Redundant underactuated robot with multi-mode control framework
11247332 · 2022-02-15
Assignee
Inventors
- Muhammad E. Abdallah (Rochester Hills, MI, US)
- James W. Wells (Rochester Hills, MI, US)
- Pascal Labrecque (Alberta, CA)
- Clement Gosselin (Quebec, CA)
- Thierry LALIBERTE (Quebec, CA)
Cpc classification
B25J9/1633
PERFORMING OPERATIONS; TRANSPORTING
B25J13/088
PERFORMING OPERATIONS; TRANSPORTING
G05B2219/40198
PHYSICS
G05B2219/40241
PHYSICS
B25J9/1653
PERFORMING OPERATIONS; TRANSPORTING
G05B2219/40297
PHYSICS
G05B2219/39195
PHYSICS
International classification
B25J9/00
PERFORMING OPERATIONS; TRANSPORTING
Abstract
A jointed mechanism includes a passive pendulum system attached to and suspended from the multi-axis robot. The system includes one or more position sensors configured to measure a joint angle on the pendulum system, at least one arm, and an end-effector attached to a distal end of the pendulum system. A controller implements a method to selectively control motion of the robot in a plurality of control modes. The control modes include a Cooperative Mode and an Autonomous Mode. The controller is configured to detect contact with the end-effector when operating in the Autonomous Mode, and to automatically initiate a control action in response to the contact. The pendulum system may be a parallelogram arrangement.
Claims
1. A jointed mechanism comprising: a multi-axis robot; and a passive pendulum system attached to and suspended from the multi-axis robot, the passive pendulum system having an equilibrium position and including: one or more position sensors configured to measure one or more joint angles on the passive pendulum system; at least one arm; and an end-effector attached to the at least one arm at a distal end of the pendulum system; and a controller in communication with the one or more position sensors, wherein the controller is configured, in response to the one or more joint angles, to selectively control the robot in a plurality of control modes, including: a Cooperative Mode configured, in response to a physical interaction by a human operator with the end-effector, to cause a displacement in the passive pendulum system from the equilibrium position, and in which the controller is configured to command the robot to move in such a manner as to close the displacement and thereby return the passive pendulum system to the equilibrium position; and an Autonomous Mode configured to move the robot without a physical interaction with the end-effector by the human operator, wherein the controller is configured to detect unexpected contact with the end-effector when operating in the Autonomous Mode based on a deviation of a measured joint motion of the passive pendulum system from an expected joint motion, and to automatically initiate a control action in response to the unexpected contact.
2. The jointed mechanism of claim 1, wherein the at least one arm includes parallel arms, the passive pendulum system is a passive parallelogram arrangement having a cross member connected to the parallel arms, and the end-effector is connected to the cross member at the distal end.
3. The jointed mechanism of claim 2, wherein the passive parallelogram arrangement is configured to allow the end-effector to translate in two Cartesian horizontal degrees of freedom.
4. The jointed mechanism of claim 1, wherein the control action includes executing an automatic stop in motion of the robot.
5. The jointed mechanism of claim 1, wherein the control action includes an automatic transition from the Autonomous Mode to the Cooperative Control Mode.
6. The jointed mechanism of claim 1, wherein the controller is programmed to control the jointed mechanism in the Autonomous Mode in a manner that ensures the end-effector does not exhibit under-damped oscillations.
7. A method for controlling a jointed mechanism having a multi-axis robot and a passive pendulum system attached thereto and suspended therefrom, the method comprising: measuring rotational joint positions on the passive pendulum system using a plurality of position sensors; outputting position signals indicative of the rotational joint positions to a controller; and in response to the position signals, using the controller to selectively control motion of the robot in a plurality of control modes, including: a Cooperative Mode configured, in response to a physical interaction by a human operator with the end-effector, to cause a displacement in the passive pendulum system from an equilibrium position, and in which the controller is configured to command the robot to move in such a manner as to close the displacement and thereby return the passive pendulum system to the equilibrium position; and an Autonomous Mode configured to move the robot without a physical interaction with the end-effector by the human operator, wherein the controller is configured to detect unexpected contact with the end-effector when operating in the Autonomous Mode, and to automatically initiate a control action in response to the contact, wherein detecting the unexpected contact is based on a deviation of a measured joint motion of the passive pendulum system from an expected joint motion.
8. The method of claim 7, wherein the passive pendulum system includes at least one arm attached to the end-effector and to the robot.
9. The method of claim 7, further comprising: moving the robot in the Cooperative Mode and the Autonomous Mode by translating the end-effector in a first Cartesian horizontal degree of freedom; and translating the end-effector in a second Cartesian horizontal degree of freedom that is different than the first Cartesian horizontal degree of freedom.
10. The method of claim 9, wherein the robot includes a horizontal overhead support beam, and wherein translating the end-effector occurs along an axis of the overhead support beam.
11. The method of claim 7, wherein the control action includes regulating a force applied to an object by the end-effector.
12. The method of claim 7, wherein the control action includes executing an automatic stop in motion of the robot.
13. The method of claim 7, the method further comprising: receiving data via the controller during a work task; and identifying an occurrence of an error or a completion of the work task using the received data, wherein the data includes position data, force data, and/or vision data.
14. A jointed mechanism comprising: a horizontal overhead support beam; a robot, including an actuated positioning mechanism connected to and configured to translate along the overhead support beam in two Cartesian degrees of freedom; a passive parallelogram arrangement attached to and suspended from the actuated positioning mechanism, having an equilibrium position, and including: one or more position sensors configured to measure one or more joint angles on the passive parallelogram arrangement; parallel arms; a cross member connected to the parallel arms; and an end-effector attached to the cross member at a distal end of the passive parallelogram arrangement; and a controller in communication with the one or more position sensors, wherein the controller is configured, in response to the one or more joint angles, to selectively control the passive parallelogram arrangement in a plurality of control modes, including: a Cooperative Mode configured, in response to a physical interaction by a human operator with the end-effector, to cause a displacement in the passive parallelogram arrangement from the equilibrium position, and in which the controller is configured to command the robot to move in such a manner as to close the displacement and thereby return the passive parallelogram arrangement to the equilibrium position; and an Autonomous Mode configured to move the robot without a physical interaction with the end-effector by the human operator, wherein the controller is configured to detect unexpected contact with the end-effector when operating in the Autonomous Mode based on a deviation of a measured joint motion of the passive pendulum system from an expected joint motion, and to automatically initiate a control action in response to the unexpected contact.
15. The jointed mechanism of claim 14, wherein the control action includes an automatic transition from the Autonomous Mode to the Cooperative Control Mode.
16. The jointed mechanism of claim 14, wherein the control action includes executing an automatic stop in motion of the robot.
17. The jointed mechanism of claim 14, wherein the controller is programmed to control the jointed mechanism in the Autonomous Mode in a manner that ensures the end-effector does not exhibit under-damped oscillations.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1)
(2)
(3)
(4)
(5)
DETAILED DESCRIPTION
(6) Several embodiments of the disclosure are illustrated in the accompanying drawings. The same or similar reference numerals are used in the drawings and the description to refer to the same or similar structure. The drawings are in simplified form and are not to scale. For purposes of convenience and clarity, directional terms such as top, bottom, left, right, up, over, above, below, beneath, rear, and front, may be used with respect to the drawings. These and similar to directional terms are not to be construed to limit the scope of the disclosure.
(7) An example robotic system 10 is shown in
(8) In the non-limiting embodiment shown in
(9) The mini mechanism 14, a non-limiting example of which is shown in
(10) The robotic system 10 includes a controller (C) 50, which in some embodiments is an impedance controller of the type described below. The controller 50 may be programmed to receive such data during a manual work task and identify an occurrence of an error or a completion of the manual task using the received data. The controller 50 may be embodied as one or more digital computers having a processor (P) and memory (M). The memory (M) includes sufficient amounts of tangible, non-transitory memory, e.g., read only memory, flash memory, optical and/or magnetic memory, electrically-programmable read only memory, and the like. Memory (M) also includes sufficient transient memory such as random access memory, electronic buffers. Hardware of the controller 50 may include a high-speed clock, analog-to-digital and digital-to-analog circuitry, and input/output circuitry and devices, as well as appropriate signal conditioning and buffer circuitry.
(11) The memory (M) may be programmed with computer-readable instructions 100 enabling the controller 50 to control active joints, brakes, and/or locking mechanisms of the robotic system 10 as needed to execute and switch between the available control modes (arrow CM) noted above, i.e., the Autonomous Mode and the Cooperative Control Mode, with force control modes also available or, in the example embodiment of
(12) Referring briefly to
(13) The controller 150 in such an embodiment may receive joint position signals (arrow θ) from a corresponding position sensor 15P and, using the recorded instructions 200, perform an error-proofing operation resulting in an output signal (arrow CC.sub.o). By way of example, some operations require a manual application of force, such as the example panel adhesive operation noted above. Variation in the force applied via an actuator 45 may result in differences in adhesion quality around a perimeter of such a panel. By using force control with the jointed mechanism 220 with the mini mechanism 140 as a redundant, underactuated robotic system alternative to the robotic system 10 of
(14) As will be now be described with particular reference to
(15) A moving cart-pendulum system may be exemplified as the overhead configuration of
Impedance Control Law
(16) The behavior of the robotic system 10 may be modeled in logic of the impedance controller 50 of
m{umlaut over (x)}+b{dot over (x)}+kΔx=ΔF
with Δx being the change in a position (x) of the mass (m) in response to a change in force (ΔF). Thus, using impedance control of the controller 50 of
(17) The present approach is based on a computer technique formulation, and thus applies to both control modes of the controller 50 without requiring linearization or estimation of the force. Moreover, the present approach operates directly in the operational space of the end-effector 14H of
Linear Model
(18) Referring to
(19)
where m is the mass of the end-effector 14H, b is the desired damping coefficient, k is the desired stiffness, i.e., the actively-controlled effective stiffness, and x.sub.2.sup.* is the reference position of the mass (m). F in the above-noted formulation is the external force on the mass (m) from the operator and F* is the commanded force from the controller 50. The steady-state force F.sub.SS is thus determined as noted in equation (2) differently in the Autonomous Mode and the Cooperative Control Mode.
(20) Force analysis on the end-effector 14 of
m{umlaut over (x)}.sub.2=F+k.sub.S(x.sub.1−x.sub.2) (3)
where k.sub.s is the actual physical stiffness of the spring 20 used in the model (a constant). Assuming the jointed mechanism 12/cart 120 employs a 1.sup.st order position controller:
{dot over (x)}.sub.1=−k.sub.p(x.sub.1−x.sub.1.sup.*) (4)
where k.sub.p is a proportional gain and {dot over (x)}.sub.1 is proportional to error in position of the cart 120/robot 12. Solving from equations (1) and (2), the control law for the desired macro position follows as:
(21)
Closed-Loop Dynamics
(22) Assuming a perfect 1.sup.st order controller, the dynamics of the jointed mechanism 12 follows:
(23)
where
(24)
In the Autonomous Mode, closed-loop dynamics may be provided from equations (3), (5), and (6) in the Laplace domain as follows:
(25)
When operating in the Autonomous Mode, the controller 50 is concerned with the position of the end-effector 14. Thus, the following transfer function follows, assuming F=0:
(26)
As the jointed mechanism 12 speeds up, i.e., as a becomes smaller, the transfer function of equation (8) approaches the desired 2.sup.nd order response behavior.
(27) As noted above, impedance control offers the opportunity to model the behavior of an active system like that of a simple mass-spring-damper system to obtain the desired 2.sup.nd order response behavior. The dynamic response of such a mass-spring-damper system is shown schematically in the response plot 70 of
(28) In the Cooperative Control Mode, intuitiveness of control is of primary concern to the controller 50 of
(29)
In this case, as the jointed mechanism 12 speeds up, the response approaches a 1.sup.st order response. Such 1.sup.st order behavior, without oscillations of the mass (m) or the end-effector 14H, is a targeted behavior to result in the most intuitive interaction for cooperative manipulation. Speeding up the jointed mechanism 12 reduces the severity of oscillations for an overdamped behavior without reducing response time.
(30) Referring to
(31)
Hence, increasing the value of k.sub.p also increases the low-frequency gain of the robotic system 10. In other words, less force is required to achieve the same velocity.
(32) It is desirable to have the jointed mechanism 12 respond as quickly as possible, given the 1.sup.st order position follower behavior demonstrated above. The faster the jointed mechanism 12 can respond, the more intuitive an interaction with an operator will be, and with less effort required. In Autonomous Mode, the damping coefficient b adds damping to reduce oscillations, which may be desirable. In Cooperative Mode, the damping coefficient b adds effective stiffness to the response. It thus increases the tendency to oscillate, which is generally undesirable. It also decreases the steady-state gain, which may be beneficial as explained below. It can be shown that a window of damping exists that allows both control modes to be overdamped with the same b value. Otherwise, different values can be used for each control mode.
Non-Linear Model
(33) Referring to
0={umlaut over (x)}.sub.2+{dot over (θ)}.sup.2l sin θ+(cos.sup.2θ−1){umlaut over (x)}.sub.1+g sin θ cos θ (10)
Here, l is the length of the pendulum shown in
(34)
Since lsinθ=x.sub.2−x.sub.1, the desired acceleration can be found from the impedance relationship (1) noted above. Solving for the control law:
(35)
where
(36)
The parallel to relationship (5) above is thus apparent.
(37) The detailed description and the drawings or figures are supportive and descriptive of the disclosure, but the scope of the disclosure is defined solely by the claims. While some of the best modes and other embodiments for carrying out the claimed disclosure have been described in detail, various alternative designs and embodiments exist for practicing the disclosure defined in the appended claims.