This thesis presents an investigation of the modelling and optimal design of a particular 3-degree-of-freedom (DOF) XYθz micro-motion stage. This stage provides micron-scale motion in X and Y directions and a rotation about the Z-axis. Such a stage can be used for applications where positioning of components with micrometre, or even nanometre positioning accuracy is required. Some applications are; the positioning of samples in a scanning-electron-microscope; the positioning of masks in lithography; aligning fibre-optics and lasers; and manipulation of micro-scale objects in micro-biology or micro-systems assembly. The XYθz micro-motion stage investigated in this study uses a particular topology of monolithic compliant mechanism and three stack piezoelectric actuators. The compliant mechanism used is a 3RRR (three revolute-revolute-revolute) parallel compliant mechanism using flexure hinges. This parallel mechanism uses three RRR linkages. Each of the three RRR linkages uses three circular profile flexure hinges. Each flexure hinge provides predominantly rotational motion about one axis. This topology of mechanism has a symmetrical structure and provides numerous advantages that make it appropriate for use in a micro-motion stage. However, as yet this topology of compliant mechanism has only been investigated by a handful of researchers and it has not been used in any commercially developed systems. The design methodology of a stage using the 3RRR compliant mechanism has not been investigated in detail. In this thesis a study is presented that investigates different approaches to model the 3RRR compliant mechanism and also considers the piezo-actuator modelling, to give the complete XYθz micro-motion stage. Three models are presented and compared; the Pseudo-Rigid-Body Model (PRBM); a two-dimensional Finite-Element-Model (2-D FEM); and a third model is developed that is similar to the PRBM, but uses analytical equations to model the multiple degree-of-freedom compliance of the flexure hinges. The models developed are then used in parametric study so that the relationship between design parameters and output behaviour can be understood. An optimal design approach is then presented to develop an XYθz micro-motion stage for a particular application in a Scanning-Electron-Microscope (SEM). Finally experimental validation of the models is presented. The results of this study indicate which modelling approaches are accurate enough to prove useful for design, while also considering which models are computationally simple enough to be efficient and easy to use. The kinematic and dynamic behaviour of the 3RRR compliant mechanism and XYθz micro-motion stage is discussed in detail. This includes; a comprehensive description of the stage workspace, defining reachable and constant-rotation workspace areas; a discussion of actuator coupling; and in depth investigation of the modes of vibration. The results of the parametric study provide useful insight to aid the design of the XYz micro-motion stage and help simplify optimal design. The parametric study also highlights the difference in trends predicted by different modelling methods, which demonstrates the importance of using an appropriate model in design. The experimental validation demonstrates the accuracy of some modelling approaches while highlighting the limited accuracy of others. / http://proxy.library.adelaide.edu.au/login?url= http://library.adelaide.edu.au/cgi-bin/Pwebrecon.cgi?BBID=1272186 / Thesis (Ph.D.) -- University of Adelaide, School of Mechanical Engineering, 2007

Neste trabalho, um novo enfoque para detecção e diagnóstico de falhas (DDF) em robôs manipuladores é apresentado. Um robô com falhas pode causar sérios danos e pode colocar em risco o pessoal presente no ambiente de trabalho. Geralmente, os pesquisadores têm proposto esquemas de DDF baseados no modelo matemático do sistema. Contudo, erros de modelagem podem ocultar os efeitos das falhas e podem ser uma fonte de alarmes falsos. Aqui, duas redes neurais artificiais são utilizadas em um sistema de DDF para robôs manipuladores. Um perceptron multicamadas treinado por retropropagação do erro é usado para reproduzir o comportamento dinâmico do manipulador. As saídas do perceptron são comparadas com as variáveis medidas, gerando o vetor de resíduos. Em seguida, uma rede com função de base radial é usada para classificar os resíduos, gerando a isolação das falhas. Quatro algoritmos diferentes são empregados para treinar esta rede. O primeiro utiliza regularização para reduzir a flexibilidade do modelo. O segundo emprega regularização também, mas ao invés de um único termo de penalidade, cada unidade radial tem um regularização individual. O terceiro algoritmo emprega seleção de subconjuntos para selecionar as unidades radiais a partir dos padrões de treinamento. O quarto emprega o mapa auto-organizável de Kohonen para fixar os centros das unidades radiais próximos aos centros dos aglomerados de padrões. Simulações usando um manipulador com dois graus de liberdade e um Puma 560 são apresentadas, demostrando que o sistema consegue detectar e diagnosticar corretamente falhas que ocorrem em conjuntos de padrões não-treinados. / In this work, a new approach for fault detection and diagnosis in robotic manipulators is presented. A faulty robot could cause serious damages and put in risk the people involved. Usually, researchers have proposed fault detection and diagnosis schemes based on the mathematical model of the system. However, modeling errors could obscure the fault effects and could be a false alarm source. In this work, two artificial neural networks are employed in a fault detection and diagnosis system to robotic manipulators. A multilayer perceptron trained with backpropagation algorithm is employed to reproduce the robotic manipulator dynamical behavior. The perceptron outputs are compared with the real measurements, generating the residual vector. A radial basis function network is utilized to classify the residual vector, generating the fault isolation. Four different algorithms have been employed to train this network. The first utilizes regularization to reduce the flexibility of the model. The second employs regularization too, but instead of only one penalty term, each radial unit has a individual penalty term. The third employs subset selection to choose the radial units from the training patterns. The forth algorithm employs the Kohonen’s self-organizing map to fix the radial unit center near to the cluster centers. Simulations employing a two link manipulator and a Puma 560 manipulator are presented, demonstrating that the system can detect and isolate correctly faults that occur in nontrained pattern sets.

Industrial robot manipulators are general-purpose machines used for industrial automation in order to increase productivity, flexibility, and quality. Other reasons for using industrial robots are cost saving, and elimination of heavy and health-hazardous work. Robot motion control is a key competence for robot manufacturers, and the current development is focused on increasing the robot performance, reducing the robot cost, improving safety, and introducing new functionalities. Therefore, there is a need to continuously improve the models and control methods in order to fulfil all conflicting requirements, such as increased performance for a robot with lower weight, and thus lower mechanical stiffness and more complicated vibration modes. One reason for this development of the robot mechanical structure is of course cost-reduction, but other benefits are lower power consumption, improved dexterity, safety issues, and low environmental impact. This thesis deals with three different aspects of modeling and control of flexible, i.e., elastic, manipulators. For an accurate description of a modern industrial manipulator, the traditional flexible joint model, described in literature, is not sufficient. An improved model where the elasticity is described by a number of localized multidimensional spring-damper pairs is therefore proposed. This model is called the extended flexible joint model. This work describes identification, feedforward control, and feedback control, using this model. The proposed identification method is a frequency-domain non-linear gray-box method, which is evaluated by the identification of a modern six-axes robot manipulator. The identified model gives a good description of the global behavior of this robot. The inverse dynamics control problem is discussed, and a solution methodology is proposed. This methodology is based on a differential algebraic equation (DAE) formulation of the problem. Feedforward control of a two-axes manipulator is then studied using this DAE approach. Finally, a benchmark problem for robust feedback control of a single-axis extended flexible joint model is presented and some proposed solutions are analyzed.

<p>Industrial robot manipulators are general-purpose machines used for industrial automation in order to increase productivity, flexibility, and quality. Other reasons for using industrial robots are cost saving, and elimination of heavy and health-hazardous work. Robot motion control is a key competence for robot manufacturers, and the current development is focused on increasing the robot performance, reducing the robot cost, improving safety, and introducing new functionalities. Therefore, there is a need to continuously improve the models and control methods in order to fulfil all conflicting requirements, such as increased performance for a robot with lower weight, and thus lower mechanical stiffness and more complicated vibration modes. One reason for this development of the robot mechanical structure is of course cost-reduction, but other benefits are lower power consumption, improved dexterity, safety issues, and low environmental impact.</p><p>This thesis deals with three different aspects of modeling and control of flexible, i.e., elastic, manipulators. For an accurate description of a modern industrial manipulator, the traditional flexible joint model, described in literature, is not sufficient. An improved model where the elasticity is described by a number of localized multidimensional spring-damper pairs is therefore proposed. This model is called the extended flexible joint model. This work describes identification, feedforward control, and feedback control, using this model.</p><p>The proposed identification method is a frequency-domain non-linear gray-box method, which is evaluated by the identification of a modern six-axes robot manipulator. The identified model gives a good description of the global behavior of this robot.</p><p>The inverse dynamics control problem is discussed, and a solution methodology is proposed. This methodology is based on a differential algebraic equation (DAE) formulation of the problem. Feedforward control of a two-axes manipulator is then studied using this DAE approach.</p><p>Finally, a benchmark problem for robust feedback control of a single-axis extended flexible joint model is presented and some proposed solutions are analyzed.</p>

Neste trabalho, um novo enfoque para detecção e diagnóstico de falhas (DDF) em robôs manipuladores é apresentado. Um robô com falhas pode causar sérios danos e pode colocar em risco o pessoal presente no ambiente de trabalho. Geralmente, os pesquisadores têm proposto esquemas de DDF baseados no modelo matemático do sistema. Contudo, erros de modelagem podem ocultar os efeitos das falhas e podem ser uma fonte de alarmes falsos. Aqui, duas redes neurais artificiais são utilizadas em um sistema de DDF para robôs manipuladores. Um perceptron multicamadas treinado por retropropagação do erro é usado para reproduzir o comportamento dinâmico do manipulador. As saídas do perceptron são comparadas com as variáveis medidas, gerando o vetor de resíduos. Em seguida, uma rede com função de base radial é usada para classificar os resíduos, gerando a isolação das falhas. Quatro algoritmos diferentes são empregados para treinar esta rede. O primeiro utiliza regularização para reduzir a flexibilidade do modelo. O segundo emprega regularização também, mas ao invés de um único termo de penalidade, cada unidade radial tem um regularização individual. O terceiro algoritmo emprega seleção de subconjuntos para selecionar as unidades radiais a partir dos padrões de treinamento. O quarto emprega o mapa auto-organizável de Kohonen para fixar os centros das unidades radiais próximos aos centros dos aglomerados de padrões. Simulações usando um manipulador com dois graus de liberdade e um Puma 560 são apresentadas, demostrando que o sistema consegue detectar e diagnosticar corretamente falhas que ocorrem em conjuntos de padrões não-treinados. / In this work, a new approach for fault detection and diagnosis in robotic manipulators is presented. A faulty robot could cause serious damages and put in risk the people involved. Usually, researchers have proposed fault detection and diagnosis schemes based on the mathematical model of the system. However, modeling errors could obscure the fault effects and could be a false alarm source. In this work, two artificial neural networks are employed in a fault detection and diagnosis system to robotic manipulators. A multilayer perceptron trained with backpropagation algorithm is employed to reproduce the robotic manipulator dynamical behavior. The perceptron outputs are compared with the real measurements, generating the residual vector. A radial basis function network is utilized to classify the residual vector, generating the fault isolation. Four different algorithms have been employed to train this network. The first utilizes regularization to reduce the flexibility of the model. The second employs regularization too, but instead of only one penalty term, each radial unit has a individual penalty term. The third employs subset selection to choose the radial units from the training patterns. The forth algorithm employs the Kohonen’s self-organizing map to fix the radial unit center near to the cluster centers. Simulations employing a two link manipulator and a Puma 560 manipulator are presented, demonstrating that the system can detect and isolate correctly faults that occur in nontrained pattern sets.

In concentrated solar power (CSP) stations, large arrays of mirrors which are capable of changing its orientation are used to reflect the incident solar energy to a stationary receiver kept at a distance. Such mirrors are often called as heliostats. The receiver contains a heat absorbing medium like molten salt. By absorbing the thermal energy reflected from thousands of heliostats, the temperature would reach around 6000C and the heat can be used in thermal power plants to generate steam and thus run a turbine to produce electricity. One of the biggest advantages of CSP over conventional energy harvesting from Sun is that it can generate electricity during night for long hours of time from the thermal energy stored during daytime. This eliminates the usage of batteries or any other energy storing methods. The conversion efficiency is also high in CSP due to the high temperature achieved. With prior knowledge of the station coordinates, viz., the latitude and longitude, the day of the year and time, the direction or the path of sun can be fully determined. Typically, the sun's motion is tracked by the azimuth-elevation (Az-El) or the target-aligned configuration heliostats. In both these approaches, the mirror needs to be moved about two axes independently using two actuators in series with the mirror effectively mounted at a single point at the centre. This arrangement causes the mirror to deform in presence of gusty winds in a solar field which results in loss of pointing accuracy. Typically a beam error of less than 2-3 mrad is desirable in a large solar field and this value also includes other sources of loss of pointing accuracy like gravity and wind loading. In order to prevent this, a rigid support frame is required for each of the heliostats. In this work, two three degree-of-freedom parallel manipulators, viz., the 3-UPU wrist and 3-RPS, have been proposed to track the sun in central receiver systems. The main reasons for choosing a parallel manipulator as heliostat are its desirable characteristics like large load carrying capacity, high accuracy in positioning the mirror and easy to obtain the inverse kinematics and convenient for real time control. The proposed parallel manipulators support the load of the mirror, structure and wind loading at three points resulting in less deflection and thus a much larger mirror can be moved with the required tracking accuracy and without increasing the weight of the support structure. The algorithm for sun tracking is developed, extensive simulation study with respect to actuations required, variation of joint angles, spillage loss and leg intersection has been carried out. Using FEA, it is shown that for same sized mirror, wind loading of 22 m/s and maximum deflection requirement (2 mrad), the weight of the support structure is between 15% and 60% less with the parallel manipulators when compared to azimuth-elevation or the target-aligned configurations. A comprehensive study on stroke minimization of prismatic joints is carried out. It is found that a stroke of 700 mm is required for a 2 m x 2 m heliostat at Bangalore when the farthest heliostat is at a distance of 300 m from the tower. Although, there is an extra motor required to track the sun, the 3-RPS manipulator is better than the conventional methods if the mirror area per actuator criteria is taken into consideration. Prototypes of the Az-El and 3-RPS heliostats were made with a mirror size of 1 m x 1 m. A PID controller implemented using MATLAB-Simulink and a low cost, custom made motor driver circuit is used to control the motion of the 3-RPS heliostat. The algorithm developed is tested on the prototype by tracking a point marked on the wall of the lab space and is found to have a tracking error of only 7.1 mrad. Finally, the actual sun tracking is carried out on the roof of a building reflecting the sun-light to a wall situated 6.72 m above and a distance of 15.87 m from the heliostats. The images are captured at various instances of time from 11:30 a.m. to 3:30 p.m. on October 15th and November 10th, 2016, tracking errors are quantified and it is demonstrated that the proposed 3-RPS parallel manipulator can indeed work as a heliostat in concentrated solar power plants.

Les environnements CAO fournissent des outils puissants pour la programmation graphique et la manipulation d’entités géométriques complexes. Dans cette thèse, nous proposons d’exploiter ce potentiel dans le domaine de la conception de robots parallèles. Ces robots sont considérés comme une alternative intéressante vis-à-vis de leurs homologues sériels dans différentes applications comme le « pick and place » et l’usinage. Cependant, leur utilisation industrielle est encore restreinte en raison d’un espace de travail limité, de modèles géométriques difficiles à résoudre et l’existence de configurations singulières délimitant leur domaine d’exploitation. L’analyse et la caractérisation de l’espace de travail jouent alors un rôle fondamental dans la phase de conception de robots manipulateurs parallèles. Dans ce travail de thèse, nous proposons des approches géométriques originales donnant lieu à un ensemble de méthodes et techniques basées CAO pour l’analyse et la caractérisation de l’espace de travail de robots parallèles plans et spatiaux. L’espace de travail est généré comme un solide dans l’environnement CAO à partir d’un paramétrage géométrique, d’esquisses et d’opérations élémentaires telles que le balayage hélicoïdal et l’intersection. Nous avons montré que ces méthodes constituent des outils pertinents et efficaces d’aide à la conception des mécanismes parallèles. Ils permettent également la résolution du problème géométrique direct et la génération de trajectoires libres de singularités. Plusieurs types de manipulateurs ont été considérés dans ce travail pour mettre en avant et illustrer les techniques CAO / Géométriques proposées : robots parallèles plans à 3 degrés de mobilité de type 3-RPR, 3-RRR, 3-PPR et 3-PRR, robots parallèles spatiaux à 6 degrés de mobilité de type ou 3-CRS ou 3-PRRS. / CAD environments provide very powerful tools for graphical programming and manipulation of complex geometric entities. In this thesis, we propose to exploit such potential in the design of parallel robots. These robots are considered an attractive and important alternative towards their serials counterparts in various applications, like “pick and place” and machining. However, their industrial applications are restricted due to limited workspace, complexity related to resolution of the direct geometric model, and in addition the existence of the singular configurations which bound their application field. The analysis and the characterization of the workspace therefore play an essential role in the design phase of parallel robotic manipulators. In this thesis, we suggest original geometric approaches giving rise to a set of methodologies and techniques based on the use of CAD in order to analyze and characterize the workspace of planar and spatial parallel robotic manipulators. Workspace is generated as a solid in CAD environment by using a parametric geometric model, sketches, and elementary operations such as helical scanning and performing then Boolean intersection operation. We have shown in this thesis, that the proposed methodologies represent relevant and efficient tools which assist designers of parallel mechanisms. Moreover, they allow us to solve the direct geometric problem and to plan singularity-free trajectories. Several types of robotic manipulators have been considered in this work to highlight and illustrate the proposed CAD / Geometric techniques : planar parallel manipulators having three degree of freedom such as 3-RPR, 3-RRR, 3-PPR, and 3-PRR, and spatial parallel robotic manipulators having six degree of freedom 3-CRS-type.

Ce travail présente une nouvelle approche de synthèse de la commande non linéaire en suivi de trajectoire de robots manipulateurs. Malgré la richesse de la littérature dans le domaine, le problème n'a pas encore été traité de manière adéquate : en raison de l'existence inévitable dans les applications pratiques de perturbations et incertitudes telles que les forces de frottement, des perturbations externes ou les variations des paramètres il est difficile d'assurer un suivi de trajectoire de haute précision. Afin de résoudre ce problème, nous proposons tout d'abord une méthode de commande prenant en compte la performance H∞ pour le suivi de trajectoire d'un robot manipulateur. Deuxièmement, nous proposons un nouveau cadre pour la synthèse de lois de commande combinant une action anticipatrice et un retour d'état basée sur une représentation sous forme Takagi-Sugeno descripteur de la dynamique du manipulateur. Un avantage de la représentation choisie est de pouvoir simultanément simplifier le calcul des gains de commande à l'aide de LMI de dimension réduite et de réduire la complexité du correcteur en agissant sur le nombre de règles du modèle de Takagi-Sugeno. Basé sur la théorie de la stabilité de Lyapunov, le réglage du correcteur est formulé comme un problème d'optimisation LMI (inégalité matricielle linéaire). Les résultats obtenus en simulation effectuée avec un modèle de manipulateur série développé dans l'environnement Simscape MultibodyTM de Matlab R démontrent clairement l'efficacité de la méthode proposée en comparaison avec le régulateur PID et la commande CTC (Computed Torque Control). / This work presents a new design approach for trajectory tracking control of robot manipulators. In spite of the rich literature in the field, the problem has not yet been addressed adequately due to the lack of an effective control design. In general, it is difficult to adopt design to achieve high-precision tracking control due to the uncertainties in practical applications, such as friction forces, external disturbances and parameter variations. In order to cope this problem, we propose first control with H∞ performance to reference trajectory tracking control of two degrees of freedom robot. Secondly, we propose a new design framework with parametric uncertainties and unknown disturbances by using the feedback and the feedforward controllers. Using the descriptor Takagi-Sugeno systems, the design goal is to achieve a guaranteed tracking performance while signicantly reducing the numerical complexity of the designed controller through a robust control scheme. Based on Lyapunov stability theory, the control design is formulated as an LMI (linear matrix inequality) optimization problem. Simulation results carried out with a high-fidelity serial manipulator model embedded in the Simscape MultibodyTM environment of MatlabR clearly demonstrate the effectiveness of the proposed method by comparing with PID controller and computed torque controller.

[pt] Os avanços da Robótica nas últimas décadas permitem um aumento nas gamas de aplicações de manipuladores robóticos em diversos setores da indústria. Isto, impacta diretamente a interação Homem-Robô (HRI), resultando em um aumento de tarefas que requerem compartilhamento de ambiente de trabalho, desempenho de segurança e a habilidade de detecção de contato do manipulador robótico. Consequentemente, métodos de controle capazes de prever contato, controlar força ou trajetória para evitar danos durante colisões se tornam cada vez mais necessários seja por questões de segurança ou de desempenho. Separando a dinâmica de um manipulador de um único elo em dois modos, sendo eles modo de controle de posição (modo livre) e modo de controle de torque (modo de contato), a primeira parte desta dissertação, lida com o problema de estimação de estados para detecção do modo ativo através da implementação do método de Estimação de Estados de Horizonte móvel com Redes Neurais (NNMHSE). A efetividade do método de estimação proposto é avaliada através da comparação dos estados e modos gerados pelo MHSE e dos estimados pela Rede Neural. Este método apresentou baixos valores de RMSE, altos valores de R(2), e uma redução do tempo de processamento do algoritmo de estimação. A segunda parte desta dissertação lida com o problema de controle de posição e força chaveado para um manipulador robótico não linear, aplicando Controle Preditivo Baseado em Modelo (MPC). O algoritmo MPC chaveado implementado mostrou-se capaz de controlar efetivamente ambos os modos do sistema apresentando baixo erro na predição, aproximadamente 2 por cento no modo de controle de posição e 0.5 por cento no modo de controle de torque, mesmo considerando alterações cíclicas nos modos. Ambos os métodos provam ser adequados para controle de manipuladores robóticos colocalizados com seres humanos ou em ambientes desestruturados por meio da detecção do modo de operação e do controle chaveado posição-torque. / [en] The advances in Robotics in recent decades allow a growing range of robotic manipulator applications in various industry sectors. This directly impacts Human-Robot Interaction (HRI), increasing tasks that require a shared work environment, safety performance, and the contact detection ability of the robotic manipulator. Consequently, control methods capable of predicting contact, and controlling force or trajectory to avoid damage during collisions become increasingly necessary either for safety or performance reasons. Separating the dynamics of a single-link manipulator into two modes, namely position control mode (free mode) and torque control mode (contact mode), the first part of this dissertation deals with the estimation problem of states for active mode detection through the implementation of the Moving Horizon State Estimation with Neural Networks (NNMHSE) method. The effectiveness of the proposed estimation method is evaluated by comparing the states and modes generated by the MHSE and those estimated by the Neural Network. This method showed low RMSE values, high values of R(2), and a reduction in the processing time of the estimation algorithm. The second part of this dissertation deals with the position and force switching problem for a non-linear robotic manipulator, applying Model-Based Predictive Control (MPC). The implemented switched MPC algorithm effectively controlled both modes of the system, presenting low prediction error, approximately 2 percent in position control mode and 0.5 percent in torque control mode, even considering cyclical changes in the modes. Both methods prove to be suitable for controlling co-located robotic manipulators with humans or in unstructured environments through operation mode detection and position-torque switching control.

Cable-actuated manipulators (or 'cable robots') constitute a relatively new classification of robots which use motors, located at fixed remote locations, to manipulate an end-effector by extending or retracting cables. These manipulators possess a number of unique properties which make them proficient with tasks involving high payloads, large workspaces, and dangerous or contaminated environments. However, a number of challenges exist which have limited the mainstream emergence of cable robots. This thesis addresses two of the most important of these issues-- workspace analysis and disturbance compensation. Workspace issues are particularly important, as many large-scale applications require the end-effector to operate in regions of a particular shape, and to exert certain minimum forces throughout those regions. The 'Force-Feasible Workspace' represents the set of end-effector positions, for a given robot design, for which the robot can exert a set of required forces on its environment. This can be considered as the robot's 'usable' workspace, and an analysis of this workspace shape for point-mass cable robots is therefore presented to facilitate optimal cable robot design. Numerical simulation results are also presented to validate the analytical results, and to aid visualization of certain complex workspace shapes. Some cable robot applications may require mounting motors to moving bases (i.e. mobile robots) or other surfaces which are subject to disturbances (i.e. helicopters or crane arms). Such disturbances can propagate to the end-effector and cause undesired motion, so the rejection of motor mount disturbances is also of interest. This thesis presents a strategy for measuring these disturbances and compensating for them. General approaches and implementation issues are explored qualitatively with a simple one-degree-of-freedom prototype (including a strategy for mitigating accelerometer drift), and quantitative simulation results are presented as a proof of concept.