Cross-section distortion and springback characteristics of double-cavity aluminum profile in force controlled stretch-bending

3D elastic-plastic FE model for simulating the force controlled stretch-bending process of double-cavity aluminum profile was established using hybrid explicit−implicit solvent method.Considering the computational accuracy and efficiency,the optimal choices of numerical parameters and algorithms in FE modelling were determined.The formation mechanisms of cross-section distortion and springback were revealed.The effects of pre-stretching,post-stretching,friction,and the addition of internal fillers on forming quality were investigated.The results show that the stress state of profile in stretch-bending is uniaxial with only a circumferential stress.The stress distribution along the length direction of profile is non-uniform and the maximum tensile stress is located at a certain distance away from the center of profile.As aluminum profile is gradually attached to bending die,the distribution characteristic of cross-section distortion along the length direction of profile changes from V-shape to W-shape.After unloading the forming tools,cross-section distortion decreases obviously due to the stress relaxation,with a maximum distortion difference of 13%before and after unloading.As pre-stretching and post-stretching forces increase,cross-section distortion increases gradually,while springback first decreases and then remains unchanged.With increasing friction between bending die and profile,cross-section distortion slightly decreases,while springback increases.Cross-section distortion decreases by 83%with adding PVC fillers into the cavities of profile,while springback increases by 192.2%.

Force Compensation Control for Electro-Hydraulic Servo System with Pump-Valve Compound Drive via QFT-DTOC

Each joint of a hydraulic-driven legged robot adopts a highly integrated hydraulic drive unit(HDU),which features a high power-weight ratio.However,most HDUs are throttling-valve-controlled cylinder systems,which exhibit high energy losses.By contrast,pump control systems offer a high efficiency.Nevertheless,their response ability is unsatisfactory.To fully utilize the advantages of pump and valve control systems,in this study,a new type of pump-valve compound drive system(PCDS)is designed,which can not only effectively reduce the energy loss,but can also ensure the response speed and response accuracy of the HDUs in robot joints to satisfy the performance requirements of robots.Herein,considering the force control requirements of energy conservation,high precision,and fast response of the robot joint HDU,a nonlinear mathematical model of the PCDS force control system is first introduced.In addition,pressure-flow nonlinearity,friction nonlinearity,load complexity and variability,and other factors affecting the system are considered,and a novel force control method based on quantitative feedback theory(QFT)and a disturbance torque observer(DTO)is designed,which is denoted as QFT-DTOC herein.This method improves the control accuracy and robustness of the force control system,reduces the effect of the disturbance torque on the control performance of the servo motor,and improves the overall force control performance of the system.Finally,experimental verification is performed using the PCDS performance test platform.The experimental results and quantitative data show that the QFT-DTOC proposed herein can significantly improve the force control performance of the PCDS.The relevant force control method can be used as a bottom-control method for the hydraulic servo system to provide a foundation for implementing the top-level trajectory planning of the robot.

Calculation of Contact Forces in Grasping by Space Decomposition

Robotic hands grasp and manipulate objects through the contact forces between the fingers and the objects. The determination of contact forces in grasping is discussed in this paper. To systematically investigate the characteristics of different grasps, the vector space of contact forces is decomposed into four subspaces and their basis is found by an efficient computational method. The vector of contact forces is then formulated into four components: active and passive grasping forces, controllable and uncontrollable internal forces. The dimensions of the subspaces identify uncontrollable internal forces. The contact force is further expressed into an explicit function of the external wrench and the joint torques. The resulting formulation simplifies the computation in the optimization of contact forces and makes the optimal variables controllable. Two numerical cases are given to show the simplicity and validity of the method.

Control of mean and fluctuating forces on a circular cylinder at high Reynolds numbers

A narrow strip is used to control mean and fluctuating forces on a circular cylinder at Reynolds numbers from 2.0 ×10^4 to 1.0 ×^ 10^5. The axes of the strip and cylinder are parallel. The control parameters are strip width ratio and strip position characterized by angle of attack and distance from the cylinder. Wind tunnel tests show that the vortex shedding from both sides of the cylinder can be suppressed, and mean drag and fluctuating lift on the cylinder can be reduced if the strip is installed in an effective zone downstream of the cylinder. A phenomenon of mono-side vortex shedding is found. The strip-induced local changes of velocity profiles in the near wake of the cylinder are measured, and the relation between base suction and peak value in the power spectrum of fluctuating lift is studied. The control mechanism is then discussed from different points of view.

Research on Suspension Gravity Compensation System of Lunar Rover with Magnetic Levitation Servo

In order to overcome the shortcomings of the traditional sling suspension method,such as complex structure of suspension truss,large running resistance,and low precision of position servo system,a gravity compensation method of lunar rover based on the combination of active suspension and active position following of magnetic levitation is proposed,and the overall design is carried out.The dynamic model of the suspension module of microgravity compensation system was established,and the decoupling control between the constant force component and the position servo component was analyzed and verified.The constant tension control was achieved by using hybrid force/position control.The position following control was realized by using fuzzy adaptive PID(proportional⁃integral⁃differential)control.The stable suspension control was realized based on the principle of force balance.The simulation results show that the compensation accuracy of constant tension could reach more than 95%,the position deviation was less than 5 mm,the position deviation angle was less than 0.025°,and the air gap recovered stability within 0.1 s.The gravity compensation system has excellent dynamic performance and can meet the requirements of microgravity simulation experiment of lunar rover.

Proportion Integration Differentiation(PID)Control Strategy of Belt Sander Based on Fuzzy Algorithm

Aiming at solving the problems of response lag and lack of precision and stability in constant grinding force control of industrial robot belts,a constant force control strategy combining fuzzy control and proportion integration differentiation(PID)was proposed by analyzing the signal transmission process and the dynamic characteristics of the grinding mechanism.The simulation results showed that compared with the classical PID control strategy,the system adjustment time was shortened by 98.7%,the overshoot was reduced by 5.1%,and the control error was 0.2%-0.5%when the system was stabilized.The optimized fuzzy control system had fast adjustment speeds,precise force control and stability.The experimental analysis of the surface morphology of the machined blade was carried out by the industrial robot abrasive grinding mechanism,and the correctness of the theoretical analysis and the effectiveness of the control strategy were verified.

FUZZY COORDINATION AND FORCE/POSITION CONTROL OF ROBOTIC MANIPULATOR

It is crucial for implementing force/position control of robotic manipulator under the constraint of unknown environment to determine the force control and the position control directions. This paper presents an on line algorithm to real timely estimate the tangent and the normal vectors of the constraint surface based on the measured contact force under the consideration of frictional force. A fuzzy synthesis policy is proposed to coordinate the conflict between the compliant force control and the stiff position control. An experimental study on an AdeptThree, a SCARA type robotic manipulator, is conducted. The experimental results show that the policy presented in the paper is effective.

Impedance force control for position controlled robotic manipulators under the constraint of unknown environments

A force control strategy for position controlled robotic manipulators is presented. On line force feedback data are employed to estimate the local shape of the unknown constraint. The estimated vectors are used to generate the virtual reference trajectory for the target impedance model that is driven by the force error to produce command position. By following the command position trajectory the robotic manipulator can follow the unknown constraint surface while keeping an acceptable force error in a manner depicted by the target impedance model. Computer simulation on a 3 linked planar manipulator and experimental studies on an Adept 3, an SCARA type robotic manipulator, are conducted to verify the force tracking capability of the proposed control strategy.

Parameters Sensitivity Characteristics of Highly Integrated Valve-Controlled Cylinder Force Control System

Nowadays, a highly integrated valve?controlled cylinder(HIVC) is applied to drive the joints of legged robots. Although the adoption of HIVC has resulted in high?performance robot control, the hydraulic force system still has problems, such as strong nonlinearity, and time?varying parameters. This makes HIVC force control very diffcult and complex. How to improve the control performance of the HIVC force control system and find the influence rule of the system parameters on the control performance is very significant. Firstly, the mathematical model of HIVC force control system is established. Then the mathematical expression for parameter sensitivity matrix is obtained by applying matrix sensitivity analysis(PSM). Then, aimed at the sinusoidal response under(three factors and three levels) working conditions, the simulation and the experiment are conducted. While the error between the simulation and experiment can’t be avoided. Therefore, combined with the range analysis, the error in the two performance indexes of sinusoidal response under the whole working condition is analyzed. Besides, the sensitivity variation pattern for each system parameter under the whole working condition is figured out. Then the two sensitivity indexes for the three system parameters, which are supply pressure, proportional gain and initial displacement of piston, are proved experimentally. The proposed method significantly reveals the sensitivity characteristics of HIVC force control system, which can make the contribution to improve the control performance.

Trajectory Tracking of a Planer Parallel Manipulator by Using Computed Force Control Method

Despite small workspace, parallel manipulators have some advantages over their serial counterparts in terms of higher speed, acceleration, rigidity, accuracy, manufacturing cost and payload. Accordingly, this type of manipulators can be used in many applications such as in high-speed machine tools, tuning machine for feeding, sensitive cutting, assembly and packaging. This paper presents a special type of planar parallel manipulator with three degrees of freedom. It is constructed as a variable geometry truss generally known planar Stewart platform. The reachable and orientation workspaces are obtained for this manipulator. The inverse kinematic analysis is solved for the trajectory tracking according to the redundancy and joint limit avoidance. Then, the dynamics model of the manipulator is established by using Virtual Work method. The simulations are performed to follow the given planar trajectories by using the dynamic equations of the variable geometry truss manipulator and computed force control method. In computed force control method, the feedback gain matrices for PD control are tuned with fixed matrices by trail end error and variable ones by means of optimization with genetic algorithm.

Optimal Design and Force Control of a Nine-Cable-Driven Parallel Mechanism for Lunar Takeoff Simulation

Traditional simulation methods are unable to meet the requirements of lunar takeo simulations, such as high force output precision, low cost, and repeated use. Considering that cable-driven parallel mechanisms have the advantages of high payload to weight ratio, potentially large workspace, and high-speed motion, these mechanisms have the potential to be used for lunar takeo simulations. Thus, this paper presents a parallel mechanism driven by nine cables. The purpose of this study is to optimize the dimensions of the cable-driven parallel mechanism to meet dynamic workspace requirements under cable tension constraints. The dynamic workspace requirements are derived from the kinematical function requests of the lunar takeo simulation equipment. Experimental design and response surface methods are adopted for building the surrogate mathematical model linking the optimal variables and the optimization indices. A set of dimensional parameters are determined by analyzing the surrogate mathematical model. The volume of the dynamic workspace increased by 46% after optimization. Besides, a force control method is proposed for calculating output vector and sinusoidal forces. A force control loop is introduced into the traditional position control loop to adjust the cable force precisely, while controlling the cable length. The e ectiveness of the proposed control method is verified through experiments. A 5% vector output accuracy and 12 Hz undulation force output can be realized. This paper proposes a cable-driven parallel mechanism which can be used for lunar takeo simulation.

Application of μ Theory in Compliant Force Control

The application of μ theory in compliant force control system is studied. A compliant force control strategy is developed based on the inner loop position control of 6-DOF parallel robot in order to simulate the push and pull process of forcible alignment in space docking, Considering uncertainties such as parameter perturbations, model perturbations and external disturbances, etc., a robust force controller is designed using μ synthesis theory. The robust stability and robust performance are compared by analysis between the designed robust force controller and the classical force controller. The experiment results of the designed robust force controller and the classical force controller are shown. The results indicate that the designed robust force controller is of efficiency and superiority.

Improved hybrid position/force controller design of a flexible robot manipulator using a sliding observer

An improved hybrid position/force controller design of a flexible robot manipulator is presented using a sliding observer. The friction between the end effector and the environment is considered and compensated. For systematic reasons the controller is designed taking into consideration the rigid link subsystems and the flexible joints. The proposed control system satisfies the stability of the two subsystems and copes with the uncertainty of robot dynamics. A sliding observer is designed to estimate the time derivative of the torque applied as input to the rigid part of the robot. For the stability of the observer, it is assumed that the uncertainty of the observed system is bounded. A MRAC algorithm is used for the estimation of the friction forces at the contact point between the end effector and the environment. Finally simulation and experimental results are given, to demonstrate the effectiveness of the proposed controller.

Adaptive robust output force tracking control of pneumatic cylinder while maximizing/minimizing its stiffness

The system considered in this work consists of a cylinder which is controlled by a pair of three-way servo valves rather than a four-way one.Therefore,the cylinder output stiffness is independently controllable of the output force.A discontinuous projection based adaptive robust controller (ARC) was constructed to achieve high-accuracy output force trajectory tracking for the system.In ARC,on-line parameter adaptation method was adopted to reduce the extent of parametric uncertainties due to the variation of friction parameters,and sliding mode control method was utilized to attenuate the effects of parameter estimation errors,unmodelled dynamics and disturbance.Furthermore,output stiffness maximization/minimization was introduced to fulfill the requirement of many robotic applications.Extensive experimental results were presented to illustrate the effectiveness and the achievable performance of the proposed scheme.For tracking a 0.5 Hz sinusoidal trajectory,maximum tracking error is 4.1 N and average tracking error is 2.2 N.Meanwhile,the output stiffness can be made and maintained near its maximum/minimum.

A novel grasping force control strategy for multi-fingered prosthetic hand

A grasping force control strategy is proposed in order to complete various free manipulations by using anthropomorphic prosthetic hand. The position-based impedance control and force-tracking impedance control are used in free and constraint spaces, respectively. The fuzzy observer is adopted in transition in order to switch control mode. Two control modes use one position-based impedance controller. In order to achieve grasping force track, reference force is added to the impedance controller in the constraint space. Trajectory tracking in free space and torque tracking in constrained space are realized, and reliability of mode switch and stability of system are achieved. An adaptive sliding mode friction compensation method is proposed. This method makes use of terminal sliding mode idea to design sliding mode function, which makes the tracking error converge to zero in finite time and avoids the problem of conventional sliding surface that tracking error cannot converge to zero. Based on the characteristic of the exponential form friction, the sliding mode control law including the estimation of friction parameter is obtained through terminal sliding mode idea, and the online parameter update laws are obtained based on Lyapunov stability theorem. The experiments on the HIT Prosthetic Hand IV are carried out to evaluate the grasping force control strategy, and the experiment results verify the effectiveness of this control strategy.

Active Compliance Control of a Position‑Controlled Industrial Robot for Simulating Space Operations

An industrial robot with a six-axis force/torque sensor is usually used to produce a zero-gravity environment for testing space robotic operations.However,using traditional force control methods,such as admittance control,causes position-controlled industrial robots to undergo from force divergence owing to intrinsic time delay.In this paper,a new force control method is proposed to eliminate the force divergence.A hardware-in-the-loop(HIL)simulator with an industrial robot is first presented.The free-floating satellite dynamics and the motion mapping from the satellites to simulator are both established.Thus,the effects of measurement delay and dynamic response delay on contact velocity and force are investigated.After that,a real-time estimation method for contact stiffness and damping is proposed based on the adaptive Kalman filter.The measurement delay is compensated by a phase lead model.Moreover,the identified contact parameters are adopted to modify contact forces,and thus the dynamics response delay can be compensated for.Finally,a co-simulation and experiments were conducted to verify the force control method.The results show that contact stiffness and damping could be identified exactly and that the simulation divergence could be prevented.This paper proposes an active compliance control method that can deal with force constrained tasks of a position-controlled robot in unknown environments.

Design of Passive Constant‑Force End‑Effector for Robotic Polishing of Optical Reflective Mirrors

Polishing plays an indispensable role in optical processing,especially for large-aperture optical reflective mirrors with freeform surfaces.Robotic polishing requires effective control of the contact force between the robot and the mirror during processing.In order to maintain a constant contact force during polishing,traditional polishing robots rely on closed-loop control of air cylinders,whose performances heavily rely on high-fidelity force sensing and real-time control.This paper proposes to employ a compliant constant-force mechanism in the end-effector of a polishing robot to passively maintain a constant force between the robot and the mirror,thus eliminating the requirement for force sensing and closed-loop control.The compliant constant force mechanism utilizing the second bending mode of fixed-guided compliant beams is adopted and elaborated for the passive end-effector.An end-effector providing a constant contact force of 40 N is designed and prototyped.The polishing experiment shows that the passive constant-force end-effector provides stable contact force between the robot and the mirror with fluctuation within 3.43 N,and achieves RMS(Root Mean Square)lower thanλ/10(λ=632.8 nm)of the polished surface of the largeaperture optical reflective mirror.It is concluded that the constant-force compliant mechanism provides a low-cost and reliable solution for force control in robotic polishing.

Force Control Compensation Method with Variable Load Stiffness and Damping of the Hydraulic Drive Unit Force Control System

Each joint of hydraulic drive quadruped robot is driven by the hydraulic drive unit（HDU）, and the contacting between the robot foot end and the ground is complex and variable, which increases the difficulty of force control inevitably. In the recent years, although many scholars researched some control methods such as disturbance rejection control, parameter self-adaptive control, impedance control and so on, to improve the force control performance of HDU, the robustness of the force control still needs improving. Therefore, how to simulate the complex and variable load characteristics of the environment structure and how to ensure HDU having excellent force control performance with the complex and variable load characteristics are key issues to be solved in this paper. The force control system mathematic model of HDU is established by the mechanism modeling method, and the theoretical models of a novel force control compensation method and a load characteristics simulation method under different environment structures are derived, considering the dynamic characteristics of the load stiffness and the load damping under different environment structures. Then, simulation effects of the variable load stiffness and load damping under the step and sinusoidal load force are analyzed experimentally on the HDU force control performance test platform, which provides the foundation for the force control compensation experiment research. In addition, the optimized PID control parameters are designed to make the HDU have better force control performance with suitable load stiffness and load damping, under which the force control compensation method is introduced, and the robustness of the force control system with several constant load characteristics and the variable load characteristics respectively are comparatively analyzed by experiment. The research results indicate that if the load characteristics are known, the force control compensation method presented in this paper has positive compensation effects on the load characteristics variation, i.e., this method decreases the effects of the load characteristics variation on the force control performance and enhances the force control system robustness with the constant PID parameters, thereby, the online PID parameters tuning control method which is complex needs not be adopted. All the above research provides theoretical and experimental foundation for the force control method of the quadruped robot joints with high robustness.

Decentralized adaptive neural network sliding mode position/force control of constrained reconfigurable manipulators

A decentralized adaptive neural network sliding mode position/force control scheme is proposed for constrained reconfigurable manipulators. Different from the decentralized control strategy in multi-manipulator cooperation, the proposed decentralized position/force control scheme can be applied to series constrained reconfigurable manipulators. By multiplying each row of Jacobian matrix in the dynamics by contact force vector, the converted joint torque is obtained. Furthermore, using desired information of other joints instead of their actual values, the dynamics can be represented as a set of interconnected subsystems by model decomposition technique. An adaptive neural network controller is introduced to approximate the unknown dynamics of subsystem. The interconnection and the whole error term are removed by employing an adaptive sliding mode term. And then, the Lyapunov stability theory guarantees the stability of the closed-loop system. Finally, two reconfigurable manipulators with different configurations are employed to show the effectiveness of the proposed decentralized position/force control scheme.

Impactless biped walking on a slope

Walking without impacts has been considered in dynamics as a motion/force control problem. In order to avoid impacts, an approach for both the specified motion of the biped and its ground reaction forces was presented yielding a combined motion and force control problem. As an application, a walker on a horizontal plane has been considered. In this paper, it is shown how the control of the ground reaction forces and the energy consumption depend on the gradient of a slope. The biped dynamics and the constraints within the biped system and on the ground are discussed. A motion control synthesis is developed using the inverse dynamics principle proven to be most efficient for human walking research, too. The impactless walking with controlled legs is illustrated by a seven-link biped. The ＂flying＂ biped has nine degrees of freedom, with six control inputs. During locomotion, the standing leg has three scleronomic constraints, and the trunk has three rheonomic constraints. However, there are three rheonomic constraints for the prescribed leg motion or three scleronomic constraints for reaction forces of the trailing leg, respectively. The nominal control action for impactless walking can be precomputed and stored. The model proposed allows the investigation of several problems： uphill and downhill walking, optimization of step length,stiction of the feet on the slope and many more. All these findings are also of interest in biomechanics. C 2013 The Chinese Society of Theoretical and Applied Mechanics. [doi：10.1063/2.1301302]