Actuators, Volume 13, Issue 6 (June 2024) – 14 articles

In recent years, robot manipulator arms have become increasingly prevalent and are playing pivotal roles across various industries. Their ability to replace human labor in arduous and hazardous tasks has positioned them as indispensable assets. Consequently, there has been a surge in research efforts aimed at enhancing their operational performance. The imperative to improve their efficiency and effectiveness has garnered significant attention within the research community. In this study, a novel fault-tolerant control (FTC) scheme for robot manipulators to handle the effects of the unknown input is proposed to aid robots in achieving good tracking performance. In the first step, an extended state observer (ESO) is constructed to approximate both velocities and the unknown input in the robot system. The observer offers estimation information with good accuracy and quick convergence. The estimated signals are then combined with computed torque control (CTC), which is a useful control technique for trajectory tracking of robot manipulator systems, to construct an active FTC to decrease the influences of the unknown input. The proposed algorithm does not require velocity measurement in the design process. In addition, with a novel design approach, the combination of controller and observer provides a novel control signal that delivers higher tracking performance compared to the traditional design approach. The global and asymptotic stability of the suggested technique is proved through the Lyapunov theory. Finally, simulations are implemented on a 2-degree-of-freedom (DOF) robot manipulator to validate the efficiency of the proposed controller–observer method. Full article

Aiming at the disadvantages of traditional manual docking, such as low assembly efficiency and large positioning error, a six-DOF dual-arm robot system for module docking is designed. Firstly, according to the operation tasks of the cabin docking robot, its functional requirements and key indicators are determined, the overall scheme of the robot is designed, and the composition and working principle of the robot joints are introduced in detail. Secondly, a strength analysis of the core components of the docking robot is carried out by finite element analysis software to ensure its load capacity. Based on the kinematics model of the robot, the working space of the robot mechanism is simulated and analyzed. Finally, the experimental platform of the docking robot is built, and the working space, repeated positioning accuracy, and motion control accuracy of the docking robot mechanism are verified through experiments, which meet the design requirements. Full article

This study proposes a robust geometric controller tailored for quadrotor unmanned aerial vehicles (UAVs). The original geometric controller exhibits excellent performance in quadrotor UAV maneuvers. However, as a model-based nonlinear control method, it is sensitive to system model parameters. By integrating a novel extended Kalman filter (EKF)-based estimator for real-time, online estimation of the quadrotor’s inertia parameters, the controller adeptly handles internal uncertainties and external perturbations during flight maneuvers. This approach significantly improves the robustness of the control system against model inaccuracies. Empirical evidence is provided through both simulation and extensive real-world flight tests, demonstrating the controller’s effectiveness and its practical applicability in dynamic environments. The results confirm that this integration substantially enhances system reliability and performance under varied operational conditions. Full article

Saturated nonlinear affine systems are widely encountered in many engineering fields. Currently, most control methods on saturated nonlinear affine systems are not specifically designed based on sparsity-based control methodologies, and they might require sparse identification at the beginning stage and applying tracking control afterwards. In this paper, a sparse neural network (SNN)-based control method from an l_p-norm (1 ≤ p < 2) optimization perspective is proposed for saturated nonlinear affine systems by taking advantage of the nice properties of primal dual neural networks for optimization. In particular, when p = 1, a new alternative controller based on SNN is derived, encountering computational difficulties distinct from those of another solution set in the basic dual neural network. The convergence properties of such SNN-based controllers are investigated and analyzed to find a control solution. Five illustrative examples further are shown to demonstrate the efficiency of the proposed SNN-based control method for tracking the desired references of saturated nonlinear affine systems. In the practical application scenario involving the UR5 robot control, the trajectory’s average errors are consistently confined to a minimal magnitude of 10⁻⁴ m. These findings substantiate the efficacy of the SNN-based control approach proposed for precise tracking control in saturated nonlinear affine systems. Full article

Extended back electromotive force (EEMF)-based position sensorless field-oriented control (FOC) is widely utilized for ultra-high-speed surface-mounted permanent magnet synchronous motors (UHS-SPMSMs) driven fuel cell air compressors in medium-high speed applications. Unfortunately, the estimated position is imprecise due to too small EEMF under low speed operation. Hence, current-to-frequency (I-f) control is more suitable for startup. Conventional I-f methods rarely achieve the tradeoff between startup acceleration and load capacity, and the transition to sensorless FOC is mostly realized in the constant-speed stage, which is unacceptable for UHS-SPMSM considering the critical requirement of startup time. In this article, a new closed-loop I-f control approach is proposed to achieve fast and efficient startup. The frequency of reference current vector is corrected automatically based on the active power and the real-time motor torque, which contributes to damping effect for startup reliability. Moreover, an amplitude compensator of reference current vector is designed based on the reactive power, ensuring the maximum torque per ampere operation and higher efficiency. Furthermore, the speed PI controller is enhanced by variable bandwidth design for smoother sensorless transition. These theoretical advantages are validated through experiments with a 550 V, 35 kW UHS-SPMSM. The experimental results demonstrated the enhanced startup performance compared with conventional I-f control. Full article

As important auxiliary equipment, rehabilitation robots are widely used in rehabilitation treatment and daily life assistance. The rehabilitation robot proposed in this paper is mainly composed of an omnidirectional mobile platform module, a lower limb exoskeleton module, and a support module. According to the characteristics of the robot’s omnidirectional mobility and good stiffness, the overall kinematic model of the robot is established using the analytical method. Passive and active training control strategies for an omnidirectional mobile lower limb exoskeleton robot are proposed. The passive training mode facilitates the realization of the goal of walking guidance and assistance to the human lower limb. The active training mode can realize the cooperative movement between the robot and the human through the admittance controller and the tension sensor and enhance the active participation of the patient. In the simulation experiment, a set of optimal admittance parameters was obtained, and the parameters were substituted into the controller for the prototype experiment. The experimental results show that the admittance-controlled rehabilitation robot can perceive the patient’s motion intention and realize the two walking training modes. In summary, the passive and active training control strategies based on admittance control proposed in this paper achieve the expected purpose and effectively improve the patient’s active rehabilitation willingness and rehabilitation effect. Full article

In order to improve the performance of self-driving commercial vehicles for half-hill starting, a ramp control strategy based on the back-slip speed corresponding to the parking moment is proposed. Firstly, the longitudinal dynamics model of the vehicle is established, the force of the vehicle on the ramp is analyzed, and the rear slip speed of the vehicle is matched with the parking moment, and finally the target speed is tracked based on the sliding-mode controller, and in order to validate the validity of the method, two comparative algorithms of the pure PI controller and the proportional gain controller based on the back-sliding speed corresponding to the resting moment are designed for comparative experiments, and the data results show that the control strategy based on the resting moment corresponding to the backsliding speed of the sliding mode ramp start control strategy can stably complete the ramp start under different weights and different slopes, and greatly reduce the backsliding distance of the vehicle. Full article

High-performance electroactive polymer actuators with large bending, fast response, and high durability have gained attention in the development of micromanipulators and multifunctional bionic soft robots. Herein, we developed high-performance electroactive soft actuators fabricated with ultrathin free-standing microfibrillated cellulose (MFC)-reinforced poly(3,4-ethylenedioxythiophene)/poly(4-styrenesulfonate) (PEDOT/PSS) with multi-walled carbon nanotube (MWCNT)-doped composite electrode films and ion-exchange Nafion membranes by a hot-pressing method. The prepared PEDOT/PSS-MFC-MWCNT electrodes have good film-forming properties with a Young’s modulus of 448 MPa and an electrical conductivity of 75 S/cm. The proposed PEDOT/PSS-MFC-MWCNT/Nafion soft actuators have a sustained peak displacement of 2.1 mm and a long-term cyclic stability of 94% with no degradation over 1 h at 1.0 V, 0.1 Hz. Furthermore, we fabricated soft micro-grippers based on the actuators for mimicking actual finger actions for grasping, pointing, and counting, which introduces new possibilities for the next-generation development of micromanipulators and bionic soft robotics. Full article

Soft transportation devices with high flexibility, good stability, and quick controllability have attracted increasing attention. However, a smart soft transportation device with tactile perception and a non-contact actuating mode remains a challenge. This work reports a magnetic soft pipeline (MSP) composed of sensor film, a magnetorheological elastomer (MRE) cavity pipeline, and heater film, which can not only respond well to tactile compression stimuli but also be transported by magnetic actuation. Notably, the sensor film was integrated on the upper surface of an MRE pipeline, and the relative resistance change (∆R/R₀) of the MSP was maintained at 55.8% under 2.2 mm compression displacement during 4000 loading cycles. Moreover, the heater film was integrated on the lower surface of the MRE pipeline, which endows the MSP with an electrothermal heating characteristic. The temperature of the MSP can be increased from 26.7 °C to 38.1 °C within 1 min under 0.6 V. Furthermore, the MSP was attracted and deformed under the magnetic field, and the ∆R/R₀ of the MSP reached 69.1% under application of a 165 mT magnetic field density. Benefiting from the excellent perception and magnetic deformation performances, the magnetic actuate transportation of the MSP with self-sensing was successfully achieved. This multi-functional soft pipeline integrated with in situ self-sensing, electrothermal heating, and non-contact magnetic actuating transportation performance possess high potential in smart flexible electronic devices. Full article

In this paper, the impact of parameter matching on the steady-state performance of permanent magnet-assisted synchronous reluctance motors (PMaSynRM) under vector control is analyzed and discussed. First, based on the mathematical model of motors under the maximum torque per ampere (MTPA) control strategy, an analysis is conducted concerning two main parameters, i.e., the matching relationship between the back electromotive force (back-EMF) and the saliency ratio. The impact of these two parameters on the operational status of the motor is investigated. Then, the motor’s voltage operating conditions are examined, and the operating curve under minimum voltage is derived. Furthermore, in the overvoltage region under the MTPA control strategy, the operation of the motor under the maximum torque per voltage (MTPV) control strategy is explored. This analysis illuminated the patterns of influence exerted by the back-EMF and the saliency ratio on the motor’s voltage operating condition. Between these two control strategies, there remains scope for the motor to operate at its limits. An enhanced understanding of the effects of the back-EMF and saliency ratio within this range on motor performance was achieved, resulting in the optimal matching curve for the back-EMF and saliency ratio. Finally, a 45 kW PMaSynRM was designed, prototyped, and tested to validate the correctness of the design techniques, with the motor achieving IE5 efficiency. Full article

In response to the challenges posed by the difficult cleaning of tunnel retro-reflective rings and the unsuitability of existing climbing robots for ascending tunnel retro-reflective rings, a tunnel retro-reflective ring cleaning robot is proposed. Firstly, based on the analysis of the operational and environmental characteristics and functional requirements inside the tunnel, the design and planning of the robot’s main framework, motion system, cleaning mechanism, and intelligent detection system are conducted to evaluate its walking ability under various working conditions, such as aluminum plate overlaps and rivet protrusions. Subsequently, stability analysis is performed on the robot. The static analysis explored conditions that can make the climbing robot stable, the dynamic analysis obtained the minimum driving torque and finally, verified the stability of the robot through experiments. After that, by changing the material and thickness of the main framework for deformation simulation analysis, the optimal parameters to optimize the design of the main framework are found. Finally, the three factors affecting the cleaning effect of the robot are discussed by the response surface method, and single factor analysis and response surface regression analysis are carried out, respectively. The mathematical regression model of the three factors is established and the best combination of the three factors is found. The cleaning effect is best when the cleaning disc pressure is 5.101 N, the walking wheel motor speed is 36.93 rad/min, and the cleaning disc motor speed is 38.252 rad/min. The development of this machine can provide equipment support for the cleaning of tunnel retro-reflective rings, reducing the requirement of manpower and material resources. Full article

This paper analyzes the viability of different solutions to passively augment the axial stiffness of a horizontal axis radial levitation passive magnetic bearing (PMB) with a previously studied topology. The zero-field cooling (ZFC) of high-temperature superconductor (HTS) bulks promotes higher magnetic impulsion and levitation forces and lower electromagnetic losses than those with field-cooling (FC) but, on the other hand, the guiding stability is much lower than those with FC. Because of stability reasons, FC was adopted in most superconducting maglev systems. The trend of this research group has been to develop a horizontal axis HTS ZFC radial levitation PMB presenting notable levitation forces with reduced electromagnetic losses, defined by a topology that creates guiding stability. Previous work has shown that optimizing the bearing geometry to maximize magnetic guidance forces might not be enough to guarantee the axial stiffness required for many applications. First, the extent to which guidance forces are augmented by increasing the number of HTS bulks in the stator is evaluated. Then, the axial stiffness augmentation by passively adding two limiting permanent magnet (PM) rings is evaluated. The results show that the axial stiffness is highly augmented by adding limiting PM rings with no significant additional investment. This change enables the use of the studied ZFC superconducting PMB in high-precision axial stability applications, such as precision gyroscopes, horizontal axis propellers, and turbines. Full article

Carbon fiber-reinforced polymers (CFRPs) are extensively employed in the aerospace industry due to their excellent properties. Delamination damage occurring at critical locations in CFRPs can seriously reduce the safety of in-service components. The detection and localization of delamination damage using Lamb waves hold significant potential for widespread application in non-destructive testing. However, the choice of damage localization algorithm may produce different delamination damage localization results. This research presented an IRAPID (improved reconstruction algorithm for probabilistic inspection of defects) method derived from the RAPID (reconstruction algorithm for probabilistic inspection of defects) method, aiming to improve the accuracy and reliability of delamination damage localization. Three CFRP curved plates, including a healthy curved plate and two curved plates with delamination damage sizes of Φ20 mm and Φ40 mm, were prepared in the experiment. The detection experiment of the CFRP curved plate using lead zirconate titanate (PZT) as a transducer to excite and receive Lamb waves was conducted, and the influence of excitation signal frequency on the performance of the proposed method was discussed. Under the condition of an excitation signal frequency of 220~320 kHz and a step size of 10 kHz, the accuracy of the delamination damage localization method proposed in this paper was compared with that of existing methods. The experimental results indicate that the IRAPID algorithm exhibits good stability in the localization of delamination damage across the range of frequency variations considered. The localization error of the IRAPID algorithm for delamination damage is significantly lower than that of the DaS (delay-and-sum) algorithm and the RAPID algorithm. As the size of the delamination damage increases, so does the localization error. The accuracy of delamination damage localization is lower in the X-axis direction than in the Y-axis direction. By averaging the localization results across various frequencies, we can mitigate the potential localization errors associated with single-frequency detection to a certain extent. For the localization of delamination damage, Lamb waves at multiple frequencies can be employed for detection, and the detection results at each frequency are averaged to enhance the reliability of localization. Full article

The rapid acquisition of flow field characterization information is crucial for closed-loop active flow control. The proper orthogonal decomposition (POD) method is a widely used flow field downscaling modeling method to obtain flow characteristics effectively. Based on the POD method, a flow field reduced-order model (ROM) is constructed in this paper for the flow field control of a hydrofoil of a blended-wing-body underwater glider (BWB-UG) with stabilized suction and blowing forces. Compared with the computational fluid dynamics (CFD) simulation, the computational time required to predict the target flow field using the established POD-ROM is only about 0.1 s, which is significantly less than the CFD simulation time. The average relative error of the predicted surface pressure is not more than 6.9%. These results confirm the accuracy and efficiency of the POD-ROM in reconstructing flow characteristics. The timeliness problem of fast flow field prediction in BWB-UG active flow control is solved by establishing a fast prediction model in an innovative way. Full article