Die motorischen Fähigkeiten humanoider Roboter werden häufig von antriebsbedingten Nichtlinearitäten und Reibungseffekten negativ beeinflusst. Zur deren Kompensation werden üblicherweise modellbasierte Regelkreise genutzt, die i.d.R. von einer hochfrequenten Signalverarbeitung und mehreren Sensorqualitäten abhängen. Entgegen solch modellbasierten Techniken werden in der vorliegenden Arbeit modellfreie Steuerungsmethoden auf Basis parallel gekoppelter Antriebe entwickelt. Zur Entwicklung und Untersuchung dieser Steuerungsmethoden wird nach der von Pfeifer in seinem Werk “How the body shapes the way we think” beschriebenen synthetischen Methodik vorgegangen. Entgegen modellbasierten Untersuchungen auf Basis von Simulationen stehen bei der synthetischen Methodik empirische Untersuchungen am realen System im Vordergrund. Als Ausgangspunkt dienen konventionelle elektromechanische Antriebe mit deren bekannten leistungseinschränkenden Nichtlinearitäten und Reibungseffekten. Durch die parallele Kopplung mehrerer Antriebe an einem einzelnen Gelenk wird das Spektrum der Steuerungsmöglichkeiten deutlich erweitert. Es zeigt sich, dass (1) durch eine konstante antagonistische Vorspannung das Arbeitsverhalten von konventionellen Proportionalreglern optimiert werden kann, (2) durch dynamische asymmetrische Änderung der Vorspannung Nichtlinearitäten bei niedrigen Geschwindigkeiten ausgeglichen werden können und (3) getriebebedingte Reibungseffekte mit einer phasenverschobenen Pulsmodulation der Steuersignale kompensiert werden können. Weiterhin wird gezeigt, wie die erarbeiteten Steuerungsmethoden auf beliebig viele parallel gekoppelte Antriebe übertragen werden können. Für den praktischen Einsatz der Steuerungsmethoden werden diese in einer hybriden Steuerung zusammengeführt. Diese wird durch eine weitere Funktion, den Energiesparmodus beim Halten statischer Positionen, ergänzt und am humanoiden Roboter Myon implementiert und experimentell evaluiert. / Motor functions of humanoid robots are often negatively influenced by nonlinearities and friction effects of the actuators. The popular means of compensation are control circuits based on modelling, which rely on powerful HF Signal processing and various sensor qualities. In contrast, this thesis develops non-modelling control methods based on parallel coupled actuators. Development and exploration of these control methods follow Pfeifer’s synthetic methodology as described in his work “How the body shapes the way we think”. In contrast to the analysis based on emulation as used in modelling, the synthetic methodology focuses rather on empirical tests within the real system. The present work explores control methods for parallel coupled actuators for use in robot points. It starts from conventional electromechanical actuators with their known power limiting nonlinearities and frictional effects. Linking several parallel coupled actuators to a single joint significantly expands the spectrum of control capabilities. Using two parallel coupled actuators as an example, it is examined to which extent undesirable properties of single actuators can be compensated. The results show that (1) the Performance of conventional proportional controllers can be optimized by a constant antagonistic bias voltage, (2) nonlinearities at low velocities can be balanced out by a dynamic asymmetrical adjustment of the bias, and that (3) gear related frictional effects can be compensated by a phase shifted pulse modulation of the control signals. In addition, it is shown how the developed control methods can be applied to a random number of parallel coupled actuators. For practical use, the various control methods are combined in a hybrid control, which is supplemented by an energy saving mode when maintaining static positions. The hybrid control is being implemented into the humanoid robot Myon and evaluated by experiment.

<div>Powder Bed Fusion Additive Manufacturing enables the fabrication of metal parts with complex geometry and elaborates internal features, the simplication of the assembly process, and the reduction of development time. However, the lack of consis-tent quality hinders its tremendous potential for widespread application in industry. This limits its ability as a viable manufacturing process particularly in the aerospace and medical industries where high quality and repeatability are critical. A variety of defects, which may be initiated during the powder-bed fusion additive manufacturing process, compromise the repeatability, precision, and resulting mechanical properties of the final part. The literature review shows that a non-uniform temperature distribution throughout fabricated layers is a signicant source of the majority of thermal defects. Therefore, the work introduces an online thermography methodology to study temperature distribution, thermal evolution, and thermal specications of the fabricated layers in powder-bed fusion process or any other thermal inherent AM process. This methodology utilizes infrared technique and segmentation image processing to extract the required data about temperature distribution and HAZs of the layer under fabrication. We conducted some primary experiments in the FDM process to leverage the thermography technique and achieve a certain insight to be able to propose a technique to generate a more uniform temperature distribution. These experiments lead to proposing an innovative chessboard scanning strategy called tessellation algorithm, which can generate more uniform temperature distribution and diminish the layer warpage consequently especially throughout the layers with either geometry that is more complex or poses relatively longer dimensions. In the next step, this work develops a new technique in ABAQUS to verify the proposed scanning strategy. This technique simulates temperature distribution throughout a layer printed by chessboard printing patterns in powder-bed fusion process in a fraction of the time taken by current methods in the literature. This technique compares the temperature distribution throughout a designed layer printed by three presented chessboard-scanning patterns, namely, rastering pattern, helical pattern, and tessellation pattern. The results conrm that the tessellation pattern generates more uniform temperature distribution compared with the other two patterns. Further research is in progress to leverage the thermography methodology to verify the simulation technique. It is also pursuing a hybrid closed-loop online monitoring (OM) and control methodology, which bases on the introduced tessellation algorithm and online thermography in this work and Articial Neural Networking (ANN) to generate the most possible uniform temperature distribution within a safe temperature range layer-by-layer.</div>

The topic of this dissertation is the derivation, development, and evaluation of novel hybrid algorithms for process control that use a limited number of measurements and that are suitable to operate in the presence of large amounts of process noise. As an initial step, affine and neural network statistical process models are developed in order to simulate the steady-state system behavior. Such models are vitally important in the evaluation, testing, and improvement of all other process controllers referred to in this work. Afterwards, fuzzy logic controller rules are assimilated into a mathematical characterization of a model that includes the modes and mode transition rules that define a hybrid hierarchical process control. The main processing entity in such framework is a closed-loop control algorithm that performs global and then local optimizations in order to asymptotically reach minimum bias error; this is done while requiring a minimum number of iterations in order to promptly reach a desired operational window. The results of this research are applied to surface mount technology manufacturing-lines yield optimization. This work achieves a practical degree of control over the solder-paste volume deposition in the Stencil Printing Process (SPP). Results show that it is possible to change the operating point of the process by modifying certain machine parameters and even compensate for the difference in height due to change in print direction.

Purdue School of Engineering and Technology, Indianapolis / Powder Bed Fusion Additive Manufacturing enables the fabrication of metal parts with complex geometry and elaborates internal features, the simplification of the assembly process, and the reduction of development time. However, the lack of consistent quality hinders its tremendous potential for widespread application in industry. This limits its ability as a viable manufacturing process particularly in the aerospace and medical industries where high quality and repeatability are critical. A variety of defects, which may be initiated during the powder-bed fusion additive manufacturing process, compromise the repeatability, precision, and resulting mechanical properties of the final part. The literature review shows that a non-uniform temperature distribution throughout fabricated layers is a significant source of the majority of thermal defects. Therefore, the work introduces an online thermography methodology to study temperature distribution, thermal evolution, and thermal specifications of the fabricated layers in powder-bed fusion process or any other thermal inherent AM process. This methodology utilizes infrared technique and segmentation image processing to extract the required data about temperature distribution and HAZs of the layer under fabrication. We conducted some primary experiments in the FDM process to leverage the thermography technique and achieve a certain insight to be able to propose a technique to generate a more uniform temperature distribution. These experiments lead to proposing an innovative chessboard scanning strategy called tessellation algorithm, which can generate more uniform temperature distribution and diminish the layer warpage consequently especially throughout the layers with either geometry that is more complex or poses relatively longer dimensions. In the next step, this work develops a new technique in ABAQUS to verify the proposed scanning strategy. This technique simulates temperature distribution throughout a layer printed by chessboard printing patterns in powder-bed fusion process in a fraction of the time taken by current methods in the literature. This technique compares the temperature distribution throughout a designed layer printed by three presented chessboard-scanning patterns, namely, rastering pattern, helical pattern, and tessellation pattern. The results confirm that the tessellation pattern generates more uniform temperature distribution compared with the other two patterns. Further research is in progress to leverage the thermography methodology to verify the simulation technique. It is also pursuing a hybrid closed-loop online monitoring and control methodology, which bases on the introduced tessellation algorithm and online thermography in this work and Artificial Neural Networking (ANN) to generate the most possible uniform temperature distribution within a safe temperature range layer-by-layer.