Miniaturized modular manipulator design for high precision assembly and manipulation tasks

In this paper, design and control issues for the development of miniaturized manipulators which are aimed to be used in high precision assembly and manipulation tasks are presented. The developed manipulators are size adapted devices, miniaturized versions of conventional robots based on well-known kinematic structures. 3 degrees of freedom (DOF) delta robot and a 2 DOF pantograph mechanism enhanced with a rotational axis at the tip and a Z axis actuating the whole mechanism are given as examples of study. These parallel mechanisms are designed and developed to be used in modular assembly systems for the realization of high precision assembly and manipulation tasks. In that sense, modularity is addressed as an important design consideration. The design procedures are given in details in order to provide solutions for miniaturization and experimental results are given to show the achieved performances

Exploiting Artificial Swarms for the Virtual Measurement of Backlash in Industrial Robots

The backlash is a lost motion in a mechanism created by gaps between its parts. It causes vibrations that increase over time and negatively affect accuracy and performance. The quickest and most precise way to measure the backlash is to use specific sensors, that have to be added to the standard equipment of the robot. However, this solution is little used in practice because raises the manufacturing costs. An alternative solution can be to exploit a virtual sensor, i.e., the information about phenomena that are not directly measured is reconstructed by signals from sensors used for other measurements. This work evaluates the use of bio-inspired swarm algorithms as the processing core of a virtual sensor for the backlash of a robotic joint. Swarm-based approaches, with their relatively modest occupation of memory and low computational load, could be ideal candidates to solve the roblem. In this paper, we exploit four state-of-the-art swarm-based optimization algorithms: the Dragonfly Algorithm, the Ant Lion Optimizer, the Grasshopper Optimization Algorithm, and the Grey Wolf Optimizer. The four candidate algorithms are compared on 20 different datasets covering a range of backlash values that reflect an industrial case scenario. Numerical results indicate that, unfortunately, none of the algorithms considered provides satisfactory solutions for the problem analyzed. Therefore, even if promising, these algorithms cannot represent the final choice for the problem of interest

Incorporation of the influences of kinematics parameters and joints tilting for the calibration of serial robotic manipulators

Serial robotic manipulators are calibrated to improve and restore their accuracy and repeatability. Kinematics parameters calibration of a robot reduces difference between the model of a robot in the controller and its actual mechanism to improve accuracy. Kinematics parameter’s error identification in the standard kinematics calibration has been configuration independent which does not consider the influence of kinematics parameter on robot tool pose accuracy for a given configuration. This research analyses the configuration dependent influences of kinematics parameters error on pose accuracy of a robot. Based on the effect of kinematics parameters, errors in the kinematics parameters are identified. Another issue is that current kinematics calibration models do not incorporate the joints tilting as a result of joint clearance, backlash, and flexibility, which is critical to the accuracy of serial robotic manipulators, and therefore compromises a pose accuracy. To address this issue which has not been carefully considered in the literature, this research suggested an approach to model configuration dependent joint tilting and presents a novel approach to encapsulate them in the calibration of serial robotic manipulators. The joint tilting along with the kinematics errors are identified and compensated in the kinematics model of the robot. Both conventional and proposed calibration approach are tested experimentally, and the calibration results are investigated to demonstrate the effectiveness of this research. Finally, the improvement in the trajectory tracking accuracy of the robot has been validated with the help of proposed low-cost measurement set-up.Thesis (M.Phil.) (Research by Publication) -- University of Adelaide, School of Mechanical Engineering , 201

Robotically assisted eye surgery : a haptic master console

Vitreo-retinal surgery encompasses the surgical procedures performed on the vitreous humor and the retina. A procedure typically consists of the removal of the vitreous humor, the peeling of a membrane and/or the repair of a retinal detachment. Operations are performed with needle shaped instruments which enter the eye through surgeon made scleral openings. An instrument is moved by hand in four degrees of freedom (three rotations and one translation) through this opening. Two rotations (? and ? ) are for a lateral instrument tip movement. The other two DoFs (z and ?) are the translation and rotation along the instrument axis. Actuation of for example a forceps can be considered as a fifth DoF. Characteristically, the manipulation of delicate, micrometer range thick intraocular tissue is required. Today, eye surgery is performed with a maximum of two instruments simultaneously. The surgeon relies on visual feedback only, since instrument forces are below the human detection limit. A microscope provides the visual feedback. It forces the surgeon to work in a static and non ergonomic body posture. Although the surgeon’s proficiency improves throughout his career, hand tremor may become a problem around his mid-fifties. Robotically assisted surgery with a master-slave system enhances dexterity. The slave with instrument manipulators is placed over the eye. The surgeon controls the instrument manipulators via haptic interfaces at the master. The master and slave are connected by electronic hardware and control software. Implementation of tremor filtering in the control software and downscaling of the hand motion allow prolongation of the surgeon’s career. Furthermore, it becomes possible to do tasks like intraocular cannulation which can not be done by manually performed surgery. This thesis focusses on the master console. Eye surgery procedures are observed in the operating room of different hospitals to gain insight in the requirements for the master. The master console as designed has an adjustable frame, a 3D display and two haptic interfaces with a coarse adjustment arm each. The console is mounted at the head of the operating table and is combined with the slave. It is compact, easy to place and allows the surgeon to have a direct view on and a physical contact with the patient. Furthermore, it fits in today’s manual surgery arrangement. Each haptic interface has the same five degrees of freedom as the instrument inside the eye. Through these interfaces, the surgeon can feel the augmented instrument forces. Downscaling of the hand motion results in a more accurate instrument movement compared to manually performed surgery. Together with the visual feedback, it is like the surgeon grasps the instrument near the tip inside the eye. The similarity between hand motion and motion of the instrument tip as seen on the display results in an intuitive manipulation. Pre-adjustment of the interface is done via the coarse adjustment arm. Mode switching enables to control three or more instruments manipulators with only two interfaces. Two one degree of freedom master-slave systems with force feedback are built to derive the requirements for the haptic interface. Hardware in the loop testing provides valuable insights and shows the possibility of force feedback without the use of force sensors. Two five DoF haptic interfaces are realized for bimanual operation. Each DoF has a position encoder and a force feedback motor. A correct representation of the upscaled instrument forces is only possible if the disturbance forces are low. Actuators are therefore mounted to the fixed world or in the neighborhood of the pivoting point for a low contribution to the inertia. The use of direct drive for ' and and low geared, backdriveable transmissions for the other three DoFs gives a minimum of friction. Disturbance forces are further minimized by a proper cable layout and actuator-amplifier combinations without torque ripple. The similarity in DoFs between vitreo-retinal eye surgery and minimally invasive surgery (MIS) enables the system to be used for MIS as well. Experiments in combination with a slave robot for laparoscopic and thoracoscopic surgery show that an instrument can be manipulated in a comfortable and intuitive way. User experience of surgeons and others is utilized to improve the haptic interface further. A parallel instead of a serial actuation concept for the ' and DoFs reduces the inertia, eliminates the flexible cable connection between frame and motor and allows that the heat of the motor is transferred directly to the frame. A newly designed z-?? module combines the actuation and suspension of the hand held part of the interface and has a three times larger z range than in the first design of the haptic interface

Measurement assisted assembly for high accuracy aerospace manufacturing

Measurement Assisted Assembly is a key concept for the modernisation of aerospace assembly processes, i.e. improving their efficiency while reducing the manufacturing costs. This concept suggests a paradigm shift in the assembly of high-complexity products as it encompasses the development and the use of robotics solutions smartly integrated with innovative measurement technologies. Expected outcomes are, among others, a better positioning accuracy of the components and a significant reduction of the rectification and rework requirements that are usually common with traditional assembly processes, especially but not limited to aerospace manufacturing. To achieve these objectives, a high precision metrology system that automatically inspects and corrects the pose of the robotic manipulators during the assembly operations is of great importance. In this paper, a high-accuracy real-life application of the concept of Measurement Assisted Assembly is presented as a part of the Future Automated Aircraft Assembly Demonstrator developed by the University of Nottingham. Experimentations have shown that, using the production environment described hereafter, a positioning accuracy better than +- 0.1 mm can be achieved for large airframe components

UBOT-7: THE DESIGN OF A COMPLIANT DEXTEROUS MOBILE MANIPULATOR

This thesis presents the design of uBot-7, the latest version of a dexterous mobile manipulator. This platform has been iteratively developed to realize a high performance-to-cost dexterous whole body manipulator with respect to mobile manipulation. The semi-anthropomorphic design of the uBot is a demonstrated and functional research platform for developing advanced autonomous perception, manipulation, and mobility tasks. The goal of this work is to improve the uBot’s ability to sense and interact with its environment in order to increase the platforms capability to operate dexterously, through the incorporation of joint torque feedback, and safely, through the implementation of passive and active compliance. This is accomplished through incorporating series elastic actuators in its arms and torso joints, improving the mechanical design to reduce backlash, and incorporating impedance controllers in the robot. The focus of this thesis is the development of the mechanical, sensor, and controller design for the uBot-7 platform. An impedance controller is developed and evaluated on a bench top prototype series elastic actuator

Robotic Catheters for Beating Heart Surgery

Compliant and flexible cardiac catheters provide direct access to the inside of the heart via the vascular system without requiring clinicians to stop the heart or open the chest. However, the fast motion of the intracardiac structures makes it difficult to modify and repair the cardiac tissue in a controlled and safe manner. In addition, rigid robotic tools for beating heart surgery require the chest to be opened and the heart exposed, making the procedures highly invasive. The novel robotic catheter system presented here enables minimally invasive repair on the fast-moving structures inside the heart, like the mitral valve annulus, without the invasiveness or risks of stopped heart procedures. In this thesis, I investigate the development of 3D ultrasound-guided robotic catheters for beating heart surgery. First, the force and stiffness values of tissue structures in the left atrium are measured to develop design requirements for the system. This research shows that a catheter will experience contractile forces of 0.5 – 1.0 N and a mean tissue structure stiffness of approximately 0.1 N/mm while interacting with the mitral valve annulus. Next, this thesis presents the catheter system design, including force sensing, tissue resection, and ablation end effectors. In order to operate inside the beating heart, position and force control systems were developed to compensate for the catheter performance limitations of friction and deadzone backlash and evaluated with ex vivo and in vivo experiments. Through the addition of friction and deadzone compensation terms, the system is able to achieve position tracking with less than 1 mm RMS error and force tracking with 0.08 N RMS error under ultrasound image guidance. Finally, this thesis examines how the robotic catheter system enhances beating heart clinical procedures. Specifically, this system improves resection quality while reducing the forces experienced by the tissue by almost 80% and improves ablation performance by reducing contact resistance variations by 97% while applying a constant force on the moving tissue.Engineering and Applied Science