This study focuses on the design and analysis of a specialised mechanical gripper for an assembly process of batteries, with particular emphasis on the study of the associated forces and deformations. The project commences with comprehensive market research to identify existing solutions. This is followed by the definition of requirements and an iterative design process utilising computer-aided design (CAD). Subsequently, a comprehensive force and deformation analysis is conducted using the finite element method (FEM) in Abaqus CAE. The results demonstrate that the designed gripper can withstand the applied loads with minimal deformation, indicating that it possesses adequate structural stiffness. The utility of finite element method (FEM) analysis in evaluating the viability of the proposed design is demonstrated. According to the design and analysis in this study, it manages to propose and developed a new kind of gripper with a higher grip range than those available on the market. These findings contribute to a deeper understanding of the suitability of the gripper design in relation to the expected loads and highlight the importance of the design methodology employed.

This master thesis project is focused on the development of an LQR controller and its comparison with other controllers (PID and MPC), in order to successfully control an Autonomous Underwater Vehicle manipulation system. The modelling of the manipulator was performed first in Matlab and later on in Simulink-Simscape. Once the manipulator was integrated with the AUV model, the LQR controller was also developed initially in Matlab and then in Simulink. The controller was then extracted from Simulink as a C-code and verified in Stonefish. After confirming that the LQR code was working in Stonefish, its results from Simulink were compared with PID and MPC results for two different trajectories. The data for comparison and statistical analysis were divided into the two trajectory scenarios (horizontal and vertical) since the weight matrices of both controllers were different. Looking at the system’s overall behavior the Model Predictive Control (MPC) and LQR had similar results, regarding the rise time, overshoot, steady-state error and robustness to disturbances. An anticipated fact for the MPC was that it takes the longest run time for both scenarios. Lastly, as expected the PID had the worst response of all three controllers, in both scenarios. Implementing a PID on a nonlinear system, produced many oscillations without being able to stabilize at the reference value, thus giving a large steady-state error. In addition, it could not counteract the noise disturbances in the signal. / Detta examensarbete är inriktat på utvecklingen av en LQR-styrenhet och dess jämförelse med andra kontroller (PID och MPC), för att framgångsrikt styra ett autonomt undervattensfordon-manipulationssystem. Modelleringen av manipulatorn utfördes först i Matlab och senare i Simulink-Simscape. När manipulatorn väl hade integrerats med AUV modellen, utvecklades LQR styrenheten också inledningsvis i Matlab och sedan i Simulink. Kontrollenheten extraherades sedan från Simulink som en C-kod och verifierades i Stonefish. Efter att ha bekräftat att LQR koden fungerade i Stonefish, jämfördes resultaten från Simulink med PID och MPC resultat för två olika banor. Data för jämförelse och statistisk analys delades in i de två bana-scenarierna (horisontella och vertikala), eftersom viktmatriserna för båda kontrollerna var olika. När man tittar på systemets övergripande beteende hade Model Predictive Controller (MPC) och LQR liknande resultat när det gäller stigningstid, överskott, steady-state fel och robusthet mot störningar. Ett förväntat faktum för MPC var att det tar den längsta körtiden för båda scenarierna. Slutligen, som väntat, hade PID det sämsta svaret av alla tre kontrollerna, i båda scenarierna. Implementering av ett PID på ett olinjärt system gav många oscillationer utan att kunna stabilisera sig vid referensvärdet, vilket gav ett stort steady-state fel. Dessutom kunde den inte motverka bullerstörningarna i signalen.

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Cette thèse étudie le problème de nano-positionnement à l'intérieur d'un microscope électronique à balayage (MEB). Pour obtenir des informations de position avec rapidité et précision, une installation dédiée composée d’un vibromètre placé à l'intérieur du MEB a été mise en œuvre. Cette approche diffère de méthodes basées sur le traitement d'images, car elle permet de saisir des données en temps réel sur le comportement dynamique des structures étudiées. Dans une première étude, les perturbations mécaniques agissant à l'intérieur de la chambre à vide du microscope ont été caractérisées et leurs sources ont été identifiées. Cela a démontré comment les vibrations mécaniques externes et les bruits acoustiques peuvent influer largement sur les composants à l'intérieur du MEB par couplage mécanique, limitant ainsi la précision des manipulateurs. Dans un deuxième temps, une micro-pince du commerce a été étudiée. Une différence entre ses comportements dans l'air et dans le vide a été mise en évidence, ce qui a permis d'obtenir deux modèles dynamiques pour cet organe terminal, un pour chaque environnement. Deux lois de commande ont été proposées (commande H-infini et commande basée sur un observateur d'état étendu), afin d'obtenir en temps réel un positionnement précis dans le vide, et d'atténuer les effets des perturbations mécaniques externes. Les résultats ont été validés en simulation et expérimentalement. / This work studies the nano-positioning problem inside the scanning electron microscope (SEM). To acquire fast and accurate positional information, a dedicated setup was implemented consisting of a vibrometer placed inside the SEM. This approach differs from methods based on image processing, as it allows to capture real-time data on the dynamic behavior of structures. In a first study, the mechanical disturbances acting inside the microscope’s vacuum chamber were characterized and its sources were identified. This demonstrated how external mechanical vibrations and acoustic noises can largely influence the components inside the SEM through mechanical coupling, limiting the effective positioning precision of manipulators. Next, a commercial micro-gripper was studied, both in air and in vacuum, and the differences between its response were highlighted. This allowed to obtain two dynamic models for this end-effector, one for each environment. Two control laws were proposed (H-infinity control and Extended State Observer based control) for the system, to obtain a real-time, precise positioning in the vacuum environment and to attenuate the effects of the external mechanical disturbances. Results were demonstrated through simulation and experimental validation.

Indiana University-Purdue University Indianapolis (IUPUI) / This thesis proposes an automated grid-based alignment system utilizing lasers and an array of light-detecting photodiodes. The intent is to create an inexpensive and scalable alignment system for pick-and-place robotic systems. The system utilizes the transformation matrix, geometry, and trigonometry to determine the movements to align the robot with a grid-based array of photodiodes. The alignment system consists of a sending unit utilizing lasers, a receiving module consisting of photodiodes, a data acquisition unit, a computer-based control system, and the robot being aligned. The control system computes the robot movements needed to position the lasers based on the laser positions detected by the photodiodes. A transformation matrix converts movements from the coordinate system of the grid formed by the photodiodes to the coordinate system of the robot. The photodiode grid can detect a single laser spot and move it to any part of the grid, or it can detect up to four laser spots and use their relative positions to determine rotational misalignment of the robot. Testing the alignment consists of detecting the position of a single laser at individual points in a distinct pattern on the grid array of photodiodes, and running the entire alignment process multiple times starting with different misalignment cases. The first test provides a measure of the position detection accuracy of the system, while the second test demonstrates the alignment accuracy and repeatability of the system. The system detects the position of a single laser or multiple lasers by using a method similar to a center-of-gravity calculation. The intensity of each photodiode is multiplied by the X-position of that photodiode. The summed result from each photodiode intensity and position product is divided by the summed value of all of the photodiode intensities to get the X-position of the laser. The same thing is done with the Y-values to get the Y-position of the laser. Results show that with this method the system can read a single laser position value with a resolution of 0.1mm, and with a maximum X-error of 2.9mm and Y-error of 2.0mm. It takes approximately 1.5 seconds to process the reading. The alignment procedure calculates the initial misalignment between the robot and the grid of photodiodes by moving the robot to two distinct points along the robot’s X-axis so that only one laser is over the grid. Using these two detected points, a movement trajectory is generated to move that laser to the X = 0, Y = 0 position on the grid. In the process, this moves the other three lasers over the grid, allowing the system to detect the positions of four lasers and uses the positions to determine the rotational and translational offset needed to align the lasers to the grid of photodiodes. This step is run in a feedback loop to update the adjustment until it is within a permissible error value. The desired result for the complete alignment is a robot manipulator positioning within ±0.5mm along the X and Y-axes. The system shows a maximum error of 0.2mm in the X-direction and 0.5mm in the Y-direction with a run-time of approximately 4 to 5 minutes per alignment. If the permissible error value of the final alignment is tripled the alignment time goes down to 1 to 1.5 minutes and the maximum error goes up to 1.4mm in both the X and Y-directions. The run time of the alignment decreases because the system runs fewer alignment iterations.

<p dir="ltr">Origami has emerged as a design paradigm to realize morphing structures with rich kinematic and mechanical properties. Biological examples augment the potential folding design space by suggesting intriguing routes for achieving and expanding crease patterns which traditional origami laws are unable to capture. Specifically, spring origami theory exploits the material system architecture and energy storage mechanism of the earwig wing featuring one of the highest folding ratios in the animal kingdom (1:18), minimal energy required for deployment and collapse of the wing, and bistability locking the wing in closed, and open configurations for crawling through tunnels, and flight, respectively. The central mechanism responsible for bistability in the wing features a non-developable crease pattern with a non-zero Gaussian curvature. Reconfiguring, or even flattening a structure with such an intrinsic property requires stretching or tearing; soft, rubbery material found in the creases of the central mechanism allows for stretching enabling shape transformations between open and closed states without tearing. In the first part of this thesis, such characteristics are transferred to a synthetic bistable soft robotic gripper leveraging the shape adaptability and conformability exhibited by the biological organism to minimize actuation energy. This is achieved by integrating soft, flexible material in the bioinspired gripper that allows kinematically driven geometries to grasp and manipulate objects without continuous actuation. Secondly, the stiffening effect from spring origami is utilized in a bioinspired wing for an aerial--aquatic robot. Transitions between air and sea in multimodal robots is challenging, however, a structurally efficient and multifunctional membrane is developed to increase locomotive capabilities and longer flights. This is motivated by the flying fish's locomotive modules and origami design principles for deployment and folding. Additionally, to keep the wing in a stiff state while gliding, spring origami bistable units are integrated into the membrane inducing self-stiffening and a global curvature reducing energy expenditure while generating lift. While the previous examples present solutions to adaptive manipulation and membrane multifunctionality, once programmed, their shapes are fixed. In the third application, a class of multistable self-folding origami architectures that are reprogrammable post fabrication are presented. This is achieved by encoding prestrain in bilayer creases with anisotropic shrinkage that change shape and induce a local curvature in the creases in response to external stimuli. The topology of the energy landscapes can thus be tuned as a function of the stimulation time and adaptable post fabrication. The proposed method and model allows for converting flat sheets with arranged facets and prestrained mountain-valley creases into self-folding multistable structures. Lasty, encoding crease prestrain is leveraged to manufacture a biomimetic earwig wing featuring the complex crease pattern, structural stability, and rapid closure of the biological counterpart. The presented method provides a route for encoding prestrain in self-folding origami, the multistability of which is adaptable after fabrication.</p>

This thesis provides a systematic guideline for evaluating, integrating and designing the collaborative end effector system associated with commercially available collaborative robots (cobots). On the basis of ISO/TS 15066:2016, customers’ demands are categorised as a macro demand framework and micro demand variables, which are parameterised and hierarchised. By analysing these parameters, the collaborative degree is determined to correlate the hazards with protection measures, which can demonstrate the collaborative safety level transparently. After that, the safety protection measures are specifically proposed corresponding to the potential risks. Finally, an industrial application is evaluated, a novel adapter utilised on the UR5 cobot is illustrated, and its characteristics for the collaborative operation are described.:1 Introduction 2 Robotic end effector in Assembly and Handling 3 Concept and Definition of Collaboration 4 Statement of the academic purpose and methodology 5 Guideline and Methodology for designing the Active Lightweight End-effector (ALE) for collaborative robots 6 Performance demand d4): multiplicity and versatility of end effector 7 A safety monitoring end effector (Adapter) for collaborative operations 8 A practical study of collaborative integration based on collaborative degree 9 Conclusion Appendix / Diese Arbeit liefert einen systematischen Leitfaden für die Bewertung, Integration und Gestaltung des kollaborierenden Endeffektorsystems in Verbindung mit kommerziell verfügbaren kollaborativen Robotern (Kobots). Auf der Grundlage der ISO/TS 15066:2016 werden die Anforderungen der Kunden in einen Makro-Bedarfsrahmen und Mikro-Bedarfsvariablen kategorisiert, die parametrisiert und hierarchisiert werden. Durch die Analyse dieser Parameter wird der Kollaborationsgrad ermittelt, um die Gefährdungen mit Schutzmaßnahmen zu korrelieren, die die kollaborierende Sicherheitsstufe transparent darstellen können. Danach werden die Schutzmaßnahmen entsprechend den potenziellen Risiken vorgeschlagen. Schließlich wird ein industrieller Anwendungsfall bewertet, ein neuartiger Adapter für den Einsatz an einem Roboter UR5 erläutert und dessen Kenndaten für den kollaborierenden Betrieb beschrieben.:1 Introduction 2 Robotic end effector in Assembly and Handling 3 Concept and Definition of Collaboration 4 Statement of the academic purpose and methodology 5 Guideline and Methodology for designing the Active Lightweight End-effector (ALE) for collaborative robots 6 Performance demand d4): multiplicity and versatility of end effector 7 A safety monitoring end effector (Adapter) for collaborative operations 8 A practical study of collaborative integration based on collaborative degree 9 Conclusion Appendix