Abstract The electroadhesion pad is mainly studied for applications, such as climbing robots and grippers. In this paper, we present our study with the confirmation of the adhesion properties of the electroadhesion pad with a double-insulating layer, pad modeling, and optimal design. Modeling and analysis consider the air layer generated during the manufacturing of both conventional single insulated structures and dual-insulated structures. Through the finite element analysis simulation,the characteristics of the electroadhesion were verified, and modeling verification was performed,based on the variables that had a large influence as follows: applied voltage, electrode area, dielectric thickness, and permittivity. The electrode is made of aluminum, the substrate is made of silicon, and the dielectric is made of polyimide film. An error of up to 8.3% was found between the modeling and simulation. The optimization results were validated based on a pad applied to a climbing robot measuring 320 × 480 mm2 and weighing 2.8 kg. As a result, the optimal pad design resulted in an error of 7.3% between the modeling and simulation.

Abstract Topology and shape optimization are still rarely applied to problems in electromagnetic design due to the computational complexity and limited commercial tooling, even though components such as electrical motors, magnetic springs or magnetic bearings could benefit from it, either to improve performance (reducing torque ripple and losses through shaping harmonic content in back electromotive force) or reduce the use of rare-earth materials. Magnetic springs are a fatigue free alternative to mechanical springs, where shape optimization can be exploited to a great degree—allowing for advanced non-linear stiffness characteristic shaping. We present the optimization methodology relying on a combination of several approaches for characteristic shaping of magnetic springs through either a modular design approach based on: (i) Fourier order decomposition;(ii) breaking conventional design symmetry; or (iii) free shaping of magnets through deviation from a nominal design using problem formulations such as spline and polynomials for material boundary definitions. Each of the parametrizations is formulated into a multi-objective optimization problem with both performance and material cost, and solved using gradient free optimization techniques (direct search, genetic algorithm). The methodology is employed on several benchmark problems—both academic and application inspired magnetic spring torque characteristic requirements. The resulting designs fit well with the requirements, with a relatively low computational cost. As such, themethodology presented is a promising candidate for other design problems in 2D shape optimization in electrical motor research and development.

Abstract The dielectric barrier discharge plasma actuator is a promising flow control device that uses surface discharge. The actuator generates an electrohydrodynamic force and Joule heating that contribute to the flow control. Thus, it is important to investigate the electrohydrodynamic and thermal effects on the air flow. To this end, the flow velocity field, density field, and surface tempera ture distribution induced by an alternating current dielectric barrier discharge plasma actuator were experimentally examined, adopting particle image velocimetry, the background oriented schlieren technique, and an infrared camera. These experiments were conducted for plate- and wire-exposed electrode plasma actuators to investigate the effect of the shape of the exposed electrode. It was confirmed that the topology of the discharge is different between the two types of plasma actuators.This results in a difference in the spatial distributions of the velocity and density fields between the two actuators. In particular, we clarified that there is an obvious difference in the peak position of the density and temperature distribution between the two actuators. We also confirmed that the difference in the spatial distribution of the vertical velocity makes the above difference.

Abstract The current work aims to compare the effects of systematic A-site substitutions on the electrical properties of potassium sodium niobate (KNN)-based coating. The A-site elements were replaced by Li+ to form (K0.4675Na0.4675Li0.065) NbO3 (KNLN). The pure KNN coating and the Li+-doped potassium sodium niobate (KNLN) coating with dense morphology and single perovskite structure were successfully prepared by supersonic plasma spraying, and the phase composition, microscopic morphology and electrical properties of the two coatings were compared and analyzed in detail by XRD, XPS, three-dimensional morphology and SEM on an Agilent 4294A (Santa Clara,CA, USA) and FE-5000 wide-range ferroelectric performance tester. The results show that: as the polarization voltage increases, the pure KNN coating is flatter and fuller, but the leakage current is large. The KNLN coating has a relatively long hysteresis loop and is easily polarized. The domain deflection responds faster to the external electric field, and the resistance of the domain wall motion to the external electric field is small. The dielectric constant of KNLN coating is 375, which is much higher than that of the pure KNN coating with 125, and the dielectric loss is stable at 0.01, which is lower than that of pure KNN coating at 0.1–0.35. This is because Li+ doping has successfully constructed a polycrystalline phase boundary in which O-T phases coexist, and has higher dielectric properties, piezoelectric properties and ferroelectric properties. At the same time, due to the high temperature acceleration process in supersonic plasma spraying, the violent volatilization of the alkaline elements Li+ , Na+ and K+leads to the presence of oxygen vacancies and part of Nb4+ in the coating, which seriously affects the electrical properties of the coating.

Abstract This paper presents a control strategy with a linear extended state observer (LESO) and Kalman filter to achieve a high performance of the motion control system. The moment of inertia of the system, which is variable with the robotic joint motion, is estimated in the established model.A LESO with variable gain is designed, which could estimate the states and the total disturbance of the plant without a precision mathematical model. The disturbance caused by variable load and unknown dynamics can be compensated based on the LESO, while the moment of inertia is variable. In order to restrain the process noise and measure the noise of the system, the Kalman filter was applied. Tracking differentiator was utilized to avoid the overshoot of the system for the step signal. The designed control strategy with the LESO and the Kalman filter could improve the tracking performance for the servo system with parametric uncertainties, unknown dynamics, and disturbances. The effectiveness of the proposed method is implemented and validated in the experiment of the robotic joint, for which desired servo tracking performance is achieved with the conditions of load variation and sudden disturbance.

Abstract High-speed Permanent Magnet Synchronous Motor (PMSM) systems have been widely used in industry and other fields for their advantages of having a simple structure, low processing cost and high efficiency. At present, the control precision of PMSM is required to be higher and higher, but it faces two major challenges. The first is that the PMSM system possesses (possibly fast) time-varying uncertainty. The second is that there exist nonlinear portions in the PMSM system, such as nonlinear elasticity, etc. To resolve these challenges, a novel performance measure βˆ is introduced as a dynamic depiction of the constraint-following error, and a new robust control design is proposed based on βˆ. While this control renders guaranteed performance regardless of uncertainty, an optimal design of a control parameter is further pursued. This inquiry is summed up as a semi-infinite constrained optimization problem. After the induction of the necessary condition, the candidate solutions can be identified. These are further screened by a sufficient condition, which results in the actual solution. To verify the effectiveness of the control design, the compressor powered by a super high-speed PMSM system is simulated, and its performance is discussed.

Abstract In this paper, an actuator fault diagnosis and reconfiguration problem is discussed for an uncertain vehicle steering system with external disturbances. Aiming at the factors affecting the control performance, a fault reconstruction strategy based on H-infinity observer is designed to improve the vehicle stability under complex conditions when the actuator fails. Firstly, aiming at the uncertain part caused by the road condition transformation, a mathematical model of dual input and dual output four-wheel steering system is established. Secondly, an augmented system is constructed in which the augmented state vector consists of the original state and actuator faults. Thirdly, the H-infinity observer is designed, and the gain of the observer is obtained by the Lyapunov function and linear matrix inequality. Finally, the effectiveness of the proposed strategy is verified by MATLAB/Simulink and Carsim co-simulation.

Abstract Torsional vibrations play a critical role in the design and operation of a mechanical or mechatronic drivetrain due to their impact on lifetime, performance, and cost. A magnetic spring allows one to reduce these vibrations and improve the actuator performance yet introduces additional challenges on the identification. As a direct torque measurement is generally not favourable because of its intrusive nature, this paper proposes a nonintrusive approach to identify torsional load profiles.The approach combines a physics-based lumped parameter model of the torsional dynamics of the drivetrain with measurements coming from a motor encoder and two MEMS accelerometers in a combined state/input estimation, using an augmented extended Kalman filter (A-EKF). In order to allow a generic magnetic spring torque estimation, a random walk input model is used,where additionally the angle-dependent behaviour is exploited by constructing an angle-dependent estimate and variance map. Experimental validation leads to a significant reduction in bias in the load torque estimation for this approach, compared to conventional estimators. Moreover, this newly proposed approach significantly reduces the variance on the estimated states by exploiting the angle dependency. The proposed approach provides knowledge of the torsional vibrations in a nonintrusive way, without the need for an extensive magnetic spring torque identification. Further, the approach is applicable on any drivetrain with angle-dependent input torques.

Abstract The preview model is one of the common methods used in trajectory tracking. The traditional fixed preview time is not adaptable to most speeds and road conditions, which not only reduces the tracking accuracy but also reduces the vehicle stability. Therefore, a controller can be designed to determine the adaptive preview time based on an optimization function of the lateral deviation, the road boundary, and the road boundary of the whole vehicle motion response characteristics. Traditional optimal preview control theory predicts the next state of the vehicle by the assumption of constant transverse pendulum angular velocity. In this paper, an expectation-based approach is used to find the ideal steering wheel turning angle based on the adaptive preview time,and a single-point preview model is established. Based on the two-degree-of-freedom dynamics model, a sliding mode controller is designed for control, and the low-pass filters are designed to suppress jitter in the sliding mode controller. Simulation results with different preview times, different speeds and different road adhesion coefficients prove that the controller has a good control effect and has good effectiveness and adaptability to speed and adhesion coefficient.

Abstract The design of a teleoperated 8-DoF redundant robot for Doppler sonography is detailed in this paper. The proposed robot is composed of a 7-DoF robotic arm mounted on a 1-DoF linear axis.This solution has been conceived to allow Doppler ultrasound examination of the entire patient’s body. This paper details the design of the platform and proposes two alternative control modes to deal with its redundancy at the torque level. The first control mode considers the robot as a full 8-DoF kinematics chain, synchronizing the action of the eight joints and improving the global robot manipulability. The second control mode decouples the 7-DoF arm and the linear axis controllers and proposes a switching strategy to activate the linear axis motion when the robot arm approaches the workspace limits. Moreover, a new adaptive Joint-Limit Avoidance (JLA) strategy is proposed with the aim of exploiting the redundancy of the 7-DoF anthropomorphic arm. Unlike classical JLA approaches, a weighting matrix is actively adapted to prioritize those joints that are approaching the mechanical limits. Simulations and experimental results are presented to verify the effectiveness of the proposed control modes.

Abstract This paper presents the mechatronic design of a biorobotic joint with controllable compli ance, for innovative applications of “assist-as-needed” robotic rehabilitation mediated by a wearable and soft exoskeleton. The soft actuation of robotic exoskeletons can provide some relevant advantages in terms of controllable compliance, adaptivity and intrinsic safety of the control performance of the robot during the interaction with the patient. Pneumatic Artificial Muscles (PAMs), which belong to the class of soft actuators, can be arranged in antagonistic configuration in order to exploit the variability of their mechanical compliance for the optimal adaptation of the robot performance during therapy. The coupling of an antagonistic configuration of PAMs with a regulation mechanism can achieve, under a customized control strategy, the optimal tuning of the mechanical compliance of the exoskeleton joint over full ranges of actuation pressure and joint rotation. This work presents a novel mechanism, for the optimal regulation of the ompliance of the biorobotic joint, which is characterized by a soft and hybrid actuation exploiting the storage/release of the elastic energy by bistable Von Mises elastic trusses. The contribution from elastic Von Mises structure can improve both the mechanical response of the soft pneumatic bellows actuating the regulation mechanism and the intrinsic safety of the whole mechanism. A comprehensive set of design steps is presented here, including the optimization of the geometry of the pneumatic bellows, the fabrication process through 3D printing of the mechanism and some experimental tests devoted to the characterization of the hybrid soft actuation. The experimental tests replicated the main operating conditions of the regulation mechanism; the advantages arising from the bistable hybrid soft actuation were evaluated in terms of static and dynamic performance, e.g., pressure and force transition thresholds of the bistable mechanism, linearity and hysteresis of the actuator response.

Abstract The finite control set model predictive torque control (FCS-MPTC) selects the optimal voltage vector (VV) by the composite cost function composed of torque and flux error, which makes it have a faster dynamic response than conventional control methods. However, the prediction state error caused by machine parameter mismatch and the difficulty in setting the weight factor in the composite cost function seriously restrict the popularization and application of FCS-MPTC. In this paper, a model-free parallel predictive torque control (MF-PPTC) based on an ultra-local (UL) model is proposed to solve above problems. The UL model replaces the machine mathematical model without any machine parameters and only uses the input and output of the system, which greatly improves the robustness of the control system. The nonlinear extended state observer proposed for the unknown part of the system has fast convergence and improves the dynamic performance of the system. In addition, the conventional parallel predictive control structure is optimized to reduce the dynamic adjustment process during the selection of optimal voltage vector. Simulation and experimental comparison between the conventional PPTC and the proposed MF-PPTC verified the superiority of the proposed method.

Abstract With an increase in renewable energy in the electricity grid, more storage capacity for grid stabilization and energy flexibilization is necessary. Dynamic grid stabilization is one possible application for flywheels. To increase the energy density of flywheels, they can be built as highly integrated outer rotor systems. The losses of the flywheel are reduced by magnetic levitation and operation under vacuum conditions. In the case of the failure or overload of the active magnetic bearings, the system needs touch-down bearings to prevent system destruction. Planetary touch down bearings consisting of several small bearing units circumferentially distributed around the stator are especially suited for these systems. In the literature, these planetary touch-down bearings are rarely investigated, especially the number of bearing units. Therefore, this paper investigates the influence of the number of touch-down bearing elements in simulations and experiments for an 8-element and a 6-element touch-down bearing arrangement. For the investigation, drop-downs at four different speeds were performed. Simulation and experimental results showed that, for the 6-element touch-down bearing, in contrast to the 8-element touch-down bearing, maximal velocity did not increase with the drop-down speed. Therefore, the touch-down bearing arrangement with fewer elements is preferrable.

Abstract Flight control electro-mechanical actuators (EMAs) are among the primary onboard systems that significantly influence the reliability and safety of unmanned aerial vehicles. Recent reliability studies have shown that the ball-screw element of a flight control EMA is subject to oscillating operating conditions that may initiate rapid degradation, such as fatigue spall defects. Accordingly,detecting and quantifying such faults are crucial for developing efficient fault prognostic and remain ing useful life estimation capabilities. In this study, a vibration-based fault quantification method is developed to quantify the fatigue faults of a ball-screw mechanism of an EMA. The method is based on identifying the ball passing instants through a localized surface defect on the vibrational jerk rather than the vibrational acceleration measurement. The jerk is numerically determined from conventional accelerometers using a Savitzky–Golay differentiator. This method was successfully tested for ball bearings and it is adjusted in this paper for ball-screw faults. The experimental vali dation is investigated on a set of fault-seeded samples on NASA’s Ames Research Center Flyable Electro-Mechanical Actuator test stand.

Abstract In order to realize the construction of environmentally friendly potassium sodium niobate ceramic coating on metal surface, potassium sodium niobate ceramic coating was prepared by supersonic plasma spraying technology. The morphology, element extension and phase structure of such coating were investigated. The dielectric and ferroelectric properties were also analyzed. The results show that the coating has good quality and tetragonal phase structure. When test frequency ≥ 2 MHz, the dielectric constant is stable at about 300, and also dielectric loss is stable at about 0.05.The coating exhibits good hysteresis loops under different applied electric fields. When the applied electric field is 16 KV/cm, residual polarization value of as-prepared coating reaches 17.02 µC·cm−2 .

Abstract Most of the multidegree-of-freedom ultrasonic motors (MDOF-USMs) use a spherical rotor,and the design of the stator is restricted due to the use of the resonance mode. (1) Therefore, there is almost impossible to freely design the overall shape, resulting in a complicated structure. (2) To solve such an inconvenience, an MDOF-USM using a metal spherical stator was proposed. The vibration mode rotation on the stator was designed by theoretical analysis of spherical vibration and finite element method analysis. Multilayer piezoelectric actuators (MPAs) were embedded in the sphere to excite the vibration mode. Cylindrical projections were attached to the surface of the stator to magnify the vibration displacement and worked as the driving part. Their effects were evaluated using an electronic circuit simulator method of performance analysis. (3) As a result, two types of vibration mode rotation methods for the 3-DOF rotation were confirmed. It was also confirmed that the rotor covering the outside stator rotates around three axes. However, tiny torque, low power factor, and slow speed were obtained. (4) An MDOF-USM using a spherical stator was realized according to the operating principle. However, since the cause of such a low performance is the excitation method of the sphere and the rotor structure, research for improvement is required in the future.

Abstract The hoisting form in which the payload is hung on the hook by two rigging ropes is widely used in the industry, but it also results in the complex double pendulum dynamic of the bridge crane, making the anti-swing trajectory planning full of challenges. In this paper, based on the concept of the equivalent rope length, an equivalent single pendulum model of the double pendulum bridge crane with the distributed mass payload is established. On this basis, the particle swarm optimization algorithm is adopted to solve the equivalent rope length and calculate the parameters of the anti-swing velocity trajectory based on the phase plane method. To evaluate the effectiveness of the proposed method, experiments with a laboratory double pendulum bridge crane are conducted.Experimental results emonstrate that the residual oscillation angle of the payload of the proposed method is smaller than those of the existing methods, such as the trajectory planning without the equivalent rope length, input shaping and command smoothing.

Abstract Tremors are the most common type of movement disorder and affect the lives of those experiencing them. The efficacy of tremor therapies varies according to the aetiology of the tremor and its correct diagnosis. This study develops a portable measurement device capable of non contact measurement of the tremor, which could assist in tremor diagnosis and classification. The performance of this device was assessed through a validation process using a shaker at a controlled frequency to measure human tremors, and the device was able to measure vibrations of 50 Hz accurately, which is more than twice the frequency of tremors produced by humans. Then, the device is tested to measure the tremors for two different activation conditions: rest and postural, for both hand and leg. The measured non-contact tremor vibration data successfully led to tremor classification in the subjects already diagnosed using a contact accelerometer.

Abstract The goal of haptic feedback in robotic teleoperation is to enable users to accurately feel the interaction force measured at the slave side and precisely understand what is happening in the slave environment. The accuracy of the feedback force describing the error between the actual feedback force felt by a user at the master side and the measured interaction force at the slave side is the key performance indicator for haptic display in robotic teleoperation. In this paper, we evaluate the haptic feedback accuracy in robotic teleoperation via experimental method. A special interface iHandle and two haptic devices, iGrasp-T and iGrasp-R, designed for robotic teleoperation are developed for experimental evaluation. The device iHandle integrates a high-performance force sensor and a micro attitude and heading reference system which can be used to identify human upper limb motor abilities, such as posture maintenance and force application. When a user is asked to grasp the iHandle and maintain a fixed position and posture, the fluctuation value of hand posture is measured to be between 2 and 8 degrees. Based on the experimental results, human hand tremble as input noise sensed by the haptic device is found to be a major reason that results in the noise of output force from haptic device if the spring-damping model is used to render feedback force. Therefore,haptic rendering algorithms should be independent of hand motion information to avoid input noise from human hand to the haptic control loop in teleoperation. Moreover, the iHandle can be fixed at the end effector of haptic devices; iGrasp-T or iGrasp-R, to measure the output force/torque from iGrasp-T or iGrasp-Rand to the user. Experimental results show that the accuracy of the output force from haptic device iGrasp-T is approximately 0.92 N, and using the force sensor in the iHandle can compensate for the output force inaccuracy of device iGrasp-T to 0.1 N. Using a force sensor as the feedback link to form a closed-loop feedback force control system is an effective way to improve the accuracy of feedback force and guarantee high-fidelity of feedback forces at the master side in robotic teleoperation.

Abstract As a critical component of the sugarcane harvester, the primary function of the crop dividers is to lift the lodged sugarcane (LS) and reduce the loss rate of the sugarcane harvest. In this study, a rigid-flexible coupling simulation method is proposed to improve the lifting efficiency of the crop dividers on severely LS and analyze the nature of interaction between the sugarcane stalk and the crop dividers. The model’s accuracy was verified using field experiments, and the operational performance of the crop dividers on sugarcane in different lodging postures was investigated. The results showed that the curve of the vertical height of the center (VHC) fluctuated more and slipped with highest frequency during the lifting process of side and forward LS. The speed of VHC was fastest during the lifting operation of side LS. The effect of side angle on the lifting effect of sugarcane was significant; the qualified values of the VHC of sugarcane being lifted in different lodged postures were: side and reverse lodged > side lodged > side and forward lodged. The coupling method and experimental results described in this paper can provide guidance for the optimal design and field operation of the crop dividers.

Abstract To improve the path tracking accuracy of autonomous tractors in operation, an improved Stanley controller (IMP-ST) is proposed in this paper. The controller was applied to a two-wheel tractor dynamics model. The parameters of the IMP-ST were optimized by multiple-population genetic algorithm (MPGA) to obtain better tracking performance. The main purpose of this paper is to implement path tracking control on an autonomous tractor. Thus, it is significant to study this field because of smart agricultural development. According to the turning strategy of tractors in field operations, five working routes for tractors were designed, including straight, U, Ω, acute-angle and obtuse-angle routes. Simulation tests were conducted to verify the effectiveness of the proposed IMP-ST in tractor path tracking for all routes. The lateral root-mean-square (RMS) error of the IMP-ST was reduced by up to 36.84% and 48.61% compared to the extended Stanley controller and the original Stanley controller, respectively. The simulation results indicate that the IMP-ST performed well in guiding the tractor to follow all planned working routes. In particular, for the U and Ω routes, the two most common turning methods in tractor field operations, the path tracking performance of the IMP-ST was improved by 41.72% and 48.61% compared to the ST, respectively. Comparing and analyzing the e-Ψ and β-γ phase plane of the three controllers, the results indicate that the IMP-ST has the best control stability .

Abstract Many industrial processes include MIMO (multiple-input, multiple-output) systems that are difficult to control by standard commercial controllers. This paper describes a MIMO case of a class of SISO-APC (single-input, single-output adaptive predictive controller) based upon an ARX (autoregressive with exogenous variable) model. This class of SISO-APC based on ARX models has been successfully and extensively used in many industrial applications. This approach aims to minimize the barriers between the theory of predictive adaptive control and its application in the industrial environment. The proposed MIMO-APC (MIMO adaptive predictive controller) performance is validated with two simulated processes: a quadrotor drone and the quadruple tank process. In the first experiment the proposed MIMO APC shows ISE-IAE-ITAE performance indices improvements of up to 25%, 25.4% and 38.9%, respectively. For the quadruple tank process the water levels in the lower tanks follow closely the set points, with the exception of a 13% overshoot in tank 1 for the minimum phase behavior response. The controller responses show significant performance improvements when compared with previously published MIMO control strategies.