Flexible multibody dynamics and intelligent control of a hydraulically driven hybrid redundant robot machine

The assembly and maintenance of the International Thermonuclear Experimental Reactor (ITER) vacuum vessel (VV) is highly challenging since the tasks performed by the robot involve welding, material handling, and machine cutting from inside the VV. The VV is made of stainless steel, which has poor machinability and tends to work harden very rapidly, and all the machining operations need to be carried out from inside of the ITER VV. A general industrial robot cannot be used due to its poor stiffness in the heavy duty machining process, and this will cause many problems, such as poor surface quality, tool damage, low accuracy. Therefore, one of the most suitable options should be a light weight mobile robot which is able to move around inside of the VV and perform different machining tasks by replacing different cutting tools. Reducing the mass of the robot manipulators offers many advantages: reduced material costs, reduced power consumption, the possibility of using smaller actuators, and a higher payload-to-robot weight ratio. Offsetting these advantages, the lighter weight robot is more flexible, which makes it more difficult to control. To achieve good machining surface quality, the tracking of the end effector must be accurate, and an accurate model for a more flexible robot must be constructed. This thesis studies the dynamics and control of a 10 degree-of-freedom (DOF) redundant hybrid robot (4-DOF serial mechanism and 6-DOF 6-UPS hexapod parallel mechanisms) hydraulically driven with flexible rods under the influence of machining forces. Firstly, the flexibility of the bodies is described using the floating frame of reference method (FFRF). A finite element model (FEM) provided the Craig-Bampton (CB) modes needed for the FFRF. A dynamic model of the system of six closed loop mechanisms was assembled using the constrained Lagrange equations and the Lagrange multiplier method. Subsequently, the reaction forces between the parallel and serial parts were used to study the dynamics of the serial robot. A PID control based on position predictions was implemented independently to control the hydraulic cylinders of the robot. Secondly, in machining, to achieve greater end effector trajectory tracking accuracy for surface quality, a robust control of the actuators for the flexible link has to be deduced. This thesis investigates the intelligent control of a hydraulically driven parallel robot part based on the dynamic model and two schemes of intelligent control for a hydraulically driven parallel mechanism based on the dynamic model: (1) a fuzzy-PID self-tuning controller composed of the conventional PID control and with fuzzy logic, and (2) adaptive neuro-fuzzy inference system-PID (ANFIS-PID) self-tuning of the gains of the PID controller, which are implemented independently to control each hydraulic cylinder of the parallel mechanism based on rod length predictions. The serial component of the hybrid robot can be analyzed using the equilibrium of reaction forces at the universal joint connections of the hexa-element. To achieve precise positional control of the end effector for maximum precision machining, the hydraulic cylinder should be controlled to hold the hexa-element. Thirdly, a finite element approach of multibody systems using the Special Euclidean group SE(3) framework is presented for a parallel mechanism with flexible piston rods under the influence of machining forces. The flexibility of the bodies is described using the nonlinear interpolation method with an exponential map. The equations of motion take the form of a differential algebraic equation on a Lie group, which is solved using a Lie group time integration scheme. The method relies on the local description of motions, so that it provides a singularity-free formulation, and no parameterization of the nodal variables needs to be introduced. The flexible slider constraint is formulated using a Lie group and used for modeling a flexible rod sliding inside a cylinder. The dynamic model of the system of six closed loop mechanisms was assembled using Hamilton’s principle and the Lagrange multiplier method. A linearized hydraulic control system based on rod length predictions was implemented independently to control the hydraulic cylinders. Consequently, the results of the simulations demonstrating the behavior of the robot machine are presented for each case study. In conclusion, this thesis studies the dynamic analysis of a special hybrid (serialparallel) robot for the above-mentioned special task involving the ITER and investigates different control algorithms that can significantly improve machining performance. These analyses and results provide valuable insight into the design and control of the parallel robot with flexible rods.

Adaptive control of Hydraulic Drive

Adaptive control systems are one of the most significant research directions of modern control theory. It is well known that every mechanical appliance’s behavior noticeably depends on environmental changes, functioning-mode parameter changes and changes in technical characteristics of internal functional devices. An adaptive controller involved in control process allows reducing an influence of such changes. In spite of this such type of control methods is applied seldom due to specifics of a controller designing. The work presented in this paper shows the design process of the adaptive controller built by Lyapunov’s function method for the Hydraulic Drive. The calculation needed and the modeling were conducting with MATLAB® software including Simulink® and Symbolic Math Toolbox™ etc. In the work there was applied the Jacobi matrix linearization of the object’s mathematical model and derivation of the suitable reference models based on Newton’s characteristic polynomial. The intelligent adaptive to nonlinearities algorithm for solving Lyapunov’s equation was developed. Developed algorithm works properly but considered plant is not met requirement of functioning with. The results showed confirmation that adaptive systems application significantly increases possibilities in use devices and might be used for correction a system’s behavior dynamics.

Stiffness based trajectory planning and feedforward based vibration suppression control of parallel robot machines

The dissertation proposes two control strategies, which include the trajectory planning and vibration suppression, for a kinematic redundant serial-parallel robot machine, with the aim of attaining the satisfactory machining performance. For a given prescribed trajectory of the robot's end-effector in the Cartesian space, a set of trajectories in the robot's joint space are generated based on the best stiffness performance of the robot along the prescribed trajectory. To construct the required system-wide analytical stiffness model for the serial-parallel robot machine, a variant of the virtual joint method (VJM) is proposed in the dissertation. The modified method is an evolution of Gosselin's lumped model that can account for the deformations of a flexible link in more directions. The effectiveness of this VJM variant is validated by comparing the computed stiffness results of a flexible link with the those of a matrix structural analysis (MSA) method. The comparison shows that the numerical results from both methods on an individual flexible beam are almost identical, which, in some sense, provides mutual validation. The most prominent advantage of the presented VJM variant compared with the MSA method is that it can be applied in a flexible structure system with complicated kinematics formed in terms of flexible serial links and joints. Moreover, by combining the VJM variant and the virtual work principle, a systemwide analytical stiffness model can be easily obtained for mechanisms with both serial kinematics and parallel kinematics. In the dissertation, a system-wide stiffness model of a kinematic redundant serial-parallel robot machine is constructed based on integration of the VJM variant and the virtual work principle. Numerical results of its stiffness performance are reported. For a kinematic redundant robot, to generate a set of feasible joints' trajectories for a prescribed trajectory of its end-effector, its system-wide stiffness performance is taken as the constraint in the joints trajectory planning in the dissertation. For a prescribed location of the end-effector, the robot permits an infinite number of inverse solutions, which consequently yields infinite kinds of stiffness performance. Therefore, a differential evolution (DE) algorithm in which the positions of redundant joints in the kinematics are taken as input variables was employed to search for the best stiffness performance of the robot. Numerical results of the generated joint trajectories are given for a kinematic redundant serial-parallel robot machine, IWR (Intersector Welding/Cutting Robot), when a particular trajectory of its end-effector has been prescribed. The numerical results show that the joint trajectories generated based on the stiffness optimization are feasible for realization in the control system since they are acceptably smooth. The results imply that the stiffness performance of the robot machine deviates smoothly with respect to the kinematic configuration in the adjacent domain of its best stiffness performance. To suppress the vibration of the robot machine due to varying cutting force during the machining process, this dissertation proposed a feedforward control strategy, which is constructed based on the derived inverse dynamics model of target system. The effectiveness of applying such a feedforward control in the vibration suppression has been validated in a parallel manipulator in the software environment. The experimental study of such a feedforward control has also been included in the dissertation. The difficulties of modelling the actual system due to the unknown components in its dynamics is noticed. As a solution, a back propagation (BP) neural network is proposed for identification of the unknown components of the dynamics model of the target system. To train such a BP neural network, a modified Levenberg-Marquardt algorithm that can utilize an experimental input-output data set of the entire dynamic system is introduced in the dissertation. Validation of the BP neural network and the modified Levenberg- Marquardt algorithm is done, respectively, by a sinusoidal output approximation, a second order system parameters estimation, and a friction model estimation of a parallel manipulator, which represent three different application aspects of this method.

Teollisuuspuhaltimille tarkoitetun suunnittelujärjestelmän kehittäminen

Diplomityön tavoitteena oli kehittää Dust Control Systems Oy:n nykyistä suunnittelujärjestelmää yrityksen toiminnan laadun ja suunnittelun tehokkuuden parantamiseksi. Suunnittelun suurin pullonkaula on valmistusdokumenttien tuottaminen, joten keskeinen tehtävä oli dokumenttien laadun parantaminen ja tuottamisen nopeuttaminen. Lisäksi tärkeää oli selkeyttää nykyistä nimikkeiden hallintaa ja ylläpitoa. Kehitystyö keskittyi suurelta osin suunnittelujärjestelmän ohjelmistoympäristön päivittämiseen ja sen muokkaamiseen. Teoriaosuudessa käsiteltiin nykyaikaista suunnittelua ja sen kehittämismahdollisuuksia. Lisäksi tarkasteltiin suunnittelun automatisoinnin tuomia hyötyjä sekä erilaisia tuotannon tehostamismenetelmiä. Kehitysosiossa tutkittiin yrityksen nykyistä suunnittelujärjestelmää ja ohjelmistoympäristöä, tuotteiden asettamia vaatimuksia sekä järjestelmän puutteita. Näihin liittyi suuresti yhteistyö henkilöstön sekä ohjelmistotoimittajan kanssa. Tutkimuksen perusteella ryhdyttiin kehittämään uutta järjestelmäkokonaisuutta, johon liitettiin tarvittavia ohjelmistoja ja päivityksiä. Käyttöönottoa varten ohjelmistot konfiguroitiin yrityksen tarpeita vastaaviksi. Työn tuloksena saatiin kehittyneempi ja nykyaikaisempi suunnittelujärjestelmä ja ohjelmistoympäristö. Suunnittelijoiden työtaakkaa saadaan kevennettyä toistuvien työvaiheiden pidemmälle viedyllä automatisoinnilla. Uudistettu ohjelmistoympäristö luo osaltaan ehtoja ja sääntöjä, jotta virheitä syntyy yhä vähemmän. Lisäksi suunnittelun läpimenoaikaa saadaan lyhennettyä parannetulla dokumenttien tuottamisella.

Maakaasupolttimen säätöjärjestelmän kehittäminen

Jatkuvasti kiristyvät päästörajoitukset pakottavat teollisuuden kehittämään uusia ratkaisuja päästöjen vähentämiseksi. Hiilimonoksidin ja typen oksidien päästörajoitukset ovat erityi-sen tiukat esimerkiksi Kiinassa ja Yhdysvalloissa. Maakaasun ja ilman epätäydellisessä pa-lamisessa muodostuu hiilimonoksidia ja typen oksideja. Käytännön sovelluksissa palaminen on lähes aina epätäydellistä polttoaineen ja ilman epätäydellisen sekoittumisen takia, joten palamisreaktiossa muodostuva savukaasu sisältää edellä mainittuja haitallisia komponentteja lähes poikkeuksetta. Savukaasua voidaan puhdistaa erilaisilla menetelmillä ennen sen pää-tymistä ympäristöön. Tässä diplomityössä esitellään maakaasupoltinjärjestelmän keskeiset komponentit ja aihee-seen liittyvät tarpeelliset käsitteet sekä suunnitellaan polttoaine-ilma-seossuhdesäätö eräälle maakaasupoltinjärjestelmälle. Säädön ensisijaisena tavoitteena on pitää seossuhde mahdolli-simman tarkasti halutussa arvossa savukaasun puhdistuksen kannalta. Lisäksi säädön on tarkoitus taata mahdollisimman hyvä suorituskyky transienttitilanteissa. Järjestelmän eri osien toiminta mallinnetaan ja analysoidaan. Mallinnuksen perusteella suunnitellaan ja simu-loidaan säätöjärjestelmä. Suunniteltu säätöjärjestelmä toteutetaan osaksi polttolaitoksen automaatiojärjestelmää. Mittaustulokset osoittavat, että päästöjen kannalta säätö pitää seossuhteen riittävän tarkasti halutussa arvossa: hiilimonoksidin ja typen oksidien päästöt ovat asetettujen rajojen sisällä. Testiajojen perusteella prosessi on kuitenkin erittäin häiriöinen ja transienttitilanteissa ei saavuteta simulointien mukaista suorituskykyä.

Automatic recognition of fish from video sequences

The problem of automatic recognition of the fish from the video sequences is discussed in this Master’s Thesis. This is a very urgent issue for many organizations engaged in fish farming in Finland and Russia because the process of automation control and counting of individual species is turning point in the industry. The difficulties and the specific features of the problem have been identified in order to find a solution and propose some recommendations for the components of the automated fish recognition system. Methods such as background subtraction, Kalman filtering and Viola-Jones method were implemented during this work for detection, tracking and estimation of fish parameters. Both the results of the experiments and the choice of the appropriate methods strongly depend on the quality and the type of a video which is used as an input data. Practical experiments have demonstrated that not all methods can produce good results for real data, whereas on synthetic data they operate satisfactorily.

Modelling Cutting States in Rough Turning of 34CrNiMo6 Steel

Rough turning is an important form of manufacturing cylinder-symmetric parts. Thus far, increasing the level of automation in rough turning has included process monitoring methods or adaptive turning control methods that aim to keep the process conditions constant. However, in order to improve process safety, quality and efficiency, an adaptive turning control should be transformed into an intelligent machining system optimizing cutting values to match process conditions or to actively seek to improve process conditions. In this study, primary and secondary chatter and chip formation are studied to understand how to measure the effect of these phenomena to the process conditions and how to avoid undesired cutting conditions. The concept of cutting state is used to address the combination of these phenomena and the current use of the power capacity of the lathe. The measures to the phenomena are not developed based on physical measures, but instead, the severity of the measures is modelled against expert opinion. Based on the concept of cutting state, an expert system style fuzzy control system capable of optimizing the cutting process was created. Important aspects of the system include the capability to adapt to several cutting phenomena appearing at once, even if the said phenomena would potentially require conflicting control action.

Determining vehicle drivetrain dynamics using system identification

Target of this book is to propose an approach for modelling drivetrain dynamics in order to design further a vibration control system of a hybrid bus. In this thesis two approaches are examined and compared. First model is obtained by theoretical means: drivetrain is represented as a system of rotating masses, which motion is described with differential equations. Second model is obtained using system identification method: mathematical description of the dynamic behavior of a system is formed based on measured input (torque) and output (speed) data. Then two models are compared and an optimal approach is suggested.

Aktiivisten magneettilaakereiden ohjauslaitteiston vaatimusmäärittely ja toteutus

Aktiivinen magneettilaakeri on järjestelmä joka mahdollistaa pyörivän kappaleen, esimerkiksi sähkökoneen roottorin, leijuttamisen magneettikentässä ilman fyysistä kontaktia vastakappaleiden välillä. Tekniikalla on joitain merkittäviä etuja muihin laakerointijärjestelmiin verrattuna erityisesti suurnopeuksisissa tai puhdastiloissa käytettävissä sähkökäytöissä. Magneettilaakereiden yleistymistä nopeuttaisi ja niiden hintaa laskisi mikäli laakereiden säätöön ja tehonsyöttöön voitaisiin käyttää standardeja teollisuusautomaatiolaitteita erityisesti tätä käyttötarkoitusta varten kehitettyjen laitteiden sijaan. Tässä työssä luodaan menetelmä määrittää vähimmäisvaatimukset aktiivisen magneettilaakerin säätöalgoritmien suorittamiseen käytetylle säätöjärjestelmälle ja anturoinnille sekä laakerin toimintaan tarvittavalle tehoelektroniikalle. Näiden vaatimusten perusteella luodaan katsaus soveltuviin laitteisiin ja kootaan esimerkkikokoonpanot kahdelle erilaiselle magneettilaakeroitavalle kohteelle. Lisäksi työssä esitellään LUT:ssa vuosina 2014-2015 kehitetty magneettilaakerin teholähdeprototyyppi ja selvitetään edellytykset käyttää laitetta laakerijärjestelmän osana.

Press forming of paperboard – advancement of converting tools and process control

Press forming is nowadays one of the most common industrial methods in use for producing deeper trays from paperboard. Demands for material properties like recyclability and sustainability have increased also in the packaging industry, but there are still limitations related to the formability of paperboard. A majority of recent studies have focused on material development, but the potential of the package manufacturing process can also be improved by the development of tooling and process control. In this study, advanced converting tools (die cutting tools and the press forming mould) are created for production scale paperboard tray manufacturing. Also monitoring methods that enable the production of paperboard trays with enhanced quality, and can be utilized in process control are developed. The principles for tray blank preparation, including creasing pattern and die cutting tool design are introduced. The mould heating arrangement and determination of mould clearance are investigated to improve the quality of the press formed trays. The effect of the spring back of the tray walls on the tray dimensions can be managed by adjusting the heat-related process parameters and estimating it at the mould design stage. This enables production speed optimization as the process parameters can be adjusted more freely. Real-time monitoring of pressing force by using multiple force sensors embedded in the mould structure can be utilized in the evaluation of material characteristics on a modified production machinery. Comprehensive process control can be achieved with a combination of measurement of the outer dimensions of the trays and pressing force monitoring. The control method enables detection of defects and tracking changes in the material properties. The optimized converting tools provide a basis for effective operation of the control system.

The Role of HR Management in the Corporate Matrix System

The successful performance of company in the market relates to the quality management of human capital aiming to improve the company's internal performance and external implementation of the core business strategy. Companies with matrix structure focusing on realization and development of innovation and technologies for the uncertain market need to select thoroughly the approach to HR management system. Human resource management has a significant impact on the organization and use a variety of instruments such as corporate information systems to fulfill their functions and objectives. There are three approaches to strategic control management depending on major impact on the major interference in employee decision-making, development of skills and his integration into the business strategy. The mainstream research has focus only on the framework of strategic planning of HR and general productivity of firm, but not on features of organizational structure and corporate software capabilities for human capital. This study tackles the before mentioned challenges, typical for matrix organization, by using the HR control management tools and corporate information system. The detailed analysis of industry producing and selling electromotor and heating equipment in this master thesis provides the opportunity to improve system for HR control and displays its application in the ERP software. The results emphasize the sustainable role of matrix HR input control for creating of independent project teams for matrix structure who are able to respond to various uncertainties of the market and use their skills for improving performance. Corporate information systems can be integrated into input control system by means of output monitoring to regulate and evaluate the processes of teams, using key performance indicators and reporting systems.

MTS2-kokoonpanolinjan ohjauksen modernisointi

Tämä insinöörityö tehtiin Helsingin ammattikorkeakoululle kesän 2006 ja lukuvuoden 2006 - 2007 aikana. Työn tarkoituksena oli yhdistää MTS2-kokoonpanolinjaston kuljetinjärjestelmän erilliset toimilaite- ja anturiväylät yhdeksi hallittavaksi kokonaisuudeksi sekä ottaa käyttöön RFID-saattomuistit kuljetinpalettien ohjauksessa. Työssä tutustuttiin teollisuudessa käytettävien kenttäväylien eri tasoihin, näihin liitettäviin laitteisiin sekä väylien toisiinsa liittämiseen. Linjaston alkuperäistä fyysistä rakennetta muutettiin niin, että se mahdollistaa kahden erillisen ohjausjärjestelmän käytön. AS-iväylään asennettiin IFM DTA 100 -saattomuistinlukijat ja paletteihin RFID-tunnisteet. Työssä onnistuttiin osoittamaan, että kahden rinnakkaisen ohjauksen luominen linjastoon on mahdollista. Toteutuksessa joudutaan kumminkin tilanteisiin, joissa pitää tehdä kompromisseja toisen ohjausjärjestelmän toiminnan yksinkertaisuuden kustannuksella.

Power quality improving with virtual flux-based voltage source line converter

Line converters have become an attractive AC/DC power conversion solution in industrial applications. Line converters are based on controllable semiconductor switches, typically insulated gate bipolar transistors. Compared to the traditional diode bridge-based power converters line converters have many advantageous characteristics, including bidirectional power flow, controllable de-link voltage and power factor and sinusoidal line current. This thesis considers the control of the lineconverter and its application to power quality improving. The line converter control system studied is based on the virtual flux linkage orientation and the direct torque control (DTC) principle. A new DTC-based current control scheme is introduced and analyzed. The overmodulation characteristics of the DTC converter are considered and an analytical equation for the maximum modulation index is derived. The integration of the active filtering features to the line converter isconsidered. Three different active filtering methods are implemented. A frequency-domain method, which is based on selective harmonic sequence elimination, anda time-domain method, which is effective in a wider frequency band, are used inharmonic current compensation. Also, a voltage feedback active filtering method, which mitigates harmonic sequences of the grid voltage, is implemented. The frequency-domain and the voltage feedback active filtering control systems are analyzed and controllers are designed. The designs are verified with practical measurements. The performance and the characteristics of the implemented active filtering methods are compared and the effect of the L- and the LCL-type line filteris discussed. The importance of the correct grid impedance estimate in the voltage feedback active filter control system is discussed and a new measurement-based method to obtain it is proposed. Also, a power conditioning system (PCS) application of the line converter is considered. A new method for correcting the voltage unbalance of the PCS-fed island network is proposed and experimentally validated.

Designing Digital Filters for Servo Systems

The aim of this work was to select an appropriate digital filter for a servo application and to filter the noise from the measurement devices. Low pass filter attenuates the high frequency noise beyond the specified cut-off frequency. Digital lowpass filters in both IIR and FIR responses were designed and experimentally compared to understand their characteristics from the corresponding step responses of the system. Kaiser Windowing and Equiripple methods were selected for FIR response, whereas Butterworth, Chebyshev, InverseChebyshev and Elliptic methods were designed for IIR case. Limitations in digital filter design for a servo system were analysed. Especially the dynamic influences of each designed filter on the control stabilityof the electrical servo drive were observed. The criterion for the selection ofparameters in designing digital filters for servo systems was studied. Control system dynamics was given significant importance and the use of FIR and IIR responses in different situations were compared to justify the selection of suitableresponse in each case. The software used in the filter design was MatLab/Simulink® and dSPACE's DSP application. A speed controlled Permanent Magnet Linear synchronous Motor was used in the experimental work.

Erään hienopaperikoneen paksuusprofiilin hallinta

Työn kirjallisuusosassa perehdytään paperikoneen online-mittarien toimintaan, poikkisuuntaisten profiilien säätämiseen ja kalanterointiin. Työn tavoitteena oli löytää syyt erään hienopaperikoneen heikkoon paksuusprofiiliin ja siitä aiheutuvaan suureen rullahylkymäärään. Syitä heikkoon paksuusprofiiliin on haettu kalanterin, päällystysasemien ja laatusäätöjärjestelmän toiminnoista. Työssä on tutkittu myös karheusprofiilin vaikutusta paksuusmittaukseen. Työssä löydettiin selvä yhteys paperin karheusprofiilin ja paperikoneen paksuusmittarin mittaaman paksuusprofiilin välille. Radan reuna-alueiden karheus suurentaa online-paksuusmittarin mittaustulosta. Karheusprofiili ei kuitenkaan vaikuta laboratoriomittareilla mitattuun paksuusprofiiliin. Paperikoneen onlinepaksuusmittarin mittausvirhe on kompensoitava, jotta paperin todellinen paksuusprofiili saadaan suoraksi. Työssä tehtyjen tutkimusten perusteella muodostettiin ajomalli, jolla ajettiin koeajojakso. Ajomallin päällimmäinen tarkoitus oli kompensoida paperikoneen online- paksuusmittarin mittausvirhe. Koeajo onnistui hyvin. Koeajojakson profiilivioista johtuva rullahylyn määräoli merkittävästi pienempi kuin referenssijakson profiilivioista johtuva rullahylyn määrä.