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Chapter 11 — Robots with Flexible Elements

Alessandro De Luca and Wayne J. Book

Design issues, dynamic modeling, trajectory planning, and feedback control problems are presented for robot manipulators having components with mechanical flexibility, either concentrated at the joints or distributed along the links. The chapter is divided accordingly into two main parts. Similarities or differences between the two types of flexibility are pointed out wherever appropriate.

For robots with flexible joints, the dynamic model is derived in detail by following a Lagrangian approach and possible simplified versions are discussed. The problem of computing the nominal torques that produce a desired robot motion is then solved. Regulation and trajectory tracking tasks are addressed by means of linear and nonlinear feedback control designs.

For robots with flexible links, relevant factors that lead to the consideration of distributed flexibility are analyzed. Dynamic models are presented, based on the treatment of flexibility through lumped elements, transfer matrices, or assumed modes. Several specific issues are then highlighted, including the selection of sensors, the model order used for control design, and the generation of effective commands that reduce or eliminate residual vibrations in rest-to-rest maneuvers. Feedback control alternatives are finally discussed.

In each of the two parts of this chapter, a section is devoted to the illustration of the original references and to further readings on the subject.

Cartesian impedance control with damping off

Author  Alin Albu-Schaeffer

Video ID : 133

This 2010 video shows the performance of a Cartesian impedance controller for the torque-controlled KUKA-LWR robot holding an extra payload, when the damping term in the controller has been turned off. The response to a contact force (a human pushing on the end-effector) is oscillatory due to the joint elasticity. This is one of two coordinated videos, the other for the case with controller damping turned on. Reference: A. Albu-Schaeffer, C. Ott, G. Hirzinger: A unified passivity-based control framework for position, torque and impedance control of flexible joint robots, Int. J. Robot. Res. 26(1), 23-39 (2007) doi: 10.1177/0278364907073776

Cartesian impedance control with damping on

Author  Alin Albu-Schaeffer

Video ID : 134

This 2010 video shows the performance of a Cartesian impedance controller for the torque-controlled KUKA-LWR robot holding an extra payload when the damping term is active in the controller. The transient response to a contact force (a human pushing on the end-effector) is very short and free of oscillations. This is one of two coordinated videos, the other being for the case with controller damping turned off. Reference: A. Albu-Schaeffer, C. Ott, G. Hirzinger: A unified passivity-based control framework for position, torque and impedance control of flexible joint robots, Int. J. Robot. Res. 26(1), 23-39 (2007) doi: 10.1177/0278364907073776

Control experiments for a flexible-joint robot arm

Author  Mark Spong

Video ID : 135

This 1989 video is about an experimental single-link arm with an elastic joint moving under gravity, which was developed at the Coordinated Science Lab of the University of Illinois at Urbana. The video illustrates some of the control techniques that are mentioned in the first part of Chap. 11: e.g., computed torque using the rigid model (unstable), feedback linearizing control including elasticity (perfect design), and corrective control based on singular perturbation analysis (and its adaptive version). Reference: F. Ghorbel, J.Y. Hung, M.W. Spong: Adaptive control of flexible joint robots, IEEE Control Syst. Mag. 9(7), 9-13 (1989) doi: 10.1109/37.41450

Feedforward/feedback law for path tracking with a KUKA KR15/2 robot

Author  Michael Thümmel

Video ID : 136

This 2006 video shows the performance of a type of model-based feedforward (using the elastic joint model) plus state-feedback stabilization for trajectory tracking. Designed for an industrial KUKA KR15/2 manipulator having cycloidal gearboxes, which are known for their visco-elasticity, this controller is compared to a standard one for the robot task of moving in a rest-to-rest mode along three (orthogonal) square paths in Cartesian space. References: 1. M. Thümmel: Modellbasierte Regelung mit nichtlinearen inversen Systemen und Beobachtern von Robotern mit elastischen Gelenken, Dissertation, Technische Universität München, Munich, (2006) (in German); 2. A. De Luca, D. Schröder, M. Thümmel: An acceleration-based state observer for robot manipulators with elastic joints, IEEE Int. Conf. Robot. Autom. (ICRA), Rome (2007), pp. 3817-3823, 2007. doi: 10.1109/ROBOT.2007.364064

Trajectory generation and control for a KUKA IR 161/60 robot

Author  Joris De Schutter

Video ID : 770

This ICRA 1992 video shows the performance obtained with two simple modifications of a standard robot controller for a KUKA IR 161/60 industrial robot, namely improved trajectory generation and control of the first joint bases on a flexible joint model. At very high velocities and accelerations, there is a significant difference between the flexible controller and a classical PID controller. A nonlinear flexible controller implemented for links 2 and 3 improves the static and dynamic accuracy of the robot. Reference: J. Swevers, D. Torfs, M. Adams, J. De Schutter, H. Van Brussel: Comparison of control algorithms for flexible joint robots implemented on a Kuka IR 161/60 industrial robot, 5th Int. Conf. Adv. Robot., Pisa (1991), pp. 120-125; doi: 10.1109/ICAR.1991.240465

Input shaping on a lightweight gantry robot

Author  Wayne Book

Video ID : 777

This video shows an industrial application by CAMotion, Inc. of input command shaping to cancel modes of vibration of a large, lightweight gantry robot, designated the LDP, carrying a heavy “log” of printed paper to a conveyor. The method has been patented (D.P. Magee, W.J. Book: Optimal Arbitrary Time-delay (OAT) Filter and Method to Minimize Unwanted System Dynamics, US Patent 6078844 (2000)). This commercial robot is the one depicted also in Fig. 11.13. Its successor is marketed by PaR Systems, Inc. Reference: D.P. Magee, W.J. Book: The application of input shaping to a system with varying parameters, Proc. 1992 Japan-USA Symp. Flexible Automation, San Francisco (1992), pp. 519-526

Inverse dynamics control for a flexible link

Author  Wayne Book

Video ID : 778

A single flexible link with rotation at its base is controlled by computing the stable inverse dynamics of the flexible system associated with the desired trajectory for the end-effector. This feedforward command is made more robust by the addition of a suitable PD feedback control at the joint. Because of the non-minimum phase nature of the tip output, the resulting input command is non-causal, starting ahead of the actual output trajectory (pre-shaping the link) and ending after (discharging the link). Comparison is made with a PD joint control using a step reference input and with a full state feedback (utilizing strain gauge signals and their rates) and a nominal trajectory command. The inverse dynamics control demonstrates superiority both in terms of overshoot and residual vibrations. References: 1. D.-S. Kwon: An Inverse Dynamic Tracking Control for a Bracing Flexible Manipulator, Dissertation, School of Mechanical Engineering, Georgia Institute of Technology, Atlanta, (1991); 2. D.-S. Kwon, W.J. Book: A time-domain inverse dynamic tracking control of a single-link flexible manipulator, ASME J. Dyn. Syst. Meas. Control 116, 193-200 (1994); doi: 10.1115/1.2899210

Rest-to-rest motion for a flexible link

Author  Alessandro De Luca

Video ID : 779

This 2003 video shows a planar one-link flexible arm executing a desired rest-to-rest motion in a given finite time (90 deg in 2 s). Link deformations vanish completely at the desired final time. The applied control law is the combination of a model-based feedforward command designed for a smooth trajectory assigned to the flat output of the system and of a stabilizing PID feedback action on the joint angle around its associated trajectory. References: 1. A. De Luca, G. Di Giovanni: Rest-to-rest motion of a one-link flexible arm, Proc. IEEE/ASME Int. Conf. Adv. Intell. Mechatron., Como (2001), pp. 923-928; doi: 10.1109/AIM.2001.936793; 2. A. De Luca, V. Caiano, D. Del Vescovo: Experiments on rest-to-rest motion of a flexible arm, in B. Siciliano, P. Dario (Eds), Experimental Robotics VIII, Springer Tract. Adv. Robot. 5, 338-349 (2003); doi: 10.1007/3-540-36268-1_30

PID response to impulse in presence of link flexibility

Author  Wayne Book

Video ID : 780

A laboratory gantry robot with a final flexible link is excited by an external impulse disturbance. The video shows the very low damping of the flexible link under PID joint control. This is one of two coordinated videos, the other showing the same experiment under state feedback control. Reference: B. Post: Robust State Estimation for the Control of Flexible Robotic Manipulators, Dissertation, School of Mechanical Engineering, Georgia Institute of Technology, Atlanta (2013)

State feedback response to impulse in presence of link flexibility

Author  Wayne Book

Video ID : 781

A laboratory gantry robot with a final flexible link is excited by an external impulse disturbance. The video shows the effective damping obtained using full state feedback control with an accurately tuned estimator. The reduction in settling time compared to PID joint control is dramatic. This is one of two coordinated videos, the other showing the same experiment under PID control. Reference: B. Post: Robust State Estimation for the Control of Flexible Robotic Manipulators, Dissertation, School of Mechanical Engineering, Georgia Institute of Technology, Atlanta (2013)