Abstract With the increasing adoption of Industry 4.0, optical metrology has experienced a significant boom in its implementation, as an ever-increasing number of manufacturing processes are overhauled for in-process measurement and control. As such, optical metrology for digital manufacturing is currently a hot topic in manufacturing research. Whilst contact coordinate measurement solutions have been adopted for many years, the current trend is to increasingly exploit the advantages given by optical measurement technologies. Smart automated non-contact inspection devices allow for faster cycle times, reducing the inspection time and having a continuous monitoring of process quality. In this paper, a review for the state of the art in optical metrology is presented, highlighting the advantages and impacts of the integration of optical coordinate and surface texture measurement technologies in digital manufacturing processes. Also, the range of current software and hardware technologies for digital manufacturing metrology is discussed, as well as strategies for zero-defect manufacturing for greater sustainability, including examples and in-depth discussions of additive manufacturing applications. Finally, key current challenges are identified relating to measurement speed and data-processing bottlenecks; geometric complexity, part size and surface texture; user-dependent constraints, harsh environments and uncertainty evaluation.
This paper examines the design and control of a robotic arm inspired by the anatomy and neurophysiology of Octopus vulgaris in light of embodiment theory. Embodiment in an animal is defined as the dynamic coupling between sensorymotor control, anatomy, materials, and the environment that allows for the animal to achieve effective behaviour. Octopuses in particular are highly embodied and dexterous animals: their arms are fully flexible, can bend in any direction, grasp objects and modulate stiffness along their length. In this paper the biomechanics and neurophysiology of octopus have been analysed to extract relevant information for use in the design and control of an embodied soft robotic arm. The embodied design requirements are firstly defined, and how the biology of the octopus meets these requirements presented. Next, a prototype continuum arm and control architecture based on octopus biology, and meeting the design criteria, are presented. Finally, experimental results are presented to show how the developed prototype arm is able to reproduce motions performed by live octopus for contraction, elongation, bending, and grasping.
Modern engineering design is leading towards structures that are complex and lightweight. These structures often contain flexible and rigid components actuated through large displacements by a non-linear hydraulic system. Due to the increased system complexities, there is a need to define structural models that can be easily coupled to models of the hydraulic system for use in the design of suitable controllers. The current paper develops a modular system model composed of rigid and flexible structural components coupled directly to a non-linear hydraulic system. The resulting model allows for changes to be made to the hydraulic and structural components in an independent manner such that the entire system may be incorporated in a single simulation domain. A structural damping matrix is introduced that allows a control system designer to assign realistic modal damping ratios to well established modes, and higher damping to modes with significant uncertainty. This allows for increased steady-state accuracy and model run-time efficiency, which is beneficial to the controller design process presented in Part 2. The system modelling approach is applied to a hydraulically actuated experimental rig for validation purposes.
Continuum robots have excited increasing attention and efforts from the robotic community due to their high dexterity and safety. This paper proposes a design for a type of multimodule continuum robot equipped with an elastic backbone structure and tendon-driven actuation system. The kinematic model of the robot is formulated where the maximum bending angle of a module is obtained by identifying the interference between the backbone structure and the tendons. A superposition method is then used to determine the configuration space of the robotic module. Finally, an approximation method is presented to estimate the workspace of the tendon-driven continuum robot that reduces the computational complexity in comparison with the previously used scanning method. Experiments are provided to validate the proposed methods.
Abstract Mechanical components in a robotic system were used to provide body structure and mechanism to achieve physical motions following the commands from electronic controller. This kind of robotic system utilizes complex hardware and firmware for sensing and planning. To reduce computational cost and increase reliability for a robotic system, employing mechanical components to fully or partially take over control tasks is a promising way, which is also referred to as “mechanical intelligence” (MI). This paper proposes a shape memory alloy driven robot capable of using a reciprocating motion to crawl over a surface without any use of electronic controller. A mechanical logic switch is designed to determine the activation timing for a pair of antagonistic shape memory alloy (SMA) actuators. Meanwhile, a compliant pre-strain bistable mechanism is introduced to cooperate with the SMA actuators achieving reliable reciprocating motion between the two stable positions. The SMA actuator is modeled base on a static two-state theory while the bistable mechanism is described by combining a pseudo-rigid-body model (PRBM) with a Bi-beam constraint model (Bi-BCM). Following this, the design parameters of the bistable mechanism and SMA actuators are determined according to theoretical simulations. Finally, a robotic prototype is fabricated using anisotropic friction on its feet to convert the reciprocating motion of the actuator to uni-directional locomotion of the robot body over a surface. Experiments are carried out to validate the presented design concept and the modeling methods.
This paper presents, for the first time, the electrical response of knitted conductive fabrics to a considerable number of cycles of deformation in view of their use as wearable sensors. The changes in the electrical properties of four knitted conductive textiles, made of 20% stainless steel and 80% polyester fibers, were studied during unidirectional elongation in an Instron machine. Two tests sessions of 250 stretch–recovery cycles were conducted for each sample at two elongation rates (9.6 and 12 mm/s) and at three constant currents (1, 3 and 6 mA). The first session assessed the effects of an extended cyclic mechanical loading (preconditioning) on the electrical properties, especially on the electrical stabilization. The second session, which followed after a 5 minute interval under identical conditions, investigated whether the stabilization and repeatability of the electrical features were maintained after rest. The influence of current and elongation rate on the resistance measurements was also analyzed. In particular, the presence of a semiconducting behavior of the stainless steel fibers was proved by means of different test currents. Lastly, the article shows the time-dependence of the fabrics by means of hysteresis graphs and their non-linear behavior thanks to a time–frequency analysis. All knit patterns exhibited interesting changes in electrical properties as a result of mechanical preconditioning and extended use. For instance, the gauge factor, which indicates the sensitivity of the fabric sensor, varied considerably with the number of cycles, being up to 20 times smaller than that measured using low cycle number protocols.
This paper presents a real-time position control solution for the targets used in the high-repetition rate laser operations of high-power laser facilities. The control system is designed based on an Abbe-compliant, in-process position measurement system of targets, employing a plane mirror interferometer and a five degree-of-freedom hybrid mechanism. An error model is developed to characterise the position feedback information of target for a high-repetition rate process to determine the effects of the non-collocation of the sensor's measurement point and target on the control system's performance – a challenge for the real-time position control of targets. Behaviour of the control system is investigated with the error model and experimental data. It is found that a controller's position compensation scheme can be ineffective due to the erroneous position feedback as a result of the non-linear position information associated with the non-collocated measurement point and the actual target. To solve the problem, an angular compensation technique is proposed.
Compared to traditional rigid robots, continuum robots have intrinsic compliance and therefore behave dexterously when performing tasks in restricted environments. Although there have been many researches on the design and application of continuum robots, a theoretical investigation of their dexterity is still lacking. In this paper, a two-joint wire-driven continuum robot is utilized to demonstrate dexterity by introducing the concept of orientability taking into account two indices, the accessible ratio and angle of the robot, when its tip reaches a certain task space inside the workspace. Based on the kinematic model, the accessible ratio and angle of the continuum robot are calculated using the Monte-Carlo method. From this, the influence of individual joint lengths on the proposed orientability indices and the optimal joint length are then investigated via an improved particle swarm optimization algorithm. Finally, the presented methods were validated through experiments showing that the use of optimal joint length can increase the accessible ratio and reduce the minimum accessible angle by more than 10° in the task space.
This paper presents an improved mode shape function-based 3D dynamic model for pneumatic muscle actuated continuum arms, and validates the model and simulation results through experimental testing. The model also facilitates the direct control of pneumatic muscle actuated continuum arms through the use of input pressure. This is achieved without additional intermediary transformations and does not have singularity problems present in previous models. The proposed arm model uses a new pneumatic muscle actuator (PMA) dynamic model with hysteresis that is capable of modelling both extending and contracting PMAs. The proposed hysteric model is simple, easily adaptable, and validated experimentally. The PMA model can be applied to dynamically model any PMA based system as well as PMA actuated continuum arms utilizing different actuator configurations.
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