Integrated Sensor Fault Diagnosis and Fault-Tolerant Control for Manipulator

In this paper, an integrated scheme including fault diagnosis and fault-tolerant controller design is proposed for the manipulator system with the sensor fault. Any constant fault or time-varying fault can be estimated by the fault diagnosis scheme based on the adaptive observer rapidly and accurately, and the designed parameters can be solved by the linear matrix inequality. Using the fault estimation information, a fault-tolerant controller combining the characteristics of the proportional differentiation control and the sliding model control is designed to trace the expected trajectory via the back-stepping method. Finally, the effectiveness of the above scheme is verified by the simulation results

Impact analysis of actuator torque degradation on the IRB 120 robot performance using simscape-based model

Actuators in a robot system may become faulty during their life cycle. Locked joints, free-moving joints, and the loss of actuator torque are common faulty types of robot joints where the actuators fail. Locked and free-moving joint issues are addressed by many published articles, whereas the actuator torque loss still opens attractive investigation challenges. The objectives of this study are to classify the loss of robot actuator torque, named actuator torque degradation, into three different cases: Boundary degradation of torque, boundary degradation of torque rate, and proportional degradation of torque, and to analyze their impact on the performance of a typical 6-DOF robot (i.e., the IRB 120 robot). Typically, controllers of robots are not pre-designed specifically for anticipating these faults. To isolate and focus on the impact of only actuator torque degradation faults, all robot parameters are assumed to be known precisely, and a popular closed-loop controller is used to investigate the robot’s responses under these faults. By exploiting MATLAB-the reliable simulation environment, a simscape-based quasi-physical model of the robot is built and utilized instead of an actual expensive prototype. The simulation results indicate that the robot responses cannot follow the desired path properly in most fault cases

Sensor Fault Detection and Compensation with Performance Prescription for Robotic Manipulators

This paper focuses on sensor fault detection and compensation for robotic manipulators. The proposed method features a new adaptive observer and a new terminal sliding mode control law established on a second-order integral sliding surface. The method enables sensor fault detection without the need to impose known bounds on fault value and/or its derivative. It also enables fast and fixed-time fault-tolerant control whose performance can be prescribed beforehand by defining funnel bounds on the tracking error. The ultimate boundedness of the estimation errors for the proposed observer and the fixed-time stability of the control system are shown using Lyapunov stability analysis. The effectiveness of the proposed method is verified using numerical simulations on two different robotic manipulators, and the results are compared with existing methods. Our results demonstrate performance gains obtained by the proposed method compared to the existing results

Fault-tolerant control strategies for a class of Euler-Lagrange nonlinear systems subject to simultaneous sensor and actuator faults

The problem of Fault Detection, Isolation, and Estimation (FDIE) as well as Fault-Tolerant Control (FTC) for a class of nonlinear systems modeled with Euler-Lagrange (EL) equations subjected to simultaneous sensor and actuator faults are considered in this study. To tackle this problem, first state and output linear transformations are introduced to decouple the effects of sensor and actuator faults. These transformations do not depend on the system nonlinearities. An analytical procedure based on two Linear Matrix Inequality (LMI) feasibility conditions is proposed to obtain these transformations. Once, the effects of faults are decoupled, two Sliding Mode Observers (SMO) are designed to reconstruct each type of fault, separately. Subsequently, the results of fault estimations are fed back to the controller and the effects of faults are compensated for. In this study, the mathematical stability proof of the coupled controller, observers, and the nonlinear system is provided. Unlike previous methodologies in the literature, no limiting assumptions such as Lipschitz conditions are imposed on the system. Next, a novel fault tolerant control scheme is proposed in which a single SMO is used to reconstruct sensor faults and provide a compensation term to rectify the effects of faults. However, to deal with actuator faults, a Sliding Mode Controller (SMC) is employed. Using this robust FTC technique, zero tracking error in the presence of uncertainties, measurement noise, disturbances, and faults as well as estimation of the actuator faults are possible. The stability proof for the coupled nonlinear controller, observer and plant is provided by using the properties of Euler-Lagrange equations and sliding mode techniques. Finally, to evaluate the performance of the proposed FDIE and FTC approaches, extensive sets of simulations are performed on a 3 Degrees Of Freedom (DOF) Autonomous Underwater Vehicle (AUV). Simulation studies show the promising results obtained as a result of the presented approaches as compared to those obtained by using the existing methodologies

NASA space station automation: AI-based technology review

Research and Development projects in automation for the Space Station are discussed. Artificial Intelligence (AI) based automation technologies are planned to enhance crew safety through reduced need for EVA, increase crew productivity through the reduction of routine operations, increase space station autonomy, and augment space station capability through the use of teleoperation and robotics. AI technology will also be developed for the servicing of satellites at the Space Station, system monitoring and diagnosis, space manufacturing, and the assembly of large space structures

On Increasing the Automation Level of Heavy-Duty Hydraulic Manipulators with Condition Monitoring of the Hydraulic System and Energy-Optimised Redundancy Resolution

Hydraulic manipulators on mobile machines are predominantly used for excavation and lifting applications at construction sites and for heavy-duty material handling in the forest industry due to their superior power-density and rugged nature. These manipulators are conventionally open-loop controlled by human operators who are sufficiently skilled to operate the machines. However, in the footsteps of pioneering original equipment manufacturers (OEMs) and to keep up with the intensifying demand for innovation, more and more mobile machine OEMs have a major interest in significantly increasing the automation level of their hydraulic manipulators and improving the operation of manipulators. In this thesis, robotic software-based functionalities in the form of modelbased condition monitoring and energy-optimal redundancy resolution which facilitate increased automation level of hydraulic manipulators are proposed.A condition monitoring system generally consists of software modules and sensors which co-operate harmonically and monitor the hydraulic system’s health in real-time based on an indirect measure of this system’s health. The premise is that when this condition monitoring system recognises that the system’s health has deteriorated past a given threshold (in other words, when a minor fault is detected, such as a slowly increasing internal leakage of the hydraulic cylinder), the condition monitoring module issues an alarm to warn the system operator of the malfunction, and the module could ideally diagnose the fault cause. In addition, when faced with severe faults, such as an external leakage or an abruptly increasing internal leakage in the hydraulic system, an alarm from the condition monitoring system ensures that the machine is quickly halted to prevent any further damage to the machine or its surroundings.The basic requirement in the design of such a condition monitoring system is to make sure that this system is robust and fault-sensitive. These properties are difficult to achieve in complex mobile hydraulic systems on hydraulic manipulators due to the modelling uncertainties affecting these systems. The modelling uncertainties affecting mobile hydraulic systems are specific compared with many other types of systems and are large because of the hydraulic system complexities, nonlinearities, discontinuities and inherently time-varying parameters. A feasible solution to this modelling uncertainty problem would be to either attenuate the effect of modelling errors on the performance of model-based condition monitoring or to develop improved non-model-based methods with increased fault-sensitivity. In this research work, the former model-based approach is taken. Adaptation of the model residual thresholds based on system operating points and reliable, load-independent system models are proposed as integral parts of the condition monitoring solution to the modelling uncertainty problem. These proposed solutions make the realisation of condition monitoring solutions more difficult on heavy-duty hydraulic manipulators compared with fixed-load manipulators, for example. These solutions are covered in detail in a subset of the research publications appended to this thesis.There is wide-spread interest from hydraulic manipulator OEMs in increasing the automation level of their hydraulic manipulators. Most often, this interest is related to semi-automation of repetitive work cycles to improve work productivity and operator workload circumstances. This robotic semi-automated approach involves resolving the kinematic redundancy of hydraulic manipulators to obtain motion references for the joint controller to enable desirable closed-loop controlled motions. Because conventional redundancy resolutions are usually sub-optimal at the hydraulic system level, a hydraulic energy-optimised, global redundancy resolution is proposed in this thesis for the first time. Kinematic redundancy is resolved energy optimally from the standpoint of the hydraulic system along a prescribed path for a typical 3-degrees-of-freedom (3-DOF) and 4-DOF hydraulic manipulator. Joint motions are also constrained based on the actuators’ position, velocity and acceleration bounds in hydraulic manipulators in the proposed solution. This kinematic redundancy resolution topic is discussed in the last two research papers. Overall, both designed manipulator features, condition monitoring and energy-optimised redundancy resolution, are believed to be essential for increasing the automation of hydraulic manipulators

Multisensor Fault Identification Scheme Based on Decentralized Sliding Mode Observers Applied to Reconfigurable Manipulators

This paper concerns with a fault identification scheme in a class of nonlinear interconnected systems. The decentralized sliding mode observer is recruited for the investigation of position sensor fault or velocity sensor fault. First, a decentralized neural network controller is proposed for the system under fault-free state. The diffeomorphism theory is utilized to construct a nonlinear transformation for subsystem structure. A simple filter is implemented to convert the sensor fault into pseudo-actuator fault scenario. The decentralized sliding mode observer is then presented for multisensor fault identification of reconfigurable manipulators based on Lyapunov stable theory. Finally, two 2-DOF reconfigurable manipulators with different configurations are employed to verify the effectiveness of the proposed scheme in numerical simulation. The results demonstrate that one joint’s fault does not affect other joints and the sensor fault can be identified precisely by the proposed decentralized sliding mode observer

A control-theoretical fault prognostics and accommodation framework for a class of nonlinear discrete-time systems

Fault diagnostics and prognostics schemes (FDP) are necessary for complex industrial systems to prevent unscheduled downtime resulting from component failures. Existing schemes in continuous-time are useful for diagnosing complex industrial systems and no work has been done for prognostics. Therefore, in this dissertation, a systematic design methodology for model-based fault prognostics and accommodation is undertaken for a class of nonlinear discrete-time systems. This design methodology, which does not require any failure data, is introduced in six papers. In Paper I, a fault detection and prediction (FDP) scheme is developed for a class of nonlinear system with state faults by assuming that all the states are measurable. A novel estimator is utilized for detecting a fault. Upon detection, an online approximator in discrete-time (OLAD) and a robust adaptive term are activated online in the estimator wherein the OLAD learns the unknown fault dynamics while the robust adaptive term ensures asymptotic performance guarantee. A novel update law is proposed for tuning the OLAD parameters. Additionally, by using the parameter update law, time to reach an a priori selected failure threshold is derived for prognostics. Subsequently, the FDP scheme is used to estimate the states and detect faults in nonlinear input-output systems in Paper II and to nonlinear discrete-time systems with both state and sensor faults in Paper III. Upon detection, a novel fault isolation estimator is used to identify the faults in Paper IV. It was shown that certain faults can be accommodated via controller reconfiguration in Paper V. Finally, the performance of the FDP framework is demonstrated via Lyapunov stability analysis and experimentally on the Caterpillar hydraulics test-bed in Paper VI by using an artificial immune system as an OLAD --Abstract, page iv

LPV control and virtual-sensor-based fault tolerant strategies for a three-axis gimbal system

This paper deals with the LPV control of a three-axis gimbal including fault-tolerant capabilities. First, the derivation of an analytical model for the considered system based on the robotics Serial-Link (SL) theory is derived. Then, a series of simplifications that allow obtaining a quasi-LPV model for the considered gimbal is proposed. Gain scheduling LPV controllers with PID structure are designed using pole placement by means of linear matrix inequalities (LMIs). Moreover, exploiting the sensor redundancy available in the gimbal, a virtual-sensor-based fault tolerant control (FTC) strategy is proposed. This virtual sensor uses a Recursive Least Square (RLS) estimation algorithm and an LPV observer for fault detection and estimation. Finally, the proposed LPV control scheme including the virtual sensor strategy is tested in simulation in several scenarios.Peer ReviewedPostprint (published version