Modeling and Verification of Cable-Hole Transmission Tension Ratio Considering the Cable Lateral Extrusion

Cable-hole transmission is widely applied in cable-driven mechanisms to reduce the mechanical size. However, the driving tension is attenuated with the cable threading through the hole caused by uncertain factors such as local deformation, friction, and other effects, and errors in cable-hole transmission occur. To improve the transmission accuracy of cable-driven mechanisms, a tension distribution model considering the cable lateral extrusion is established. Then, an analytical tension ratio of the cable-hole transmission is derived based on the perturbation method and tension distribution model. Parameters of the tension ratio are identified using a particle swarm optimization algorithm. An adaptive tension control method considering the cable lateral extrusion is designed and compared with the method excluding the cable lateral extrusion in the cable-hole transmission. Finally, a cable-hole transmission experimental device was constructed to verify the tension ratio, parameter identification, and servo control method of the cable-hole transmission. The results show the motion control accuracy of the cable-driven mechanism can be significantly improved with the tension ratio considering the cable lateral extrusion. Compared to the case excluding the cable lateral extrusion, the errors in cable-hole transmission considering the lateral extrusion are reduced by an order of magnitude, and the tension vibration is significantly weakened.