Kinematic analysis and optimization of robotic milling

Robotic milling is proposed to be one of the alternatives to respond the demand for flexible and cost-effective manufacturing systems. Serial arm robots offering 6 degrees of freedom (DOF) motion capability which are utilized for robotic 5-axis milling purposes, exhibits several issues such as low accuracy, low structural rigidity and kinematic singularities etc. In 5-axis milling, the tool axis selection and workpiece positioning are still a challenge, where only geometrical issues are considered at the computer-aided-manufacturing (CAM) packages. The inverse kinematic solution of the robot i.e. positions and motion of the axes, strictly depends on the workpiece location with respect to the robot base. Therefore, workpiece placement is crucial for improved robotic milling applications. In this thesis, an approach is proposed to select the tool axis for robotic milling along an already generated 5-axis milling tool path, where the robot kinematics are considered to eliminate or decrease excessive axis rotations. The proposed approach is demonstrated through simulations and benefits are discussed. Also, the effect of workpiece positioning in robotic milling is investigated considering the robot kinematics. The investigation criterion is selected as the movement of the robot axes. It is aimed to minimize the total movement of either all axes or selected the axis responsible of the most accuracy errors. Kinematic simulations are performed on a representative milling tool path and results are discusse

Improving Reliability and Assessing Performance of Global Navigation Satellite System Precise Point Positioning Ambiguity Resolution

Conventional Precise Point Positioning (PPP) has always required a relatively long initialization period (few tens of minutes at least) for the carrier-phase ambiguities to converge to constant values and for the solution to reach its optimal precision. The classical PPP convergence period is primarily caused by the estimation of the carrier-phase ambiguity from the relatively noisy pseudoranges and the estimation of atmospheric delay. If the underlying integer nature of the ambiguity is known, it can be resolved, thereby reducing the convergence time of conventional PPP. To recover the underlying integer nature of the carrier-phase ambiguities, different strategies for mitigating the satellite and receiver dependent equipment delays have been developed, and products made publicly available to enable ambiguity resolution without any baseline restrictions. There has been limited research within the scope of interoperability of the products, combining the products to improve reliability and assessment of ambiguity resolution within the scope of being an integrity indicator. This study seeks to develop strategies to enable each of these and examine their feasibility. The advantage of interoperability of the different PPP ambiguity resolution (PPP-AR) products would be to permit the PPP user to transform independently generated PPP-AR products to obtain multiple fixed solutions of comparable precision and accuracy. The ability to provide multiple solutions would increase the reliability of the solution for, e.g., real-time processing: if there were an outage in the generation of the PPP-AR products, the user could instantly switch streams to a different provider. The satellite clock combinations routinely produced within the International GNSS Service (IGS) currently disregard that analysis centers (ACs) provide products which enable ambiguity resolution. Users have been expected to choose either an IGS product which is a combined product from multiple ACs or select an individual AC solution which provides products that enable PPP-AR. The goal of the novel research presented was to develop and test a robust satellite clock combination preserving the integer nature of the carrier-phase ambiguities at the user end. mm-level differences were noted, which was expected as the strength lies mainly in its reliability and stable median performance and the combined product is better than or equivalent to any single ACs product in the combination process. As have been shown in relative positioning and PPP-AR, ambiguity resolution is critical for enabling cm-level positioning. However, what if specifications where at the few dm-level, such as 10 cm and 20 cm horizontal what role does ambiguity resolution play? The role of ambiguity resolution relies primarily on what are the user specifications. If the user specifications are at the few cm-level, ambiguity resolution is an asset as it improves convergence and solution stability. Whereas, if the users specification is at the few dm-level, ambiguity resolution offers limited improvement over the float solution. If the user has the resources to perform ambiguity resolution, even when the specifications are at the few dm-level, it should be utilized

Wearable sensors and total knee arthroplasty: Assessing quantitative function to improve the patient experience

Osteoarthritis (OA) is a chronic degenerative disease for which the only long-term solution is total knee arthroplasty (TKA), though many patients are not satisfied with their TKA. Satisfaction in TKA patients is not well understood. Subjective questionnaires and objective functional tests have been previously used to assess TKA outcomes, but both have disadvantages. Wearable sensors have facilitated affordable biomechanical measurement in OA and TKA populations. The objective of this work was to use wearable sensors alongside functional tests with TKA patients to identify quantitative function that related to subjective function and satisfaction. A wearable sensor-setup was validated before implementation in a TKA population. Quantitative sensor metrics describing the motion of individual leg segments was found to correlate with subjective function and satisfaction. This study provided strong evidence towards the connection between quantitative function and patient experience and may be able to identify functional deficiencies for targeted therapy to improve satisfaction

A framework for flexible integration in robotics and its applications for calibration and error compensation

Robotics has been considered as a viable automation solution for the aerospace industry to address manufacturing cost. Many of the existing robot systems augmented with guidance from a large volume metrology system have proved to meet the high dimensional accuracy requirements in aero-structure assembly. However, they have been mainly deployed as costly and dedicated systems, which might not be ideal for aerospace manufacturing having low production rate and long cycle time. The work described in this thesis is to provide technical solutions to improve the flexibility and cost-efficiency of such metrology-integrated robot systems. To address the flexibility, a software framework that supports reconfigurable system integration is developed. The framework provides a design methodology to compose distributed software components which can be integrated dynamically at runtime. This provides the potential for the automation devices (robots, metrology, actuators etc.) controlled by these software components to be assembled on demand for various assembly applications. To reduce the cost of deployment, this thesis proposes a two-stage error compensation scheme for industrial robots that requires only intermittent metrology input, thus allowing for one expensive metrology system to be used by a number of robots. Robot calibration is employed in the first stage to reduce the majority of robot inaccuracy then the metrology will correct the residual errors. In this work, a new calibration model for serial robots having a parallelogram linkage is developed that takes into account both geometric errors and joint deflections induced by link masses and weight of the end-effectors. Experiments are conducted to evaluate the two pieces of work presented above. The proposed framework is adopted to create a distributed control system that implements calibration and error compensation for a large industrial robot having a parallelogram linkage. The control system is formed by hot-plugging the control applications of the robot and metrology used together. Experimental results show that the developed error model was able to improve the 3 positional accuracy of the loaded robot from several millimetres to less than one millimetre and reduce half of the time previously required to correct the errors by using only the metrology. The experiments also demonstrate the capability of sharing one metrology system to more than one robot

Intelligent Analysis of Utilization of Special Purpose Machines for Drilling Operations

Drilling and drilling-related operations constitute more than 60% of all machining processes in manufacturing industries. Consequently, it is important to know how to perform these operations properly. With availability of many machining processes capable of performing drilling operations sometimes it is difficult to decide which process would result in a higher profit or a lower unit cost for a given task. Due to increasing global competition, manufacturing industries are now more concerned with their productivity and are more sensitive than ever to their investments with respect to flexibility and efficiency of production equipment (Boothroyd and Knight, 2005, Wecka and Staimer, 2002). Researchers (Ko et al., 2005) believe that increasing the quality of production and reducing cost and time of production are very important factors in achieving higher productivity. Achieving this goal requires reconsidering current production methods that could lead to introduction of new production techniques and more advanced technologies

Advancement in robot programming with specific reference to graphical methods

This research study is concerned with the derivation of advanced robot programming methods. The methods include the use of proprietary simulation modelling and design software tools for the off-line programming of industrial robots. The study has involved the generation of integration software to facilitate the co-operative operation of these software tools. The three major researcli'themes7of "ease of usage", calibration and the integration of product design data have been followed to advance robot programming. The "ease of usage" is concerned with enhancements in the man-machine interface for robo t simulation systems in terms of computer assisted solid modelling and computer assisted task generation. Robot simulation models represent an idealised situation, and any off-line robot programs generated from'them may contain'discrepancies which could seriously effect thq programs' performance; Calibration techniques have therefore been investigated as 'a method of overcoming discrepancies between the simulation model and the real world. At the present time, most computer aided design systems operate as isolated islands of computer technology, whereas their product databases should be used to support decision making processes and ultimately facilitate the generation of machine programs. Thus the integration of product design data has been studied as an important step towards truly computer integrated manufacturing. The functionality of the three areas of study have been generalised and form the basis for recommended enhancements to future robot programming systems

Controlled motion in an elastic world. Research project: Manipulation strategies for massive space payloads

The flexibility of the drives and structures of controlled motion systems are presented as an obstacle to be overcome in the design of high performance motion systems, particularly manipulator arms. The task and the measure of performance to be applied determine the technology appropriate to overcome this obstacle. Included in the technologies proposed are control algorithms (feedback and feed forward), passive damping enhancement, operational strategies, and structural design. Modeling of the distributed, nonlinear system is difficult, and alternative approaches are discussed. The author presents personal perspectives on the history, status, and future directions in this area

Robust Thermal Error Modeling and Compensation for CNC Machine Tools.

Thermal errors are one of the most significant factors affecting machine tool accuracy. Error compensation has been widely used to reduce the thermal errors, the robustness of the thermal error models, however, still needs to be improvement. Currently, five-axis machine tools are becoming more important and extensively utilized in industry. In this regard, the geometric errors of rotary axis must be properly measured and corrected to assure the accuracy of five-axis machining. Thermal error model, relating temperature variations to thermal errors, is the core of an effective thermal error compensation strategy. Thermal modal analysis, unveiling the essence of thermo-elastic process, is explored for the determination of temperature sensor placement based on the finite element analysis and eigen analysis. Thermal error models are thus derived based on the temperature variations collected from the specified temperature sensors. The robustness of the derived models is investigated in terms of linear extrapolation and frequency sensitivity. Numerical simulation and experiments are conducted to illustrate the existence of thermal modes and validate the robustness of the thermal error models. Thermal loop analysis is developed for the thermal error compensation of an entire machine tool. A machine tool is first decomposed into several thermal links along an identified thermal loop. For each thermal link, the thermal modal analysis is carried out for the derivation of thermal error model. These thermal links are finally reassembled for the thermal error prediction of the entire machine tool. The thermal loop analysis mitigates the inaccurate modeling of machine joints, and extensively facilitates the utilization of the finite element method in the thermal error modeling and compensation. Calibration of rotary axis of five-axis machine tools is usually time-consuming and laborious by using laser interferometer or autocollimator systems. The Telescopic Magnetic Ball Bar is explored to estimate error components induced by the rotational motion of a rotary axis. The calibration algorithm is developed based on the rigorous mathematical derivation. The setup errors, including parameter variation and eccentricity, have been accounted for through the numerical simulation, enabling the practical utilization of this method. This approach shows the advantages of easy setup and quick assessment.Ph.D.Mechanical EngineeringUniversity of Michigan, Horace H. Rackham School of Graduate Studieshttp://deepblue.lib.umich.edu/bitstream/2027.42/60857/1/zhujie_1.pd

Robot Manipulators

Robot manipulators are developing more in the direction of industrial robots than of human workers. Recently, the applications of robot manipulators are spreading their focus, for example Da Vinci as a medical robot, ASIMO as a humanoid robot and so on. There are many research topics within the field of robot manipulators, e.g. motion planning, cooperation with a human, and fusion with external sensors like vision, haptic and force, etc. Moreover, these include both technical problems in the industry and theoretical problems in the academic fields. This book is a collection of papers presenting the latest research issues from around the world