Modeling and Control of the Cooperative Automated Fiber Placement System

The Automated Fiber Placement (AFP) machines have brought significant improvement on composite manufacturing. However, the current AFP machines are designed for the manufacture of simple structures like shallow shells or tubes, and not capable of handling some applications with more complex shapes. A cooperative AFP system is proposed to manufacture more complex composite components which pose high demand for trajectory planning than those by the current APF system. The system consists of a 6 degree-of-freedom (DOF) serial robot holding the fiber placement head, a 6-DOF revolute-spherical-spherical (RSS) parallel robot on which a 1-DOF mandrel holder is installed and an eye-to-hand photogrammetry sensor, i.e. C-track, to detect the poses of both end-effectors of parallel robot and serial robot. Kinematic models of the parallel robot and the serial robot are built. The analysis of constraints and singularities is conducted for the cooperative AFP system. The definitions of the tool frames for the serial robot and the parallel robot are illustrated. Some kinematic parameters of the parallel robot are calibrated using the photogrammetry sensor. Although, the cooperative AFP system increases the flexibility of composite manufacturing by adding more DOF, there might not be a feasible path for laying up the fiber in some cases due to the requirement of free from collisions and singularities. To meet the challenge, an innovative semi-offline trajectory synchronized algorithm is proposed to incorporate the on-line robot control in following the paths generated off-line especially when the generated paths are infeasible for the current multiple robots to realize. By adding correction to the path of the robots at the points where the collision and singularity occur, the fiber can be laid up continuously without interruption. The correction is calculated based on the pose tracking data of the parallel robot detected by the photogrammetry sensor on-line. Due to the flexibility of the 6-DOF parallel robot, the optimized offsets with varying movements are generated based on the different singularities and constraints. Experimental results demonstrate the successful avoidance of singularities and joint limits, and the designed cooperative AFP system can fulfill the movement needed for manufacturing a composite structure with Y-shape

Visual Calibration, Identification and Control of 6-RSS Parallel Robots

Parallel robots present some outstanding advantages in high force-to-weight ratio, better stiffness and theoretical higher accuracy compared with serial manipulators. Hence parallel robots have been utilized increasingly in various applications. However, due to the manufacturing tolerances and defections in the robot structure, the positioning accuracy of parallel robots is basically equivalent with that of serial manipulators according to previous researches on the accuracy analysis of the Stewart Platform [1], which is difficult to meet the precision requirement of many potential applications. In addition, the existence of closed-chain mechanism yields difficulties in designing control system for practical applications, due to its highly coupled dynamics. Visual sensor is a good choice for providing non-contact measurement of the end-effector pose (position and orientation) with simplicity in operation and low cost compared to other measurement methods such as the coordinate measurement machine (CMM) [2] and the laser tracker [3]. In this research, a series of solutions including kinematic calibration, dynamic identification and visual servoing are proposed to improve the positioning and tracking performance of the parallel robot based on the visual sensor. The main contributions of this research include three parts. In the first part, a relative pose-based algorithm (RPBA) is proposed to solve the kinematic calibration problem of a six-revolute-spherical-spherical (6-RSS) parallel robot by using the optical CMM sensor. Based on the relative poses between the candidate and the initial configurations, a calibration algorithm is proposed to determine the optimal error parameters of the robot kinematic model and external parameters introduced by the optical sensor. The experimental results demonstrate that the proposal RPBA using optical CMM is an implementable and effective method for the parallel robot calibration. The second part focuses on the dynamic model identification of the 6-RSS parallel robots. A visual closed-loop output-error identification method based on an optical CMM sensor is proposed for the purpose of the advanced model-based visual servoing control design of parallel robots. By using an outer loop visual servoing controller to stabilize both the parallel robot and the simulated model, the visual closed-loop output-error identification method is developed and the model parameters are identified by using a nonlinear optimization technique. The effectiveness of the proposed identification algorithm is validated by experimental tests. In the last part, a dynamic sliding mode control (DSMC) scheme combined with the visual servoing method is proposed to improve the tracking performance of the 6-RSS parallel robot based on the optical CMM sensor. By employing a position-to-torque converter, the torque command generated by DSMC can be applied to the position controlled industrial robot. The stability of the proposed DSMC has been proved by using Lyapunov theorem. The real-time experiment tests on a 6-RSS parallel robot demonstrate that the developed DSMC scheme is robust to the modeling errors and uncertainties. Compared with the classical kinematic level controllers, the proposed DSMC exhibits the superiority in terms of tracking performance and robustness

Innovative robot hand designs of reduced complexity for dexterous manipulation

This thesis investigates the mechanical design of robot hands to sensibly reduce the system complexity in terms of the number of actuators and sensors, and control needs for performing grasping and in-hand manipulations of unknown objects. Human hands are known to be the most complex, versatile, dexterous manipulators in nature, from being able to operate sophisticated surgery to carry out a wide variety of daily activity tasks (e.g. preparing food, changing cloths, playing instruments, to name some). However, the understanding of why human hands can perform such fascinating tasks still eludes complete comprehension. Since at least the end of the sixteenth century, scientists and engineers have tried to match the sensory and motor functions of the human hand. As a result, many contemporary humanoid and anthropomorphic robot hands have been developed to closely replicate the appearance and dexterity of human hands, in many cases using sophisticated designs that integrate multiple sensors and actuators---which make them prone to error and difficult to operate and control, particularly under uncertainty. In recent years, several simplification approaches and solutions have been proposed to develop more effective and reliable dexterous robot hands. These techniques, which have been based on using underactuated mechanical designs, kinematic synergies, or compliant materials, to name some, have opened up new ways to integrate hardware enhancements to facilitate grasping and dexterous manipulation control and improve reliability and robustness. Following this line of thought, this thesis studies four robot hand hardware aspects for enhancing grasping and manipulation, with a particular focus on dexterous in-hand manipulation. Namely: i) the use of passive soft fingertips; ii) the use of rigid and soft active surfaces in robot fingers; iii) the use of robot hand topologies to create particular in-hand manipulation trajectories; and iv) the decoupling of grasping and in-hand manipulation by introducing a reconfigurable palm. In summary, the findings from this thesis provide important notions for understanding the significance of mechanical and hardware elements in the performance and control of human manipulation. These findings show great potential in developing robust, easily programmable, and economically viable robot hands capable of performing dexterous manipulations under uncertainty, while exhibiting a valuable subset of functions of the human hand.Open Acces

Design of a six degree-of-freedom haptic hybrid platform manipultor

Thesis (Master)--Izmir Institute of Technology, Mechanical Engineering, Izmir, 2010Includes bibliographical references (leaves: 97-103)Text in English; Abstract: Turkish and Englishxv, 115 leavesThe word Haptic, based on an ancient Greek word called haptios, means related with touch. As an area of robotics, haptics technology provides the sense of touch for robotic applications that involve interaction with human operator and the environment. The sense of touch accompanied with the visual feedback is enough to gather most of the information about a certain environment. It increases the precision of teleoperation and sensation levels of the virtual reality (VR) applications by exerting physical properties of the environment such as forces, motions, textures. Currently, haptic devices find use in many VR and teleoperation applications. The objective of this thesis is to design a novel Six Degree-of-Freedom (DOF) haptic desktop device with a new structure that has the potential to increase the precision in the haptics technology. First, previously developed haptic devices and manipulator structures are reviewed. Following this, the conceptual designs are formed and a hybrid structured haptic device is designed manufactured and tested. Developed haptic device.s control algorithm and VR application is developed in Matlab© Simulink. Integration of the mechanism with mechanical, electromechanical and electronic components and the initial tests of the system are executed and the results are presented. According to the results, performance of the developed device is discussed and future works are addressed

A survey of dextrous manipulation

technical reportThe development of mechanical end effectors capable of dextrous manipulation is a rapidly growing and quite successful field of research. It has in some sense put the focus on control issues, in particular, how to control these remarkably humanlike manipulators to perform the deft movement that we take for granted in the human hand. The kinematic and control issues surrounding manipulation research are clouded by more basic concerns such as: what is the goal of a manipulation system, is the anthropomorphic or functional design methodology appropriate, and to what degree does the control of the manipulator depend on other sensory systems. This paper examines the potential of creating a general purpose, anthropomorphically motivated, dextrous manipulation system. The discussion will focus on features of the human hand that permit its general usefulness as a manipulator. A survey of machinery designed to emulate these capabilities is presented. Finally, the tasks of grasping and manipulation are examined from the control standpoint to suggest a control paradigm which is descriptive, yet flexible and computationally efficient1

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

Visual Servoing in Robotics

Visual servoing is a well-known approach to guide robots using visual information. Image processing, robotics, and control theory are combined in order to control the motion of a robot depending on the visual information extracted from the images captured by one or several cameras. With respect to vision issues, a number of issues are currently being addressed by ongoing research, such as the use of different types of image features (or different types of cameras such as RGBD cameras), image processing at high velocity, and convergence properties. As shown in this book, the use of new control schemes allows the system to behave more robustly, efficiently, or compliantly, with fewer delays. Related issues such as optimal and robust approaches, direct control, path tracking, or sensor fusion are also addressed. Additionally, we can currently find visual servoing systems being applied in a number of different domains. This book considers various aspects of visual servoing systems, such as the design of new strategies for their application to parallel robots, mobile manipulators, teleoperation, and the application of this type of control system in new areas