Dynamic visual servo control of a 4-axis joint tool to track image trajectories during machining complex shapes

A large part of the new generation of computer numerical control systems has adopted an architecture based on robotic systems. This architecture improves the implementation of many manufacturing processes in terms of flexibility, efficiency, accuracy and velocity. This paper presents a 4-axis robot tool based on a joint structure whose primary use is to perform complex machining shapes in some non-contact processes. A new dynamic visual controller is proposed in order to control the 4-axis joint structure, where image information is used in the control loop to guide the robot tool in the machining task. In addition, this controller eliminates the chaotic joint behavior which appears during tracking of the quasi-repetitive trajectories required in machining processes. Moreover, this robot tool can be coupled to a manipulator robot in order to form a multi-robot platform for complex manufacturing tasks. Therefore, the robot tool could perform a machining task using a piece grasped from the workspace by a manipulator robot. This manipulator robot could be guided by using visual information given by the robot tool, thereby obtaining an intelligent multi-robot platform controlled by only one camera.

Design methodology for the servo control of high speed multi-axis machinery (BL): decoupling and synchronisation of a generic machine by blockwise decentralised MIMO control

Traditional machinery for manufacturing processes are characterised by actuators powered and co-ordinated by mechanical linkages driven from a central drive. Increasingly, these linkages are replaced by independent electrical drives, each performs a different task and follows a different motion profile, co-ordinated by computers. A design methodology for the servo control of high speed multi-axis machinery is proposed, based on the concept of a highly adaptable generic machine model. In addition to the dynamics of the drives and the loads, the model includes the inherent interactions between the motion axes and thus provides a Multi-Input Multi-Output (MIMO) description. In general, inherent interactions such as structural couplings between groups of motion axes are undesirable and needed to be compensated. On the other hand, imposed interactions such as the synchronisation of different groups of axes are often required. It is recognised that a suitable MIMO controller can simultaneously achieve these objectives and reconciles their potential conflicts. Both analytical and numerical methods for the design of MIMO controllers are investigated. At present, it is not possible to implement high order MIMO controllers for practical reasons. Based on simulations of the generic machine model under full MIMO control, however, it is possible to determine a suitable topology for a blockwise decentralised control scheme. The Block Relative Gain array (BRG) is used to compare the relative strength of closed loop interactions between sub-systems. A number of approaches to the design of the smaller decentralised MIMO controllers for these sub-systems has been investigated. For the purpose of illustration, a benchmark problem based on a 3 axes test rig has been carried through the design cycle to demonstrate the working of the design methodology.

Dynamics and Control Strategies for a Butanol Fermentation Process

Fundação de Amparo à Pesquisa do Estado de São Paulo (FAPESP)

Kolmen vapausasteen akseliston ohjaaminen mikroprosessorilla

Diplomityön tavoitteena on tehdä lasertyöasemalle liikkuva kolmen vapausasteen akselisto liikuttamaan laser-laitteiston skanneripäätä. Liikkeen tarkkuus ja tarkka toistettavuus ovat tärkeitä. Moottoreiden liikkeen nopeus sekä kiihdytys- ja jarrutusparametrien täytyy olla määriteltävissä jokaiselle moottorille erikseen. Kolmen vapausasteen akselisto muodostetaan käyttäen kolmea askelmoottoria ja lineaarivaihteistoa. Akselisto liikkuu vaaka-, pysty-, ja syvyyssuunnassa. Työssä kehitetään C-kielinen ohjelma käytettävälle prosessorille ja suunnitellaan ohjainkortti lopullista prototyyppiä varten. Moottoreiden ohjaus ja hallinta toteutetaan AT91S256-prosessorilla, jota ohjataan tietokoneen avulla RS-232 -väylää käyttäen. Vaatimuksena on myös mahdollisuus ohjata askelmoottorin sijasta servomoottoreita samalla ohjelmalla. Tietokoneen käyttöliittymä suunnitellaan erikseen.

How soccer players head the ball: a test of optic acceleration cancellation theory with virtual reality

We measured the movements of soccer players heading a football in a fully immersive virtual reality environment. In mid-flight the ball’s trajectory was altered from its normal quasi-parabolic path to a linear one, producing a jump in the rate of change of the angle of elevation of gaze (α) from player to ball. One reaction time later the players adjusted their speed so that the rate of change of α increased when it had been reduced and reduced it when it had been increased. Since the result of the player’s movement was to regain a value of the rate of change close to that before the disturbance, the data suggest that the players have an expectation of, and memory for, the pattern that the rate of change of α will follow during the flight. The results support the general claim that players intercepting balls use servo control strategies and are consistent with the particular claim of Optic Acceleration Cancellation theory that the servo strategy is to allow α to increase at a steadily decreasing rate.

Automação de equipamento triaxial visando o estudo de solos tropicais cimentados

O presente trabalho descreve o desenvolvimento de um equipamento de ensaios triaxiais, com aquisição automática de dados e controle automático de trajetórias de tensões, e resultados de ensaios utilizando este equipamento. Medidores locais de deformaçòes axial e radial foram utilizados viabilizando a análise do comportamento de solos a baixos níveis de deformações. O equipamento foi construído com componentes já existentes e elementos de baixo custo. Um programa de controle foi desenvolvido para controlar tanto trajetórias lineares de tensões como a trajetória de deformação radial nula. O sistema foi desenvolvido visando o estudo de solos tropicais cimentados, tendo sido utilizado na execução de ensaios triaxiais em um solo residual regional de arenito - arenito Botucatu. Os resultados evidenciam a adequabilidade do sistema construído ao estudo proposto tornando possível a determinação de importantes características de comportamento deste solo.

Visual Servoing for the Robotenis System: a Strategy for a 3 DOF Parallel Robot to Hit a Ping-Pong Ball

This article describes a new visual servo control and strategies that are used to carry out dynamic tasks by the Robotenis platform. This platform is basically a parallel robot that is equipped with an acquisition and processing system of visual information, its main feature is that it has a completely open architecture control, and planned in order to design, implement, test and compare control strategies and algorithms (visual and actuated joint controllers). Following sections describe a new visual control strategy specially designed to track and intercept objects in 3D space. The results are compared with a controller shown in previous woks, where the end effector of the robot keeps a constant distance from the tracked object. In this work, the controller is specially designed in order to allow changes in the tracking reference. Changes in the tracking reference can be used to grip an object that is under movement, or as in this case, hitting a hanging Ping-Pong ball. Lyapunov stability is taken into account in the controller design.

Realization of fractional-order controllers: analysis, synthesis and application to the velocity control of a servo system

The synthesis and application of fractional-order controllers is now an active research field. This article investigates the use of fractional-order PID controllers in the velocity control of an experimental modular servo system. The systern consists of a digital servomechanism and open-architecture software environment for real-time control experiments using MATLAB/Simulink. Different tuning methods will be employed, such as heuristics based on the well-known Ziegler Nichols rules, techniques based on Bode’s ideal transfer function and optimization tuning methods. Experimental responses obtained from the application of the several fractional-order controllers are presented and analyzed. The effectiveness and superior performance of the proposed algorithms are also compared with classical integer-order PID controllers.

Effect of fractional orders in the velocity control of a servo system

The application of fractional-order PID controllers is now an active field of research. This article investigates the effect of fractional (derivative and integral) orders upon system's performance in the velocity control of a servo system. The servo system consists of a digital servomechanism and an open-architecture software environment for real-time control experiments using MATLAB/Simulink tools. Experimental responses are presented and analyzed, showing the effectiveness of fractional controllers. Comparison with classical PID controllers is also investigated.

On Modelling, System Identification and Control of Servo-Systems with a Flexible Load

The present study was done with two different servo-systems. In the first system, a servo-hydraulic system was identified and then controlled by a fuzzy gainscheduling controller. The second servo-system, an electro-magnetic linear motor in suppressing the mechanical vibration and position tracking of a reference model are studied by using a neural network and an adaptive backstepping controller respectively. Followings are some descriptions of research methods. Electro Hydraulic Servo Systems (EHSS) are commonly used in industry. These kinds of systems are nonlinearin nature and their dynamic equations have several unknown parameters.System identification is a prerequisite to analysis of a dynamic system. One of the most promising novel evolutionary algorithms is the Differential Evolution (DE) for solving global optimization problems. In the study, the DE algorithm is proposed for handling nonlinear constraint functionswith boundary limits of variables to find the best parameters of a servo-hydraulic system with flexible load. The DE guarantees fast speed convergence and accurate solutions regardless the initial conditions of parameters. The control of hydraulic servo-systems has been the focus ofintense research over the past decades. These kinds of systems are nonlinear in nature and generally difficult to control. Since changing system parameters using the same gains will cause overshoot or even loss of system stability. The highly non-linear behaviour of these devices makes them ideal subjects for applying different types of sophisticated controllers. The study is concerned with a second order model reference to positioning control of a flexible load servo-hydraulic system using fuzzy gainscheduling. In the present research, to compensate the lack of dampingin a hydraulic system, an acceleration feedback was used. To compare the results, a pcontroller with feed-forward acceleration and different gains in extension and retraction is used. The design procedure for the controller and experimental results are discussed. The results suggest that using the fuzzy gain-scheduling controller decrease the error of position reference tracking. The second part of research was done on a PermanentMagnet Linear Synchronous Motor (PMLSM). In this study, a recurrent neural network compensator for suppressing mechanical vibration in PMLSM with a flexible load is studied. The linear motor is controlled by a conventional PI velocity controller, and the vibration of the flexible mechanism is suppressed by using a hybrid recurrent neural network. The differential evolution strategy and Kalman filter method are used to avoid the local minimum problem, and estimate the states of system respectively. The proposed control method is firstly designed by using non-linear simulation model built in Matlab Simulink and then implemented in practical test rig. The proposed method works satisfactorily and suppresses the vibration successfully. In the last part of research, a nonlinear load control method is developed and implemented for a PMLSM with a flexible load. The purpose of the controller is to track a flexible load to the desired position reference as fast as possible and without awkward oscillation. The control method is based on an adaptive backstepping algorithm whose stability is ensured by the Lyapunov stability theorem. The states of the system needed in the controller are estimated by using the Kalman filter. The proposed controller is implemented and tested in a linear motor test drive and responses are presented.

On sliding mode control ofhydraulic servo systems and a manipulator

The aim of the study is to developa novel robust controller based on sliding mode control technique for the hydraulic servo system with flexible load and for a flexible manipulator with the lift and jib hydraulic actuators. For the purpose of general control design, a dynamic model is derived describing the principle physical behavior for both the hydraulic servo system and the flexible hydraulic manipulator. The mechanism of hydraulic servo systems is described by basic mathematical equations of fluid powersystems and the dynamics of flexible manipulator is modeled by the assumed modemethod. The controller is constructed so as to track desired trajectories in the presence of model imprecision. Experimental and simulation results demonstratethat sliding mode control has benefits which can be used to guarantee stabilityin uncertain systems and improve the system performance and load tolerance.

Comparison between dSPACE and NI systems based on real-time intelligent control of a teleoperated hydraulic servo system

The Laboratory of Intelligent Machine researches and develops energy-efficient power transmissions and automation for mobile construction machines and industrial processes. The laboratory's particular areas of expertise include mechatronic machine design using virtual technologies and simulators and demanding industrial robotics. The laboratory has collaborated extensively with industrial actors and it has participated in significant international research projects, particularly in the field of robotics. For years, dSPACE tools were the lonely hardware which was used in the lab to develop different control algorithms in real-time. dSPACE's hardware systems are in widespread use in the automotive industry and are also employed in drives, aerospace, and industrial automation. But new competitors are developing new sophisticated systems and their features convinced the laboratory to test new products. One of these competitors is National Instrument (NI). In order to get to know the specifications and capabilities of NI tools, an agreement was made to test a NI evolutionary system. This system is used to control a 1-D hydraulic slider. The objective of this research project is to develop a control scheme for the teleoperation of a hydraulically driven manipulator, and to implement a control algorithm between human and machine interaction, and machine and task environment interaction both on NI and dSPACE systems simultaneously and to compare the results.

Novel control, haptic and calibration methods for teleoperated electrohydraulic servo systems

The aim of this thesis is to propose a novel control method for teleoperated electrohydraulic servo systems that implements a reliable haptic sense between the human and manipulator interaction, and an ideal position control between the manipulator and the task environment interaction. The proposed method has the characteristics of a universal technique independent of the actual control algorithm and it can be applied with other suitable control methods as a real-time control strategy. The motivation to develop this control method is the necessity for a reliable real-time controller for teleoperated electrohydraulic servo systems that provides highly accurate position control based on joystick inputs with haptic capabilities. The contribution of the research is that the proposed control method combines a directed random search method and a real-time simulation to develop an intelligent controller in which each generation of parameters is tested on-line by the real-time simulator before being applied to the real process. The controller was evaluated on a hydraulic position servo system. The simulator of the hydraulic system was built based on Markov chain Monte Carlo (MCMC) method. A Particle Swarm Optimization algorithm combined with the foraging behavior of E. coli bacteria was utilized as the directed random search engine. The control strategy allows the operator to be plugged into the work environment dynamically and kinetically. This helps to ensure the system has haptic sense with high stability, without abstracting away the dynamics of the hydraulic system. The new control algorithm provides asymptotically exact tracking of both, the position and the contact force. In addition, this research proposes a novel method for re-calibration of multi-axis force/torque sensors. The method makes several improvements to traditional methods. It can be used without dismantling the sensor from its application and it requires smaller number of standard loads for calibration. It is also more cost efficient and faster in comparison to traditional calibration methods. The proposed method was developed in response to re-calibration issues with the force sensors utilized in teleoperated systems. The new approach aimed to avoid dismantling of the sensors from their applications for applying calibration. A major complication with many manipulators is the difficulty accessing them when they operate inside a non-accessible environment; especially if those environments are harsh; such as in radioactive areas. The proposed technique is based on design of experiment methodology. It has been successfully applied to different force/torque sensors and this research presents experimental validation of use of the calibration method with one of the force sensors which method has been applied to.

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.

Modeling and Synthesis of Tracking Control for the Belt Drive System

Usingof belt for high precision applications has become appropriate because of the rapid development in motor and drive technology as well as the implementation of timing belts in servo systems. Belt drive systems provide highspeed and acceleration, accurate and repeatable motion with high efficiency, long stroke lengths and low cost. Modeling of a linear belt-drive system and designing its position control are examined in this work. Friction phenomena and position dependent elasticity of the belt are analyzed. Computer simulated results show that the developed model is adequate. The PID control for accurate tracking control and accurate position control is designed and applied to the real test setup. Both the simulation and the experimental results demonstrate that the designed controller meets the specified performance specifications.