposed actuator design has been based on so-called emerging actuation technologies, more specifically, on shape memory alloys (SMA). The mechanical design of the actuator is based on the Bowden transmission system. The SMA wire used as the transducer of the actuator has been routed into a flexible sheath, which, in addition to being easily adaptable to the user's body, increases the actuation bandwidth by reducing the cooling time of the SMA element by 30 %. At its nominal operating regime, the actuator provides an output displacement of 24 mm and generates a force of 64 N. Along with the actuator, a thermomechanical model of its SMA transducer has been developed to simulate its complex behavior. The developed model is a useful tool in the design process of future SMA-based applications, accelerating development ix time and reducing costs. The model shows very few discrepancies with respect to the behavior of a real wire. In addition, the model simulates characteristic phenomena of these alloys such as thermal hysteresis, including internal hysteresis loops and returnpoint memory, the dependence between transformation temperatures and applied force, or the effects of latent heat of transformation on the wire heating and cooling processes. To control the actuator, the use of a non-linear control technique called four-term bilinear proportional-integral-derivative controller (BPID) is proposed. The BPID controller compensates the non-linear behavior of the actuator caused by the thermal hysteresis of the SMA. Compared to the operation of two other implemented controllers, the BPID controller offers a very stable and robust performance, minimizing steady-state errors and without the appearance of limit cycles or other effects associated with the control of these alloys. To demonstrate that the proposed actuator together with the BPID controller are a valid solution for implementing the actuation system of a soft exoskeleton, both developments have been integrated into a real soft hand exoskeleton, designed to provide force assistance to astronauts. In this case, in addition to using the BPID controller to control the position of the actuators, it has been applied to the control of the assistive force provided by the exoskeleton. Through a simple mechanical multiplication mechanism, the actuator generates a linear displacement of 54 mm and a force of 31 N, thus fulfilling the design requirements imposed by the application of the exoskeleton. Regarding the control of the device, the BPID controller is a valid control technique to control both the position and the force of a soft exoskeleton using an actuation system based on the actuator proposed in this thesis.La robótica flexible (soft robotics) ha supuesto un cambio de paradigma en el diseño de robots convencionales; mientras que estos consisten en estructuras monolíticas, hechas de materiales duros y normalmente compuestas de varias articulaciones rígidas, el diseño de los robots flexibles se basa en el uso de materiales deformables como polímeros, fluidos o geles, resultando en un diseño biomimético que replica el comportamiento de los tejidos orgánicos. La introducción de esta filosofía de diseño en el campo de los robots vestibles (wearable robots) ha hecho que estos pasen de ser dispositivos rígidos y pesados a ser algo que podríamos llamar exo-trajes o exo-musculaturas: prendas de vestir motorizadas, ligeras y cómodas. Si se piensa en el robot vestible (exoesqueleto) flexible ideal como una prenda de vestir en la que el sistema de actuación está totalmente integrado en sus tejidos, consideramos que las tecnologías existentes que se utilizan actualmente en el diseño de estos dispositivos no satisfacen plenamente esta premisa. En última instancia, estos sistemas de actuaci on se basan en tecnologías convencionales como los motores de corriente continua o los actuadores neumáticos, que debido a su volumen y peso, hacen imposible una integraci on completa en la estructura del exoesqueleto flexible. El objetivo de esta tesis es, por tanto, el diseño de un actuador que suponga una alternativa a las tecnologias actualmente utilizadas en el campo de los exoesqueletos flexibles, tras haber determinado la necesidad de un actuador para estos dispositivos que sea compacto, flexible y ligero, y que al mismo tiempo sea capaz de producir la fuerza necesaria para mover las extremidades de un usuario humano. Dado que las tecnologías de actuación convencionales no permiten diseñar un actuador de las características necesarias, se ha optado por basar el diseño del actuador propuesto en las llamadas tecnologías de actuación emergentes, en concreto, en las aleaciones con memoria de forma (SMA). El diseño mecánico del actuador está basado en el sistema de transmisión Bowden. El hilo de SMA usado como transductor del actuador se ha introducido en una funda flexible que, además de adaptarse facilmente al cuerpo del usuario, aumenta el ancho de banda de actuación al reducir un 30 % el tiempo de enfriamiento del elemento SMA. En su régimen nominal de operaci on, el actuador proporciona un desplazamiento de salida de 24 mm y genera una fuerza de 64 N. Además del actuador, se ha desarrollado un modelo termomecánico de su transductor SMA que permite simular su complejo comportamiento. El modelo desarrollado es una herramienta útil en el proceso de diseño de futuras aplicaciones basadas en SMA, acelerando el tiempo de desarrollo y reduciendo costes. El modelo muestra muy pocas discrepancias con respecto al comportamiento de un hilo real. Además, es capaz de simular fenómenos característicos de estas aleaciones como la histéresis térmica, incluyendo los bucles internos de histéresis y la memoria de puntos de retorno (return-point memory), la dependencia entre las temperaturas de transformacion y la fuerza aplicada, o los efectos del calor latente de transformación en el calentamiento y el enfriamiento del hilo. Para controlar el actuador, se propone el uso de una t ecnica de control no lineal llamada controlador proporcional-integral-derivativo bilineal de cuatro términos (BPID). El controlador BPID compensa el comportamiento no lineal del actuador causado por la histéresis térmica del SMA. Comparado con el funcionamiento de otros dos controladores implementados, el controlador BPID ofrece un rendimiento muy estable y robusto, minimizando el error de estado estacionario y sin la aparición de ciclos límite u otros efectos asociados al control de estas aleaciones. Para demostrar que el actuador propuesto junto con el controlador BPID son una soluci on válida para implementar el sistema de actuación de un exoesqueleto flexible, se han integrado ambos desarrollos en un exoesqueleto flexible de mano real, diseñado para proporcionar asistencia de fuerza a astronautas. En este caso, además de utilizar el controlador BPID para controlar la posición de los actuadores, se ha aplicado al control de la fuerza proporcionada por el exoesqueleto. Mediante un simple mecanismo de multiplicación mecánica, el actuador genera un desplazamiento lineal de 54 mm y una fuerza de 31 N, cumpliendo así con los requisitos de diseño impuestos por la aplicación del exoesqueleto. Respecto al control del dispositivo, el controlador BPID es una técnica de control válida para controlar tanto la posición como la fuerza de un exoesqueleto flexible que use un sistema de actuación basado en el actuador propuesto en esta tesis.Programa de Doctorado en Ingeniería Eléctrica, Electrónica y Automática por la Universidad Carlos III de MadridPresidente: Fabio Bonsignorio.- Secretario: Concepción Alicia Monje Micharet.- Vocal: Elena García Armad

Application of Laguerre based adaptive predictive control to Shape Memory Alloy (SMA) actuators

This paper discusses the use of an existing adaptive predictive controller to control some Shape Memory Alloy (SMA) linear actuators. The model consists in a truncated linear combination of Laguerre filters identified online. The controller stability is studied in details. It is proven that the tracking error is asymptotically stable under some conditions on the modelling error. Moreover, the tracking error converge toward zero for step references, even if the identified model is inaccurate. Experimentalcresults obtained on two different kind of actuator validate the proposed control. They also show that it is robust with regard to input constraints.ANR MAFESM

A PHENOMENOLOGICAL MODEL OF SHAPE MEMORY ALLOYS INCLUDING TIME-VARYING STRESS

Shape memory alloys (SMAs) are metallic materials, which have two main stable crystalline phases: austenite, a high temperature phase and martensite, a low temperature phase. Austenite and martensite each have unique physical and mechanical properties, and transformation between these phases enables two effects known as the shape memory effect (SME) and superelasticity. When a material that displays the SME is plastically deformed at low temperature, a heat input will cause the SMA to return to its original shape before the deformation. At higher temperatures, the material displays an effect called superelasticity, where strains of up to 10% are recoverable. These characteristics of SMA allow for significant amounts of strain recovery, and enable the design of SMA actuators. The temperature in an SMA actuator is generally controlled by resistive heating, also know as joule heating, and the strain recovery capabilities are used to do work on a load, thereby creating an electro-mechanical actuator. SMA actuators have attractive properties such as high energy density, smooth and silent actuation, reduced part counts compared to traditional alternatives, and scalability down to the micromechanical level. The phase transformation in SMA actuators, however, is highly non-linear. Therefore, the use of SMA as actuators, for example in positioning systems, benefits from the development of good models to predict and control the materials. The goals of this work are to develop a model suitable for real-time implementation, and that reproduces the observed behaviour of SMA actuators. The model is then inverted and used to develop a model-based controller, used in conjunction with traditional PID control to improve the precision and robustness of SMA actuators. The modelling portion of this work consists of the development of a phenomenological SMA model. The forward model is split into three blocks: a heating block, a phase kinetics block and a mechanical block. Since joule heating is commonly used in SMA actuators to bring about an increase in temperature, the heating block presents equations to convert a current input into the temperature of the wire. The phase kinetics block equations convert the calculated temperature and applied stress to the fraction of martensite present in the SMA. Finally, the mechanical model calculates the strain in the material from the martensite fraction and the applied stress. Once the model equations are presented, experimental verification tests are shown to compare physical SMA behaviour with that predicted by the model. Each of the blocks of the forward model are then inverted in order to be used as a feedforward linearizing controller. The control section of this thesis deals with the response of two common types of SMA actuators: a constant force SMA actuator and a spring-biased SMA actuator. The response of the system to step and sinusoidal signals with period of 5 seconds is investigated using two types of controllers: a traditional PI controller and the inverse-model controller in feedforward with a PI controller in feedback. Additionally, the robustness of the system is investigated through the response of the system to transient and sinusoidal stress disturbances. The disturbance rejection is investigated on a constant force actuator both with and without the presence of a force sensor