Jtam-A4.dvi JOURNAL OF THEORETICAL AND APPLIED MECHANICS 54, 2, pp. 645-657, Warsaw 2016 DOI: 10.15632/jtam-pl.54.2.645 CABLE-SUSPENDED CPR-D TYPE PARALLEL ROBOT Mirjana Filipovic Mihajlo Pupin Institute, University of Belgrade, Belgrade, Serbia; e-mail: mira@robot.imp.bg.ac.rs Ana Djuric Wayne State University, Detroit, U.S.A; e-mail: ana.djuric2@wayne.edu Thispaperdealswith theanalysis andsynthesis of anewly selectedCable-suspendedParallel Robot configuration,namedCPR-Dsystem.Thecameracarrierworkspacehas the shapeofa parallelepiped.TheCPR-D systemhas a unique Jacobianmatrix thatmaps the relationship between internal and external coordinates. This geometric relationship is a key solution for the definition of the system kinematic and dynamic models. Because of the CPR-D system complexity, the Lagrangeprinciple of virtualwork has been adapted.Two significant Examples have been used for the CPR-D system analysis and validation. Keywords: cable-suspended parallel robot, camera observation, kinematics, dynamics 1. Introduction Asystem for observation of aworkspacewithmoving objects has been developed to some extent andwidely analyzed invarious researchareas aswell as for different applications. Similar systems have been analyzed andmodeled as presented by numerous publications. Thekinematicdesignof aplanar three-degree-of-freedomparallelmanipulatorwas considered by Gosselin and Grenier (2011). Four optimal different design criteria were established and analyzed.Atrajectoryplanningapproach for cable-suspendedparallelmechanismswaspresented by Gosselin et al. (2012). A planar two-degree-of-freedom parallel mechanism was used in the analysis. Carricato (2011) studied the kinematics and statics of under-constrained cable-driven parallel robotswith less than six cables in crane configuration.Amotion controller for a sixDOF tendon-based parallel manipulator (driven by seven cables) which moves a platform with high speedwas introducedbyFang et al. (2004).Acontrol designof theCPRsystemswas investigated by Kraus et al. (2013), and Avci et al. (2014). The workspace conditions and the dynamics of the manipulator were described in details. Borgstrom et al. (2007) presented algorithms that enabled precise trajectory control of theNetworked InfoMechanical Systems (NIMS), andunder constrained three-dimensional (3D) cabled robot intended for use in actuated sensing. Several prototypes of the wire-driven parallel robots with different actuation schemes were presented by Merlet (2010). Two of them were evaluated through extensive tests and showed unexpected kinematic problems.Thedetermination of thisworkspacewas an important issuebyGouttefarde et al. (2006) since the cables can only pull and not push on the mobile platform. Parallel cable-driven Stewart-Gough platforms consist of an end-effector which is connected to themachine frame bymotor driven cables. Since the cables can transmit only tension forces, at least m= n+1 cables are needed to tense a system having n-degrees-of-freedom. This will cause a kinematical redundancy and leads to an (m−n)-dimensional solution space for the cable force distribution presented by Bruckmann et al. (2007). The recent result from a newly designed parallel wire robotwhich is currently under constructionwas presented byPott (2008). It is used for developing a new technique for computation and transfer of its workspace to the available CAD software. An auto-calibration method for over constrained cable-driven parallel 646 M. Filipovic, A. Djuric robots using internal position sensors located in the motors was presented by Miermeister et al. (2012). The wire-driven parallel robot presented by Higuchi et al. (1988) has attracted the interest of researchers since the very beginning of the study of parallel robots. Oh and Agrawal (2005) addressed the issue of control design for a redundant 6-DOF cable robot with positive input constraints. Nonlinear dynamic analysis of the suspended cable system was carried out with some sensible results presented by Duan (1998) that could be useful to the real engine- ering of LSRT (Large Spherical Radio Telescopes). Integrated mechanical, electronic, optic and automatic control technologies are employed tomake considerable improvement upon the same system.Amultiple cable robotic crane designed byShiang et al. (2000) is used to provide impro- ved cargo handling. This is one of a few papers dealing with flexible ropes. For the requirement of trajectory tracking of the LSRT, a large fine tuning platform based on the Stewart platform was presented by Su and Duan (2000a,b). The mathematical model for kinematic control was developed with coordinate transformation, and dynamic analysis was made using a Jacobian matrix with singularity analysis, which built a solid base for the tracking control. Kozak et al. (2006) in their paper addressed the static analysis of cable-driven robotic manipulators with a non-negligible cable mass. A cable suspended parallel robot was analyzed by Zi et al. (2008), in which cables were utilized to replace links tomanipulate objects. It was developed from a paral- lel and serial cable-driven robot. Therefore, a cable system with j end-effectors DOFs requires at least (j+1) cables as shown by Hiller and Fang (2005). For three-translational motions of the feed in the system, a four-cable-driven parallel manipulator was developed. The goal of Yao et al. (2010) was to optimize dimensions of the four-cable-driven parallel manipulator to meet the workspace requirement of the constraint condition in terms of cable tension and stiffness. However, the same CPR can be used inmany different applications, but only some configu- rations can be used for the workspace observation. In this paper, we present a novel construction of the CPR system which is named CPR-D, seeFigs. 1 and 2.The camera carrier hangs over ropes properly connected to four highest points, i.e. four upper angles of the parallelepiped workspace. The system has been designed with only three motors and two ropes for the maximum workspace, which means that the system is not redundant.Thisworkspace is double bigger than theworkspace of similar systemswith the same number of motors. The CPR-D system has more advantages in comparison with other similar systems. This system is secured from falling during motion because it is constructed with two parallel ropes, see Fig. 1. Fig. 1. CPR-D in 3D space Acamera workspace is an area where a camera canmove silently and continuously following the observed object. A camera carrier moves freely in the space enabling the shooting of the objects from the above. This gives a unique feeling to the event observer to watch objects from the unusual proximity without disturbances. The observer will be very close to the action Cable-suspended CPR-D type Parallel Robot 647 Fig. 2. CPR-D, top view regardless of the size of the observed space. Motion of the ropes which carry the camera is controlled. The ropes can uncoil or coil, which allow the camera to reach any position in the space. The control system provides three-dimensional motion of the camera. The commands for synchronizedmotion of each winch are provided by controlling themotion of each motor which ultimately provides the three-dimensional continuous camera carrier motion. The gyroscopic sensor that is installed in the camera carrier is stabilized to the horizon. The nature of this system requires development of a newmethodology for calculation of its kinematic and dynamic models, which will be used for building the system. This work will be extended by implementing elastic properties of the ropes in the kinematic and dynamicmodels. The research of elasticity dynamics for nonlinear systemswas done by the following authors: Raskovic (1965), Rega (2004a,b), Hedrih (2010, 2012). In this paper, theCPR model has been generated using the following assumptions: transverse vibrations of the ropes are neglected and the ropes are unstretchable. InSection2, adetaileddescriptionof a selectedCPRsystemtypeand itsmathematicalmodel is given.Most of that Section is devoted to its kinematicmodel, which is directly involved in the development of its dynamicmodel. Two cases of the system responses are analyzed for different conditions in Section 3, while in Section 4 concluding remarks are presented. 2. Mathematical model of CPR-D system In this research, one subsystem of the CPR family has been selected and analyzed in depth. A graphical representation of that system, named CPR-D, is shown in Figs. 1 and 2. The camera carrier of theCPR-D structure is guided through thework area of the parallelepiped shapewith two ropes connected with three winches, each powered by a motor. The ropes coil or uncoil on the winches of radius R1, R2 and R3. The motors rotate the winches directly, and the motor shafts angular positions after gear boxes are θ1, θ2, θ3. This motion moves the camera in the x, y, z Cartesian coordinates. 648 M. Filipovic, A. Djuric Thefirst step towards the dynamicalmodel of theCPR-D is the development of its kinematic model. The geometrical relationship between the lengths k, h, m, n and Cartesian coordinates x, y, z is defined by the following equations k= √ x2+y2+z2 h= √ (d−x)2+y2+z2 m= √ (d−x)2+(s−y)2+z2 n= √ x2+(s−y)2+z2 (2.1) In Fig. 3, motions of motors 1 and 2 are depicted. Motor 1 (motor 2 as well) works so that it wounds its corresponding rope from one side and unwounds from other side. Fig. 3. Rope forces before motor 1, 2 and 3 and after motor 1 and 2 Motions of motors 1 and 2 toward the wall anchors (we call this line “before” motor) are expressed with the following equations respectively ∆θ1 ∆t R1 = ∆h ∆t + ∆m ∆t ∆θ2 ∆t R2 = ∆m ∆t + ∆n ∆t (2.2) The third motor is used to wind up the two ropes about coil 3 in the k, h, m, n directions. This motion produces winding or unwinding of both ropes at the same time. This can be seen in Figs. 2 and 3. The winch used for winding the ropes has radius Ri, i= 1,2,3. The relation between the thirdmotor motion changes∆θ3, and the lengths change∆k,∆h,∆m,∆n can be expressed either with equation (2.3)1 or (2.3)2 ∆θ3 ∆t R3 = ∆k ∆t + ∆h ∆t + ∆θ2 ∆t R2 ∆θ3 ∆t R3 = ∆k ∆t + ∆n ∆t + ∆θ1 ∆t R1 (2.3) Equation (2.4) is obtained by substituting equation (2.2)2 into (2.3)1, or equation (2.2)1 into (2.3)2 ∆θ3 ∆t R3 = ∆k ∆t + ∆h ∆t + ∆m ∆t + ∆n ∆t (2.4) If the sampling time∆t is small enough then equations (2.2) and (2.4) can be expressed, respec- tively, as θ̇1R1 = ḣ+ ṁ θ̇2R2 = ṁ+ ṅ θ̇3R3 = k̇+ ḣ+ṁ+ ṅ (2.5) By differentiating equations (2.1) and substituting them into equations (2.5), the relationship between thevelocities of the cameracarrier in theCartesian space ṗ= [ẋ, ẏ, ż]T andthevelocities of the internal coordinates φ̇= [θ̇1, θ̇2, θ̇3] T can been obtained as following φ̇=Jdṗ (2.6) Cable-suspended CPR-D type Parallel Robot 649 This procedure is named KinCPRD-Solver (Kinematic Cable Parallel Robot D-type Solver). It is clear that the JacobianmatrixJd [1/m] is a full matrix, and its elements beyond the diagonal show strong coupling between the external and internal coordinates. Thekinetic energyEk and thepotential energyEp of the camera carriermotionwithmassmc are given in the following equations Ek = 1 2 mcẋ 2+ 1 2 mcẏ 2+ 1 2 mcż 2 Ep =mcgz (2.7) The gravitational acceleration is g=9.81m/s2. TheCPR-D system has threemotors, and their mathematical model is expressed with vector equation (2.8) (Vukobratovic, 1989) u=Gvφ̈+Lvφ̇+SvMd (2.8) where u = [u1,u2,u3] T is voltage, Gv = diag(Gvi) – motor inertia characteristic, Lv = diag(Lvi) – motor damping characteristic, Sv = diag(Svi) – motor geometric characteristic, Md – motor load torque Gvi = JriRri CMi Lvi = RriBCi CMi +CEi Svi = Rri CMi (2.9) where: Rri [Ω] is rotor circuit resistance, CEi [V/(rad/s)] – back electromotive force constant, CMi [Nm/A] – constant of torque proportionality, BCi [Nm/(rad/s)] – coefficient of viscous friction, Jri [kgm 2] – moment of inertia for the rotor and the gear box. Fig. 4. Rope forces carrying the camera Vector equation (2.8) is based on Lagrange’s equation of motion. The angular positions of the motors shafts θ1, θ2, θ3 are selected as generalized coordinates. Themotor load torqueMd is defined with vector equation Md = [F1R1,F2R2,F3R3] T (2.10) The load force Fd includes three components expressed in a vector form as Fd = [F1,F2,F3] T. This force is acting on the shaft of each motor, and its value depends on the external force F. The external forceF= [Fx,Fy,Fz] T represents the sum of the camera inertial forceFp which is acting on the camera carrier described in equation (2.11)2 and the perturbation forcePp which is disturbing the camera motion F=Fp+Pp Fp =m(p̈+acc) (2.11) Thevectoracc = [0,0,−g] T represents the gravitational acceleration. Thenext step is todescribe the dynamic balance between the forceFm in them rope direction and the external forceF, see 650 M. Filipovic, A. Djuric Fig. 5. (a) Characteristic triangles in 3D space, (b) characteristic triangle in the (d-x)-m plane, (c) characteristic triangle in the (s-y)-m plane, (d) characteristic triangle in the z-m plane Figs. 5a-5d. Two similar right-angle triangles in the (d-x)-m plane, in the (s-y)-m plane, and in the z-m plane are presented in 2D space, see Figs. 5b-5d, respectively. All of these triangles can be seen in 3D space, which is shown in Fig. 5a. The hypotenuses of the GABx, GABy, GABz triangles has length m, which is changeable during motion of the camera. The other two sides of the GABx, GABy, GABz triangles have sizes d−x and k(s−y)z = √ (s−y)2+z2, s− y and k(d−x)z = √ (d−x)2+z2, z and k(d−x)(s−y) = √ (d−x)2+(s−y)2, respectively. The component of the external force F in the x direction is Fx, in the y direction is Fy, in the z direction is Fz. The projection forces Fx, Fy, Fz on the m direction are Fmx, Fmy, Fmz, respectively, which can be seen in Figs. 5b-5d. The similarities of the two triangles in Fig. 5 produce the following relations d−x m = Fmx Fx Fmx = d−x m Fx s−y m = Fmy Fy Fmy = s−y m Fy z m = Fmz Fz Fmz = z m Fz (2.12) The forceFm is a sum of the previously defined components and it is expressed in the following equation Fm =Fmx+Fmy +Fmz = d−x m Fx+ s−y m Fy + z m Fz (2.13) The Lagrange principle of virtual work has been used to find the relation between the motor load torqueMd and the external forceF (Md) T φ̇=FTṗ (2.14) By substituting equations (2.6) into (2.14), the following equations are generated (Md) T Jdṗ=F T ṗ (Jd) T Md =F (2.15) From (2.15)2, equation (2.16) can be expressed as Md = ( (Jd) T )−1 F (2.16) Equation (2.16) cannot be directly applied to the system from Figs. 1 and 2 because of the following reasons: Cable-suspended CPR-D type Parallel Robot 651 • The system has two ropes in each direction. Equation (2.16) has been corrected using the factor ♦=0.5. • Motor 3 is used to synchronize winding or unwinding of the two ropes. These will produce the adopted Jacobian matrix Jx♦d. The matrix Od [m] is generated, which represents the torquemappingmatrix, as defined below Od = ( (Jx♦d) T )−1 (2.17) The adapted Lagrange’s principle of virtual work has been used for solving the complex relation between themotor load torqueMd (acting as a load on the first, second and thirdmotor shaft) and external forces F (acting on the camera carrier) Md =OdF u=Gvφ̈+Lvφ̇+SvOdF (2.18) The torque mapping matrix Od [m] indicates that the system is highly coupled. The control law is selected by the local feedback loop for the position and velocity of themotor shaft in the following form ui =Klpi(θ o i −θi)+Klvi(θ̇ o i − θ̇i) (2.19) whereKlpi is a position constant, andKlvi is a velocity constant for the motion control. The comparison between previously published papers and this research is summarized as in the following: • The novel KinCPRD-Solver gives a relation between the internal and external coordinates through the unique Jacobian matrix Jd. • All threemotors in this systemare differently integrated in comparisonwith the previously published systems. • Most of thepreviously publishedpapers donot involve dynamics of themotor.TheCPR-D system includes the motors which significantly influence the total system response. • TheCPR-D system construction requires a novel dynamic relation between the load forces which are acting on the camera and the forces in them direction. • The previously published systems usedLagrange’s principle of virtual work for calculating the relation between the external and internal forces in the original form. This system has double ropes in all four directions, which requires an adaptation of the Lagrange principle of virtual work. 3. Simulation results The CPR-D system presented in Figs. 1 and 2 is modeled and analyzed by the software pac- kage AIRCAMD. The software package AIRCAMD is used for validation of applied theoretical contributions. This software includes three essential modules which are kinematic, dynamic and motion control law solvers for the CPR-D system. The most important element of the CPR-D system is the mathematical model of the motor which is an integral part of the software pac- kage AIRCAMD. Through the simulation results, it is shown that the dynamic characteristics of the motor significantly affect the response of the system and its stability. In order to make the results comparable, simulation ismade for the same desired system parameters. The camera carrier motion dynamics directly depends on the mechanism dynamic parameters. The camera moves in the 3D space (x, y, z directions). The workspace is characterized by length d=3.2m, width s= 2.2m and height v = 2.0m of the recorded field. The position of the camera carrier 652 M. Filipovic, A. Djuric in the Cartesian space is p = [x,y,z] [m]. The starting point is postart = [0.3m,1.8m,−0.2m], and the end point poend = [0.9m,1.2m,−0.9m], They are presented in Fig. 6a, while their re- ference velocities are shown in Fig. 6c. In Fig. 6b, we show the reference composite velocity of the camera carrier. The shape of the composite velocity is trapezoidal. Fig. 6. The reference trajectorymotion of the camera carrier (a) position xo, yo, zo, (b) velocity (maximum value: po max =0.494m/s, (c) velocity components ẋo, ẏo, żo (Examples 1, 2) The motors are Heinzman SL100F type and gears are HFUC14-50-2A-GR+belt type. The characteristics of themotors are:Rri =0.917Ω– rotor circuit resistance,CEi =3.3942V/(rad/s) – back electromotive force constant, CMi =2.5194Nm/A – constant of torque proportionality, BCi =0.0670Nm/(rad/s) – coefficient of viscous friction,Jri =1.5859kgm 2 –moment of inertia for the rotor and the gear box. The sample time is dt=0.0001s. The positional and velocity motion controller parameters are Klpi = 4200 and Klvi = 130, respectively. Winches radii are Ri = 0.15m. The system responses are comparable and therefore are shown in Table 1. The results for Example 1 are presented in Figs. 7 and 10a, while for Example 2 are presented in Figs. 8 and 10b. Figure 7 (and Fig. 8 as well) has six pictures related to: a) camera carrier position at the reference and the real frames, b) motor shaft position at the reference and the real frames, c) load force at the reference and the real frames, d) deviation between the real and the reference trajectory of the camera carrier, e) deviation between the real and the reference trajectory of the motor shaft positions, f) control signals at the reference and the real frames. Table 1.Comparison of two selected Examples Example 1 2 Figure 7, 10a 8, 10b Mathematical model of the system at the reference frame (2.1)-(2.19) (3.1)-(3.5) is defined by equations Camera carrier is under the influence of the disturbance force yes yes System at the reference frame is coupled yes no The CPR-D system is designed for outdoor use. Because of that, we analyzed the system behavior under the influence of wind impacts, determined as the force Fp = [100(sin(4πt) + sin(32πt)),0,0]T, see Fig. 9. The force has a sine shape and operates only in the x direction, while the components in the y and z directions are zero. Example 1:Themotion responseof the camera carrier has oscillatory characteristics andangular positions of all threemotors are caused by the sinusoidal disturbance force. There is a very good Cable-suspended CPR-D type Parallel Robot 653 Fig. 7. Example 1 Fig. 8. Example 2 tracking of the desired trajectory at the camera carrier real frame and at the motor motion real frame, until the moment when motor 2 enters the saturation in oscillatory manner, see Fig. 7f. The first and the third motor do not enter the saturation at all. The force Fm has two components of the same magnitude Fm1 = Fm2 acting in each rope in the m direction at the reference and the real frames, which is presented in Fig. 10a. Example 2: All system and control parameters are the same as in Example 1. This Example is donewith one illogical assumption,which is that the systemat the reference frame is uncoupled. In that case, the Jacobian matrix Jd⊕ has the diagonal form φ̇=Jd⊕ṗ (3.1) 654 M. Filipovic, A. Djuric Fig. 9. Perturbation force at the camera carrier (Examples 1, 2) Fig. 10. Components of the force F m acting in them direction at the reference and the real frames, (a) Example 1, (b) Example 2 Themathematical model of the system has the following form u=Gvφ̈+Lvφ̇+SvMd⊕ (3.2) Using the adapted Lagrange principle of virtual work, the relationship between the motor load torqueMd⊕ and the external forceF has been given below Md⊕ =Od⊕F (3.3) The diagonal adopted Jacobianmatrix isJx♦d⊕. ThematrixOd⊕ is generated, which represents the torquemappingmatrix, as defined below Od⊕ = ( (Jx♦d⊕) T )−1 (3.4) The torque mapping matrix Od⊕ is diagonal like the Jacobian matrix Jd⊕. Substituting (3.3) into equation (3.2) produces a dynamicmodel of the uncoupledCPR-D system at the reference frame u=Gvφ̈+Lvφ̇+SvOd⊕F (3.5) In this case, the mathematical model of the CPR-D system at the reference frame is defined by equations (3.1)-(3.5). At the real frame, the system is coupled and its kinematic and dynamic models are defined by equations (2.1)-(2.19), see Fig. 8. The coupling characteristics are not taken into the consideration at the reference frame. Due to that fact, the tracking of the referent trajectory in the Cartesian space is not satisfactory, see Figs. 8a and 8d. Thepositioncontrol lawproduces the ideal responseof themotor angularmotion, seeFigs. 8b and 8e. The forcesFm1 =Fm2 acting in each rope in them direction at the reference and real frames are presented in Fig. 10b. Example 2 has an important theoretical meaning, because it confirms the strong coupling between the external and internal coordinates. Cable-suspended CPR-D type Parallel Robot 655 The presented results imply that the dynamics of the individualmotor significantly depends of the selection of theCPR-Dstructure and its parameters.TheCPR-D ismodeled andanalyzed by the software package AIRCAMD. 4. Conclusion The highly authentic general mathematical model for the CPR-D system has been developed. This model represents novel kinematic and dynamic solutions of the complex Cable suspended Parallel Robot structure. TheCPR-D system is selected to carry the camera through four pivot pointswhich produce a 3Dworkspace of a parallelepiped shape.The camera carrier is controlled by two ropes in each of the three directions, and driven by threemotors. The kinematicmodel is defined for themonitored system via the Jacobianmatrix. The generalized coordinates selected for the CPR-Dmodel are angular positions of themotors θ1, θ2, θ3 named internal coordinates. Cameramotion is defined in the Cartesian space, describedwith the x, y, z coordinates, named the external coordinate system. The relation between the internal and external coordinate sys- tems is described by the Jacobian matrix Jd. This relation represents the kinematic model of the CPR-D system. The solution for the CPR-D kinematic structure has been found through a novel procedure named KinCPRD-Solver (Kinematic Cable Parallel Robot D-type Solver) which is developed and validated using two selected Examples. The relation between themotor load torque and the force acting at the camera carrier is described by the Lagrange principle of virtual work. This calculation shows that in this relation, the Jacobian matrix is involved. Because of the construction complexity of this system, the Lagrange principle of virtual work had to be adapted for two reasons. The software package AIRCAMD has been developed and used for individual analysis of theCPR-Dmodel fromvarious aspects such as selecting different workspace dimensions, camera carrier mass, external disturbances, choice of the control law, reference trajectory, avoidance of singularity andmany other characteristics. The future research will involve elastic ropes (type of nonlinear dynamic elasticity as de- fined by Filipovic et al. (2007), Filipovic and Vukobratovic (2008a,b), Filipovic (2012) in the mathematical model of the CPR system. Different CPR models previously developed will be unified according to their similarities into a single reconfigurable model, using themethodology presented byDjuric et al. (2010, 2012). Stability conditions, sensitivity analysis and singularity analysis of the CPR-D systemwill be done in the future research. Acknowledgment This research has been supported by the Ministry of Education, Science and Technological Deve- lopment, Government of the Republic of Serbia through the following two projects: Grant TR-35003 „Ambientally intelligent service robots of anthropomorphic characteristics”, byMihajlo Pupin Institute, University of Belgrade, Serbia, and partially supported by the project SNSF Care-robotics project No. IZ74Z0-137361/1by Ecole Polytechnique Federale de Lausanne, Switzerland. Weare grateful toProf.Dr.KaticaR. (Stevanovic)Hedrih fromtheMathematical Institute,Belgrade for helpful consultations during preparation of this paper. References 1. Avci E., Kenmochi M., Kawanishi M., Narikiyo T., Kawakami S., Saitoh Y., 2014, Vi- brationControl of 3P(S)4 class parallel mechanisms for high speed applications using quantitative feedback design, IROS 2014 – IEEE/RSJ International Conference on Intelligent Robots and Sys- tems, Chicago, IL, USA 2. 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