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.

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.

Development of a Control System for a Tele Operated Mobile Robot

Mobile robots are capable of performing spatial displacement motions in different environments. This motions can be calculated based on sensorial data (autonomous robot) or given by an operator (tele operated robot). This thesis is focused on the latter providing the control architecture which bridges the tele operator and the robot’s locomotion system and end effectors. Such a task might prove overwhelming in cases where the robot comprises a wide variety of sensors and actuators hence a relatively new option was selected: Robot Operating System (ROS). The control system of a new robot will be sketched and tested in a simulation model using ROS together with Gazebo in order to determine the viability of such a system. The simulated model will be based on the projected shape and main features of the real machine. A stability analysis will be performed first theoretically and afterwards using the developed model. This thesis concluded that both the physical properties and the control architecture are feasible and stable settling up the ground for further work with the same robot.

Control of a line robot system with Embedded Linux

Many, if not all, aspects of our everyday lives are related to computers and control. Microprocessors and wireless communications are involved in our lives. Embedded systems are an attracting field because they combine three key factors, small size, low power consumption and high computing capabilities. The aim of this thesis is to study how Linux communicates with the hardware, to answer the question if it is possible to use an operating system like Debian for embedded systems and finally, to build a Mechatronic real time application. In the thesis a presentation of Linux and the Xenomai real time patch is given, the bootloader and communication with the hardware is analyzed. BeagleBone the evaluation board is presented along with the application project consisted of a robot cart with a driver circuit, a line sensor reading a black line and two Xbee antennas. It makes use of Xenomai threads, the real time kernel. According to the obtained results, Linux is able to operate as a real time operating system. The issue of future research is the area of embedded Linux is also discussed.

Analysis and Control of Robot Manipulators with Kinematic Redundancy

A closed-form solution formula for the kinematic control of manipulators with redundancy is derived, using the Lagrangian multiplier method. Differential relationship equivalent to the Resolved Motion Method has been also derived. The proposed method is proved to provide with the exact equilibrium state for the Resolved Motion Method. This exactness in the proposed method fixes the repeatability problem in the Resolved Motion Method, and establishes a fixed transformation from workspace to the joint space. Also the method, owing to the exactness, is demonstrated to give more accurate trajectories than the Resolved Motion Method. In addition, a new performance measure for redundancy control has been developed. This measure, if used with kinematic control methods, helps achieve dexterous movements including singularity avoidance. Compared to other measures such as the manipulability measure and the condition number, this measure tends to give superior performances in terms of preserving the repeatability property and providing with smoother joint velocity trajectories. Using the fixed transformation property, Taylor's Bounded Deviation Paths Algorithm has been extended to the redundant manipulators.

Modeling Robot Dynamic Performance for Endpoint Force Control

This research aims to understand the fundamental dynamic behavior of servo-controlled machinery in response to various types of sensory feedback. As an example of such a system, we study robot force control, a scheme which promises to greatly expand the capabilities of industrial robots by allowing manipulators to interact with uncertain and dynamic tasks. Dynamic models are developed which allow the effects of actuator dynamics, structural flexibility, and workpiece interaction to be explored in the frequency and time domains. The models are used first to explain the causes of robot force control instability, and then to find methods of improving this performance.

The PHD: A Planar, Harmonic Drive Robot for Joint Torque Control

This thesis details the development of a model of a seven degree of freedom manipulator for position control. Then, it goes on to discuss the design and construction of a the PHD, a robot built to serve two purposes: first, to perform research on joint torque control schemes, and second, to determine the important dynamic characteristics of the Harmonic Drive. The PHD, is a planar, three degree of freedom arm with torque sensors integral to each joint. Preliminary testing has shown that a simple linear spring model of the Harmonic Drive's flexibility is suitable in many situations.

Modeling, Estimation, and Control of Robot-Soil Interactions

This thesis presents the development of hardware, theory, and experimental methods to enable a robotic manipulator arm to interact with soils and estimate soil properties from interaction forces. Unlike the majority of robotic systems interacting with soil, our objective is parameter estimation, not excavation. To this end, we design our manipulator with a flat plate for easy modeling of interactions. By using a flat plate, we take advantage of the wealth of research on the similar problem of earth pressure on retaining walls. There are a number of existing earth pressure models. These models typically provide estimates of force which are in uncertain relation to the true force. A recent technique, known as numerical limit analysis, provides upper and lower bounds on the true force. Predictions from the numerical limit analysis technique are shown to be in good agreement with other accepted models. Experimental methods for plate insertion, soil-tool interface friction estimation, and control of applied forces on the soil are presented. In addition, a novel graphical technique for inverting the soil models is developed, which is an improvement over standard nonlinear optimization. This graphical technique utilizes the uncertainties associated with each set of force measurements to obtain all possible parameters which could have produced the measured forces. The system is tested on three cohesionless soils, two in a loose state and one in a loose and dense state. The results are compared with friction angles obtained from direct shear tests. The results highlight a number of key points. Common assumptions are made in soil modeling. Most notably, the Mohr-Coulomb failure law and perfectly plastic behavior. In the direct shear tests, a marked dependence of friction angle on the normal stress at low stresses is found. This has ramifications for any study of friction done at low stresses. In addition, gradual failures are often observed for vertical tools and tools inclined away from the direction of motion. After accounting for the change in friction angle at low stresses, the results show good agreement with the direct shear values.

Virtual Model Control of a Biped Walking Robot

The transformation from high level task specification to low level motion control is a fundamental issue in sensorimotor control in animals and robots. This thesis develops a control scheme called virtual model control which addresses this issue. Virtual model control is a motion control language which uses simulations of imagined mechanical components to create forces, which are applied through joint torques, thereby creating the illusion that the components are connected to the robot. Due to the intuitive nature of this technique, designing a virtual model controller requires the same skills as designing the mechanism itself. A high level control system can be cascaded with the low level virtual model controller to modulate the parameters of the virtual mechanisms. Discrete commands from the high level controller would then result in fluid motion. An extension of Gardner's Partitioned Actuator Set Control method is developed. This method allows for the specification of constraints on the generalized forces which each serial path of a parallel mechanism can apply. Virtual model control has been applied to a bipedal walking robot. A simple algorithm utilizing a simple set of virtual components has successfully compelled the robot to walk eight consecutive steps.

Virtual Model Control of a Hexapod Walking Robot

Since robots are typically designed with an individual actuator at each joint, the control of these systems is often difficult and non-intuitive. This thesis explains a more intuitive control scheme called Virtual Model Control. This thesis also demonstrates the simplicity and ease of this control method by using it to control a simulated walking hexapod. Virtual Model Control uses imagined mechanical components to create virtual forces, which are applied through the joint torques of real actuators. This method produces a straightforward means of controlling joint torques to produce a desired robot behavior. Due to the intuitive nature of this control scheme, the design of a virtual model controller is similar to the design of a controller with basic mechanical components. The ease of this control scheme facilitates the use of a high level control system which can be used above the low level virtual model controllers to modulate the parameters of the imaginary mechanical components. In order to apply Virtual Model Control to parallel mechanisms, a solution to the force distribution problem is required. This thesis uses an extension of Gardner`s Partitioned Force Control method which allows for the specification of constrained degrees of freedom. This virtual model control technique was applied to a simulated hexapod robot. Although the hexapod is a highly non-linear, parallel mechanism, the virtual models allowed text-book control solutions to be used while the robot was walking. Using a simple linear control law, the robot walked while simultaneously balancing a pendulum and tracking an object.

Control de posició del robot wifibot

Aquest projecte pretén presentar de forma clara i detallada l’estructura i el funcionament del robot així com dels components que el conformen. Aquesta informació és de vital importància a l’hora de desenvolupar aplicacions per al robot. Un cop descrites les característiques del robot s’analitzaran les eines necessàries i/o disponibles per poder desenvolupar programari per cada nivell de la forma més senzilla i eficient possible. Posteriorment s’analitzaran els diferents nivells de programació i se’n contrastaran els avantatges i els inconvenients de cada un. Aquest anàlisi es començarà fent pel nivell més alt i anirà baixant amb la intenció de no entrar en nivells més baixos del necessari. Baixar un nivell en la programació suposa haver de crear aplicacions sempre compatibles amb els nivells superiors de forma que com més es baixa més augmenta la complexitat. A partir d’aquest anàlisi s’ha arribat a la conclusió que per tal d’aprofitar totes les prestacions del robot és precís arribar a programar en el nivell més baix del robot. Finalment l’objectiu és obtenir una sèrie de programes per cada nivell que permetin controlar el robot i fer-lo seguir senzilles trajectòries

Experimental Modeling and Control Strategies on an Open Mobile Robot Platform PRIM

This research work deals with the problem of modeling and design of low level speed controller for the mobile robot PRIM. The main objective is to develop an effective educational tool. On one hand, the interests in using the open mobile platform PRIM consist in integrating several highly related subjects to the automatic control theory in an educational context, by embracing the subjects of communications, signal processing, sensor fusion and hardware design, amongst others. On the other hand, the idea is to implement useful navigation strategies such that the robot can be served as a mobile multimedia information point. It is in this context, when navigation strategies are oriented to goal achievement, that a local model predictive control is attained. Hence, such studies are presented as a very interesting control strategy in order to develop the future capabilities of the system

Predictive motion control of a mirosot mobile robot

This paper discusses predictive motion control of a MiRoSoT robot. The dynamic model of the robot is deduced by taking into account the whole process - robot, vision, control and transmission systems. Based on the obtained dynamic model, an integrated predictive control algorithm is proposed to position precisely with either stationary or moving obstacle avoidance. This objective is achieved automatically by introducing distant constraints into the open-loop optimization of control inputs. Simulation results demonstrate the feasibility of such control strategy for the deduced dynamic model

Local model predictive control for navigation of a wheeled mobile robot using monocular information

Aquesta tesi està inspirada en els agents naturals per tal de planificar de manera dinàmica la navegació d'un robot diferencial de dues rodes. Les dades dels sistemes de percepció són integrades dins una graella d'ocupació de l'entorn local del robot. La planificació de les trajectòries es fa considerant la configuració desitjada del robot, així com els vértexs més significatius dels obstacles més propers. En el seguiment de les trajectòries s'utilitzen tècniques locals de control predictiu basades en el model, amb horitzons de predicció inferiors a un segon. La metodologia emprada és validada mitjançant nombrosos experiments.

A proposal of a behavior-based control architecture with reinforcement learning for an autonomous underwater robot

Aquesta tesi proposa l'ús d'un seguit de tècniques pel control a alt nivell d'un robot autònom i també per l'aprenentatge automàtic de comportaments. L'objectiu principal de la tesis fou el de dotar d'intel·ligència als robots autònoms que han d'acomplir unes missions determinades en entorns desconeguts i no estructurats. Una de les premisses tingudes en compte en tots els passos d'aquesta tesis va ser la selecció d'aquelles tècniques que poguessin ésser aplicades en temps real, i demostrar-ne el seu funcionament amb experiments reals. El camp d'aplicació de tots els experiments es la robòtica submarina. En una primera part, la tesis es centra en el disseny d'una arquitectura de control que ha de permetre l'assoliment d'una missió prèviament definida. En particular, la tesis proposa l'ús de les arquitectures de control basades en comportaments per a l'assoliment de cada una de les tasques que composen la totalitat de la missió. Una arquitectura d'aquest tipus està formada per un conjunt independent de comportaments, els quals representen diferents intencions del robot (ex.: "anar a una posició", "evitar obstacles",...). Es presenta una recerca bibliogràfica sobre aquest camp i alhora es mostren els resultats d'aplicar quatre de les arquitectures basades en comportaments més representatives a una tasca concreta. De l'anàlisi dels resultats se'n deriva que un dels factors que més influeixen en el rendiment d'aquestes arquitectures, és la metodologia emprada per coordinar les respostes dels comportaments. Per una banda, la coordinació competitiva és aquella en que només un dels comportaments controla el robot. Per altra banda, en la coordinació cooperativa el control del robot és realitza a partir d'una fusió de totes les respostes dels comportaments actius. La tesis, proposa un esquema híbrid d'arquitectura capaç de beneficiar-se dels principals avantatges d'ambdues metodologies. En una segona part, la tesis proposa la utilització de l'aprenentatge per reforç per aprendre l'estructura interna dels comportaments. Aquest tipus d'aprenentatge és adequat per entorns desconeguts i el procés d'aprenentatge es realitza al mateix temps que el robot està explorant l'entorn. La tesis presenta també un estat de l'art d'aquest camp, en el que es detallen els principals problemes que apareixen en utilitzar els algoritmes d'aprenentatge per reforç en aplicacions reals, com la robòtica. El problema de la generalització és un dels que més influeix i consisteix en permetre l'ús de variables continues sense augmentar substancialment el temps de convergència. Després de descriure breument les principals metodologies per generalitzar, la tesis proposa l'ús d'una xarxa neural combinada amb l'algoritme d'aprenentatge per reforç Q_learning. Aquesta combinació proporciona una gran capacitat de generalització i una molt bona disposició per aprendre en tasques de robòtica amb exigències de temps real. No obstant, les xarxes neurals són aproximadors de funcions no-locals, el que significa que en treballar amb un conjunt de dades no homogeni es produeix una interferència: aprendre en un subconjunt de l'espai significa desaprendre en la resta de l'espai. El problema de la interferència afecta de manera directa en robòtica, ja que l'exploració de l'espai es realitza sempre localment. L'algoritme proposat en la tesi té en compte aquest problema i manté una base de dades representativa de totes les zones explorades. Així doncs, totes les mostres de la base de dades s'utilitzen per actualitzar la xarxa neural, i per tant, l'aprenentatge és homogeni. Finalment, la tesi presenta els resultats obtinguts amb la arquitectura de control basada en comportaments i l'algoritme d'aprenentatge per reforç. Els experiments es realitzen amb el robot URIS, desenvolupat a la Universitat de Girona, i el comportament après és el seguiment d'un objecte mitjançant visió per computador. La tesi detalla tots els dispositius desenvolupats pels experiments així com les característiques del propi robot submarí. Els resultats obtinguts demostren la idoneïtat de les propostes en permetre l'aprenentatge del comportament en temps real. En un segon apartat de resultats es demostra la capacitat de generalització de l'algoritme d'aprenentatge mitjançant el "benchmark" del "cotxe i la muntanya". Els resultats obtinguts en aquest problema milloren els resultats d'altres metodologies, demostrant la millor capacitat de generalització de les xarxes neurals.