Approved for public release; distribution is unlimited / Today's demand for a high speed, low weight and large load capable manipulator has spurred the research on flexible manipulators. This thesis centers on an implementation of dynamic control on a single-link flexible arm utilizing a general purpose micro-computer. This research also studies the dynamic behavior of the control system with a brief comparison of the derived flexible-body-model controller to a rigid-body-model controller. / http://archive.org/details/implementationof00kirk / Lieutenant, United States Navy

Quantitative Feedback Theory (QFT) is a control system design methodology founded on the premise that feedback is necessary only because of system uncertainty. Articulating flexible structures, such as flexible manipulators, present a difficult closed-loop control problem. In such servo systems, the coupling of the rigid and flexible modes and the non-minimum phase dynamics severely limit system stability and performance. The difficulties in controlling these structures is exacerbated by the denumerably infinite number of flexible modes and associated difficulties in developing accurate dynamic models for controller design. As such, the control of articulating flexible structures presents a non-trivial testbed for the design of QFT based robust control systems. This dissertation examines the multi-input multi-output (MIMO) QFT based control of an articulating flexible structure and presents an enhancement of the theoretical basis for the MIMO QFT design methodologies. The control problem under consideration is the active vibration control of an articulating single-link flexible manipulator. This is facilitated by an actuation scheme comprised of a combination of spatially discrete actuation, in the form of a DC motor to perform articulation, and spatially distributed actuation, in the form of a piezoelectric transducer for active vibration control. In the process of developing and experimentally validating the QFT based control system, shortcomings in the theoretical basis for the MIMO QFT design methodologies are addressed. Robust stability theorems are developed for the two main MIMO QFT design methodologies, namely the sequential and non-sequential MIMO QFT design methodologies. The theorems complement and extend the existing theoretical basis for the MIMO QFT design methodologies. The dissertation results expose salient features of the MIMO QFT design methodologies and provide connections to other multivariable design methodologies.

Quantitative Feedback Theory (QFT) is a control system design methodology founded on the premise that feedback is necessary only because of system uncertainty. Articulating flexible structures, such as flexible manipulators, present a difficult closed-loop control problem. In such servo systems, the coupling of the rigid and flexible modes and the non-minimum phase dynamics severely limit system stability and performance. The difficulties in controlling these structures is exacerbated by the denumerably infinite number of flexible modes and associated difficulties in developing accurate dynamic models for controller design. As such, the control of articulating flexible structures presents a non-trivial testbed for the design of QFT based robust control systems. This dissertation examines the multi-input multi-output (MIMO) QFT based control of an articulating flexible structure and presents an enhancement of the theoretical basis for the MIMO QFT design methodologies. The control problem under consideration is the active vibration control of an articulating single-link flexible manipulator. This is facilitated by an actuation scheme comprised of a combination of spatially discrete actuation, in the form of a DC motor to perform articulation, and spatially distributed actuation, in the form of a piezoelectric transducer for active vibration control. In the process of developing and experimentally validating the QFT based control system, shortcomings in the theoretical basis for the MIMO QFT design methodologies are addressed. Robust stability theorems are developed for the two main MIMO QFT design methodologies, namely the sequential and non-sequential MIMO QFT design methodologies. The theorems complement and extend the existing theoretical basis for the MIMO QFT design methodologies. The dissertation results expose salient features of the MIMO QFT design methodologies and provide connections to other multivariable design methodologies.

Given the advantages of parallel manipulators and lightweight manipulators, a 3-PRR planar parallel manipulator with three lightweight intermediate links has been developed to provide an alternative high-speed pick-and-place positioning mechanism to serial architecture manipulators in electronic manufacturing, such as X-Y tables or gantry robots. Lightweight members are more likely to exhibit structural defection and vibrate due to the inertial forces from high speed motion, and external forces from actuators. Structural flexibility effects are much more pronounced at high operational speeds and accelerations. Therefore, this thesis presents the dynamics and vibration control of a 3-PRR parallel manipulator with three flexible links. Firstly, a procedure for the generation of dynamic equations for a 3-PRR parallel manipulator with three flexible intermediate links is presented based on the assumed mode method. The dynamic equations of the parallel manipulator with three flexible intermediate links are developed using pinned-pinned boundary conditions. Experimental modal tests are performed using an impact hammer and an accelerometer to identify the mode shapes, frequencies, and damping ratios of flexible intermediate links. The mode shapes and frequencies, obtained from experimental modal tests, match very well the assumed mode shapes and frequencies obtained based on pinned-pinned boundary conditions, and therefore the dynamic model developed is validated. Secondly, this thesis presents the investigation on dynamic stiffening and buckling of the flexible links of a 3-PRR parallel manipulator by including the effect of longitudinal forces on the modal characteristics. Natural frequencies of bending vibration of the intermediate links are derived as the functions of axial force and rigid-body motion of the manipulator. Dynamic stiffening and buckling of intermediate links is investigated and configuration-dependant frequencies are analyzed. Furthermore, using Lagrange multipliers, the fully coupled equations of motions of the flexible parallel manipulator are developed by incorporating the rigid body motions with elastic motions. The mutual dependence of elastic deformations and rigid body motions are investigated from the analysis of the derived equations of motion. Open-loop simulation without joint motion controls and closed-loop simulation with joint motion controls are performed to illustrate the effect of elastic motion on rigid body motions and the coupling effect amongst flexible links. These analyses and results provide valuable insight into the design and control of the parallel manipulator with flexible intermediate links. Thirdly, an active vibration control strategy is developed for a moving 3-PRR parallel manipulator with flexible links, each of which is equipped with multiple PZT control pairs. The active vibration controllers are designed using the modal strain rate feedback (MSRF). The amplification behavior of high modes is addressed, and the control gain selection strategy for high modes is developed through modifying the IMSC method. The filters are developed for the on-line estimation of modal coordinates and modal velocity. The second compensator is used to cut off the amplified noises and unmodeled dynamics due to the differentiation operation in the developed controller. The modal coupling behavior of intermediate links is examined with the modal analysis of vibrations measured by the PZT sensors. The error estimation of the moving platform is examined using the measurement of PZT sensors. Finally, an active vibration control experimental system is built to implement the active vibration control of a moving 3-PRR parallel manipulator with three flexible links. The smart structures are built through mounting three PZT control pairs to each intermediate flexible link. The active vibration control system is set up using National Instruments LabVIEW Real-Time Module. Active vibration control experiments are conducted for the manipulator moving with high-speed, and experimental results demonstrate that the vibration of each link is significantly reduced.

Given the advantages of parallel manipulators and lightweight manipulators, a 3-PRR planar parallel manipulator with three lightweight intermediate links has been developed to provide an alternative high-speed pick-and-place positioning mechanism to serial architecture manipulators in electronic manufacturing, such as X-Y tables or gantry robots. Lightweight members are more likely to exhibit structural defection and vibrate due to the inertial forces from high speed motion, and external forces from actuators. Structural flexibility effects are much more pronounced at high operational speeds and accelerations. Therefore, this thesis presents the dynamics and vibration control of a 3-PRR parallel manipulator with three flexible links. Firstly, a procedure for the generation of dynamic equations for a 3-PRR parallel manipulator with three flexible intermediate links is presented based on the assumed mode method. The dynamic equations of the parallel manipulator with three flexible intermediate links are developed using pinned-pinned boundary conditions. Experimental modal tests are performed using an impact hammer and an accelerometer to identify the mode shapes, frequencies, and damping ratios of flexible intermediate links. The mode shapes and frequencies, obtained from experimental modal tests, match very well the assumed mode shapes and frequencies obtained based on pinned-pinned boundary conditions, and therefore the dynamic model developed is validated. Secondly, this thesis presents the investigation on dynamic stiffening and buckling of the flexible links of a 3-PRR parallel manipulator by including the effect of longitudinal forces on the modal characteristics. Natural frequencies of bending vibration of the intermediate links are derived as the functions of axial force and rigid-body motion of the manipulator. Dynamic stiffening and buckling of intermediate links is investigated and configuration-dependant frequencies are analyzed. Furthermore, using Lagrange multipliers, the fully coupled equations of motions of the flexible parallel manipulator are developed by incorporating the rigid body motions with elastic motions. The mutual dependence of elastic deformations and rigid body motions are investigated from the analysis of the derived equations of motion. Open-loop simulation without joint motion controls and closed-loop simulation with joint motion controls are performed to illustrate the effect of elastic motion on rigid body motions and the coupling effect amongst flexible links. These analyses and results provide valuable insight into the design and control of the parallel manipulator with flexible intermediate links. Thirdly, an active vibration control strategy is developed for a moving 3-PRR parallel manipulator with flexible links, each of which is equipped with multiple PZT control pairs. The active vibration controllers are designed using the modal strain rate feedback (MSRF). The amplification behavior of high modes is addressed, and the control gain selection strategy for high modes is developed through modifying the IMSC method. The filters are developed for the on-line estimation of modal coordinates and modal velocity. The second compensator is used to cut off the amplified noises and unmodeled dynamics due to the differentiation operation in the developed controller. The modal coupling behavior of intermediate links is examined with the modal analysis of vibrations measured by the PZT sensors. The error estimation of the moving platform is examined using the measurement of PZT sensors. Finally, an active vibration control experimental system is built to implement the active vibration control of a moving 3-PRR parallel manipulator with three flexible links. The smart structures are built through mounting three PZT control pairs to each intermediate flexible link. The active vibration control system is set up using National Instruments LabVIEW Real-Time Module. Active vibration control experiments are conducted for the manipulator moving with high-speed, and experimental results demonstrate that the vibration of each link is significantly reduced.