The field of robotics is in continuous development. Driving forces for the development are higher demands on robot accuracy and being more cost effective in the development process. To reduce costs, product development is moving towards virtual prototyping to enable early analysis and testing. This process demands realistic models and modelling is therefore of utmost importance. In the process of modelling high fidelity robot dynamics many different physical aspects have to be taken into account. Phenomena studied in this thesis stretch from where to introduce flexibilities, mechanical and dynamical coupling effects, and how to describe friction. By using a bottom up approach the effects are analysed individually to evaluate their contribution both to accuracy and computationalcomplexity. A strategy for how to model a flexible parallel linkage manipulator by introducing some crucial simplifications is presented. The elastic parameters are identified using a frequency domain identification algorithm developed in [Wernholt, 2007] and shows that the presented method works well up to a certain level of fidelity. Friction is modelled using empirically derived static and dynamic models. Evaluation of accuracy is conducted through identification of friction models for a real manipulator and it is seen that to capture all existing phenomena in low velocities  a dynamic model is needed. It is also seen that friction characteristics vary with temperature and a Kalman filter is suggested to adaptively estimate friction parameters. Finally an implementation of a flexible manipulator model using the software MapleSim is presented. The tool severely simplifies the process of modelling manipulators and enables for export to other environment such as simulation, optimization and control.

The purpose of the thesis is to achieve a hybrid force and motion control method of parallel manipulators working in a constrained environment, in the presence of joint flexibility that occurs at the actuated joints. A flexible joint is modeled and the equations of motion of the parallel manipulator are derived by using the Lagrange formulation. The structural damping of the active joints, viscous friction at the passive joints and the rotor damping are also considered in the model. It is shown that in a flexible joint manipulator, the acceleration level inverse dynamic equations are singular because the control torques do not have instantaneous effect on the manipulator end-effector contact forces and accelerations due to the flexibility. Implicit numerical integration methods are utilized for solving the singular equations. As a case study, a two legged constrained planar parallel manipulator with three degrees of freedom is simulated to illustrate the performance of the method.

The purpose of this thesis is to develop a position control method for parallel manipulators so that the end effector can follow a desired trajectory specified in the task space where joint flexibility that occurs at the actuated joints is also taken into consideration. At the beginning of the study, a flexible joint is modeled, and the equations of motion of the parallel manipulators are derived for both actuator variables and joint variables by using the Lagrange formulation under three assumptions regarding dynamic coupling between the links and the actuators. These equations of motion are transformed to an input/output relation between the actuator torques and the actuated joint variables to achieve the trajectory tracking control. Moreover, the singular configurations of the parallel manipulators are explained. As a case study, a three degree of freedom, two legged planar parallel manipulator is simulated considering joint flexibility. The structural damping of the active joints, viscous friction at the passive joints and the rotor damping are also considered throughout the study. Matlab&reg / and Simulink&reg / softwares are used for the simulations. The results of the simulations reveal that steady state errors are negligibly small and good tracking performances can be achieved.

Les besoins croissants en moyens de télécommunication nécessitent le développement de grands réflecteurs spatiaux paraboliques. Un nouveau concept d'architecture d'antenne déployable est ainsi proposé en partenariat avec le CNES. La conception de son ossature repose sur une revue de solutions pour faire appel à des mécanismes de ciseau associés à des articulations flexibles. Des modélisations numériques par éléments finis sont d'abord développées pour simuler le déploiement par restitution de l'énergie emmagasinée dans ces articulations lors du pliage. Un démonstrateur expérimental avec un système de compensation gravitaire est ensuite réalisé. Des essais et mesures sont effectués pour caractériser son comportement en statique et dynamique puis sont comparés avec les résultats issus des simulations. La mise en forme de la surface réflectrice par un réseau de câbles est étudiée par la suite. Une méthode innovante de recherche de forme permettant d'obtenir un réseau parabolique en tension uniforme est alors proposée. Elle est appliquée à différentes typologies de réseaux et l'erreur de surface résultant de sa facettisation est évaluée. Le procédé d'accrochage de ce réseau sur l'ossature de l'antenne est également traité. / The growing needs in telecommunications require the development of large parabolic reflectors. A new conceptual design for the architecture of a deployable antenna is therefore proposed in partnership with the CNES. The design of its framework is based on a review of solutions which leads to scissor mechanisms associated with flexible joints. Numerical modelings with finite elements are first developed to simulate the deployment by the release of the energy stored in the joints after the folding. An experimental prototype with a gravity compensation device is then realized. Tests and measurements are performed to characterize the static and dynamic behavior and compared with the results of simulations. Shaping of the reflective surface by a net of cables is then studied. A new form-finding method for obtaining a net with a uniform tension is then proposed. It is applied to different parabolic typologies of nets and the error due to surface faceting is evaluated. The process of net attachment on the antenna rim structure is also treated.

During fast point-to-point motion, the inherent joint flexibility could be detrimental in terms of residual vibration. Aiming to minimize the vibration, the command shaping method has been developed so as to remove critical energy from the input profile at resonant frequencies. Since this method requires information of a physical model in order to find the target frequencies, the quality of the shaped command profile relies on the accuracy of the model parameter estimation. Therefore, in this work, a system identification method using Instrumental Variables is applied from the literature. Compared with the classic Ordinary Least Square method, the IV approach has successfully improved the estimation of parameters, based on simulation results. The accuracy of parameter estimation influences the command profile, as does the feedback controller. In this work, starting from a mathematical derivation with a mismatch model due to a feedback controller called Computed Torque Control, insight for the closed-loop system is given with regard to the interaction between control gains and the actual resonant frequencies. It is found that the control gain is able to modify the actual resonant frequency curve, and push it into or out of the shaping bounds which are generated from the command shaping method. Further analysis based on the simulation results shows that the overlap area between the shaping bounds and the actual frequencies affects the level of residual vibration. In light of this fact, an optimal control gain exists and is found when the estimation error is in a certain range. At the end, recommendations for choosing the control gains are provided.

La problématique traitée dans cette thèse concerne la commande de robots manipulateurs à articulations flexibles. Les méthodes développées visent à satisfaire les spécifications de performance et de robustesse en suivi de trajectoire, ainsi qu’à assurer un niveau de sécurité compatible avec un scénario de fonctionnement interactif dans lequel l’homme et le robot partagent un même espace de travail. Seules les mesures moteur sont utilisées dans un contexte d’instrumentation réduite. Le premier objectif de performance de la commande de mouvement est atteint grâce à l’identification expérimentale d’un modèle flexible représentatif du système, et l’usage de ce modèle pour la synthèse de lois de commande avancées intégrées au sein d’une structure cascade. Deux approches complémentaires fondées d’une part sur la commande prédictive de type GPC (Generalized Predictive Control), et d’autre part sur la commande Hinfini, sont considérées pour la synthèse de lois de commande à deux degrés de liberté, prédictives et robustes. Les performances de ces deux approches sont analysées et évaluées expérimentalement. Le deuxième objectif de sécurité est abordé à travers un algorithme de détection de collisions du robot avec son environnement, sans capteur d’effort et en présence d’incertitudes de modélisation. Afin de séparer efficacement les effets dynamiques des collisions de ceux des erreurs de modélisation, une stratégie adaptative de filtrage et de décision tenant compte de l’état du système est proposée. La validation expérimentale montre une très bonne sensibilité de détection, compatible avec les normes et les recommandations de sécurité relatives à la robotique collaborative. / The present thesis addresses the problem of motion control of flexible-joint robot manipulators using motor sensors only. The global objective is to guarantee tracking performance and robustness with respect to modeling uncertainties, together with safe human-robot interaction in a collaborative scenario where the robot and the human operator share the same workspace. The first objective of performance is achieved through the experimental identification of a flexible model of the system and the use of this model for the design of advanced control laws implemented in a cascade structure. Two complementary approaches, based either on predictive (Generalized Predictive Control, GPC) or Hinfinity control frameworks, are considered to design predictive and robust two degrees-of-freedom controllers. Experimental evaluation and analysis of the proposed strategies is provided. The second objective of safety is addressed by a novel algorithm for human-robot collision detection, without force sensors and in the presence of modeling uncertainties. In order to efficiently separate the dynamic effects of the collisions from the effects due to modeling errors, the proposed approach includes adaptive filtering and uses dynamic thresholds depending on the robot state. Experimental evaluation demonstrates a good detection sensitivity which is consistent with safety standards and recommendations for collaborative robotics.

Contrairement aux robots manipulateurs industriels qui sont de taille énorme et de prix élevé, beaucoup de robots manipulateurs à bas prix sont déjà entrés dans le marché, avec une petite taille, un poids léger, ce type de robots est plus accessible pour les particuliers. Cependant, limité par le coût de revient, des accessoires (matériaux, actuateurs, contrôleurs, etc) adoptés sont aussi limités, cela conduit souvent à la performance moins robuste au niveau de contrôle. Cette thèses se concentre sur la conception de contrôleur pour améliorer la performance des robots manipulateurs à bas prix. D'abord, pour des robots manipulateurs rigides, la modélisation dynamique en lien avec le système d'actualisation est établie, qui forme une équation différentielle avec paramètres constants et perturbation. Une méthode d'identification des paramètres en utilisant des observateurs et une commande adaptative sont proposées, et des résultats de simulation et d'expérimentation sont donnés. Ensuite, pour le cas d'articulation flexibles, pour simplifier, le modèle 1DOF est pris en compte. Premièrement, avec la mesure de la vitesse de lien, une méthode d'identification et une loi deux-étages adaptative sont proposées à condition que la position statique de lien puisse également être mesurée, des résultats de simulation sont donnés. Deuxièmement, en utilisant des mesures d'accélération de lien, une méthode d'identification et la même loi deux-étages adaptative sont proposées, cette idée est généralisée à l'identification et au contrôle de systèmes linéaires avec mesures de dérivées d'ordre élevé, des résultat de simulation sont présentés. Pour la mise en œuvre, des capteurs inertiels (gyroscopes et accéléromètres) sont utilisés et des résultats expérimentaux sont présentés. / Unlike industrial robot manipulators which are huge in size and of high price, many low-cost robot manipulators have already entered the market, with small size and light weight, this type of robots are more accessible to the public. However, limited by the cost, the components adopted (materials, actuators, controllers, etc.) are also limited, this often leads to less robust control performance. This thesis focuses on the controller design to improve the performance for such kind low-cost robot manipulators. To start with, for rigid case, dynamic modeling considering the actuator system is established, which forms a differential equation with constant parameters and disturbance, a method to identify the model parameters using observers and then an adaptive controller are proposed, simulation and experimental results are given. Then, in case of flexible joints, for simplicity, a single-link case model is considered. Firstly, link velocity measurement is assumed to provide link information, and an identification method and a two-stage adaptive control low are proposed provided that the static link position can also be measured, simulation result is given. Secondly, by using link acceleration measurement, an identification method and the same two-stage adaptive control low areproposed, this idea is generalized to identification and control of linear system using high-order derivative measurements, simulation result is presented. For implementation, inertial sensors (gyro and accelerometer) are used and experimental result is presented.

In dieser Arbeit werden die Methoden zur Modellierung, Identifikation, Regelung und Reibungskompensation von DLR-Medizinrobotern mit elastischen und differentiell getriebenen Gelenken vorgestellt. In der Praxis zeigt sich, dass bei den DLR-Medizinrobotern sowohl die Gelenkelastizität als auch die Gelenkverkopplung innerhalb des Doppelgelenks in der Modellierung und Regelung berücksichtigt werden muss. Daher ist es das Hauptziel dieser Arbeit, eine Regelungsstruktur zu entwickeln, die das gewünschte Folge- und Einschwingverhalten erreicht. Zur Regelung wird mit Hilfe der modalen Entkopplung ein MIMO – Zustandsregler für die Doppelgelenkstruktur eingeführt, der auf der Rückführung der antriebsseitigen Positionen und abtriebsseitigen Drehmomente sowie deren Ableitungen basiert. Für die medizinischen Anwendungen spielt die Positionsgenauigkeit, die durch die hohe Reibung stark beeinflusst wird, eine entscheidende Rolle. Um die Positioniergenauigkeit des Roboters zu verbessern, wird ein Reibungsbeobachter entwickelt, der eine passive Reibungskompensation ermöglicht. Da der Reibungsbeobachter nur den Momentenfehler, nicht aber den Positionsfehler integriert, wird diese Kompensation außer zur Positionsregelung auch zur Verbesserung der Qualität der Drehmoment- und Impedanzregelung eingesetzt. Für die gesamte Regelungsstruktur aus Zustandsregler und Reibungsbeobachter wird global asymptotische Stabilität des gesamten nichtlinearen Roboters nachgewiesen. Diese Regelungsstruktur wird derzeit in zahlreichen Anwendungen mit den DLR-Medizinrobotern benutzt und validiert.

In dieser Arbeit werden die Methoden zur Modellierung, Identifikation, Regelung und Reibungskompensation von DLR-Medizinrobotern mit elastischen und differentiell getriebenen Gelenken vorgestellt. In der Praxis zeigt sich, dass bei den DLR-Medizinrobotern sowohl die Gelenkelastizität als auch die Gelenkverkopplung innerhalb des Doppelgelenks in der Modellierung und Regelung berücksichtigt werden muss. Daher ist es das Hauptziel dieser Arbeit, eine Regelungsstruktur zu entwickeln, die das gewünschte Folge- und Einschwingverhalten erreicht. Zur Regelung wird mit Hilfe der modalen Entkopplung ein MIMO – Zustandsregler für die Doppelgelenkstruktur eingeführt, der auf der Rückführung der antriebsseitigen Positionen und abtriebsseitigen Drehmomente sowie deren Ableitungen basiert. Für die medizinischen Anwendungen spielt die Positionsgenauigkeit, die durch die hohe Reibung stark beeinflusst wird, eine entscheidende Rolle. Um die Positioniergenauigkeit des Roboters zu verbessern, wird ein Reibungsbeobachter entwickelt, der eine passive Reibungskompensation ermöglicht. Da der Reibungsbeobachter nur den Momentenfehler, nicht aber den Positionsfehler integriert, wird diese Kompensation außer zur Positionsregelung auch zur Verbesserung der Qualität der Drehmoment- und Impedanzregelung eingesetzt. Für die gesamte Regelungsstruktur aus Zustandsregler und Reibungsbeobachter wird global asymptotische Stabilität des gesamten nichtlinearen Roboters nachgewiesen. Diese Regelungsstruktur wird derzeit in zahlreichen Anwendungen mit den DLR-Medizinrobotern benutzt und validiert.

[pt] Questões de segurança têm sido fatores cruciais para que robôs se tornem aptos a trabalhar em colaboração com seres humanos. Esse esforço envolve um controle de força mais refinado e uma certa flexibilidade nas juntas para que a adaptação dos robôs ao ambiente real e às atividades comuns dos seres humanos seja efetiva. Uma das tecnologias com esse objetivo é o Atuador Elástico em Série (SEA - Series Elastic Actuator), que apresenta um bom desempenho para controle de força, tolerância a impactos causados por agentes externos, baixa impedância, e a redução de vibrações mecânicas. Em um SEA, um elemento elástico passivo é adicionado entre o motor e o elo acionado, a fim de gerar flexibilidade. Este elemento pode ser uma mola, ou outro elemento deformável com flexibilidade caracterizada por sua geometria e pela elasticidade do material utilizado. Esta tese propõe um Atuador Elástico em Série Baseado em Elastômero (eSEA), cuja flexibilidade é obtida a partir de um elastômero depositado entre dois elementos metálicos: um interno acoplado ao atuador, e o outro externo acoplado ao elo. O eSEA foi projetado e avaliado por software de CAD e Elementos Finitos, com o intuito de obter a flexibilidade desejada para a aplicação. Foram produzidas duas versões do eSEA, com duas durezas diferentes: 10 e 55 Shore A. Testes estáticos com células de carga foram executados para caracterizar a rigidez dos eSEA. Os eSEA foram instalados em manipuladores robóticos especialmente desenvolvidos para essa tese. Experimentos compararam o desempenho das técnicas de controle com e sem a influência dos eSEA, mostrando que o uso dos eSEA diminuiu os erros de posicionamento do manipulador e possibilitou o controle de força sem a necessidade de sensores específicos. A fim de criar um modelo para que a estimativa do torque seja mais precisa a partir do eSEA, foram realizadas técnicas de identificação para estimar uma função de transferência que melhor representa o alongamento da borracha. E combinados com modelos NARX e NARMAX do erro de estimativa, gerou-se um modelo híbrido para o elemento elástico no qual soma-se a função de transferência com o erro modelado. / [en] Safety issues have been crucial factors for robots to become able to work in collaboration with humans. This effort involves more refined force control and a certain flexibility at the joints, for the robots to better adapt to real environments and common human tasks. A technology with this objective is the Series Elastic Actuator (SEA), which presents good performance for force control, tolerance to impacts caused by external agents, low impedance, and dampening of mechanical vibrations. In an SEA, a passive elastic element is added between the motor and the driven link, in order to generate a desired flexibility. This element can be a spring, or else another deformable element with flexibility characterized by its geometry and material elasticity. This thesis proposes an Elastomer-Based Series Elastic Actuator (eSEA), whose flexibility is obtained from an elastomer deposited between two metallic elements: an internal element attached to the actuator, and an external element attached to the link. The eSEA was designed and evaluated by CAD and Finite Element software, in order to obtain the desired flexibility for the application. Two versions of the eSEA were produced, with two different hardnesses: 10 and 55 Shore A. Static tests with load cells were then executed to characterize the stiffness of the eSEA. The eSEA elements were installed on robotic manipulators especially developed for this thesis. Experiments compared the performance of control techniques with and without the influence of eSEA, showing that the use of the eSEA reduced manipulator positioning errors and enabled force control without the need for specific sensors. In order to create a model for more accurate torque estimation from eSEA, identification techniques were performed to estimate a transfer function that best represents the rubber elongation. And combined with NARX and NARMAX models of the estimation error, a hybrid model was generated for the elastic element in which the transfer function is added together with the modeled error.