Extended PKM Fixturing System for Micro-Positioning and Vibration Rejection in Machining Application.

The paper aims to present a mechatronic device able to micro-position the workpiece and to reject disturbances due to machining operation. A decoupling method is proposed for a parallel kinematic machine (PKM) fixturing platform composed by a 3-DoF flexure-based piezo-actuated mechanism. The parallel platform, with a vertical motion and two rotations, is described and its kinematics and dynamics are studied. The coupling undesirable effect is investigated based on a set of poses. To improve the quasi-static regulator model for a set-point following system, a bump less switching controller and a fine-tuning procedure, to estimate the parameter uncertainty and enable the external disturbance containment in an extended broadband frequency range, are presented. The platform and the piezo-actuator controllers are modelled based on a gain scheduling, standard ISA form method, to guarantee the stability. The accuracy is demonstrated through a set of simulations and experimental comparisons. A sensitivity analysis that evaluates the tracking performance and the disturbance rejection based on the number of signal amplitudes, frequencies, and phases is discussed. A validation phase has shown that the developed architecture presents a steady state error lower than 1.2 µm, a vibration reduction of 96% at 1130 Hz with a maximum resolving time of 6.60 ms.

Real-Time Performance of Mechatronic PZT Module Using Active Vibration Feedback Control.

This paper proposes an innovative mechatronic piezo-actuated module to control vibrations in modern machine tools. Vibrations represent one of the main issues that seriously compromise the quality of the workpiece. The active vibration control (AVC) device is composed of a host part integrated with sensors and actuators synchronized by a regulator; it is able to make a self-assessment and adjust to alterations in the environment. In particular, an innovative smart actuator has been designed and developed to satisfy machining requirements during active vibration control. This study presents the mechatronic model based on the kinematic and dynamic analysis of the AVC device. To ensure a real time performance, a H2-LQG controller has been developed and validated by simulations involving a machine tool, PZT actuator and controller models. The Hardware in the Loop (HIL) architecture is adopted to control and attenuate the vibrations. A set of experimental tests has been performed to validate the AVC module on a commercial machine tool. The feasibility of the real time vibration damping is demonstrated and the simulation accuracy is evaluated.

Dual Control for Jerk-Driven Robotics in Rehabilitative Planar Applications.

This study compares a set of strategies to plan and control the trajectory of a robotic device in a planar workspace. These strategies are based on an affective application of jerk-laws able to indicate undesirable conditions (e.g., vibrations) facilitating the device control. The jerk is the time derivative of acceleration, and this solution provides an indirect means to control the variation rate of the actuator torques, while avoiding the complex robot dynamic models and their algorithms for computing the dynamics. In order to obtain a smooth trajectory, a regulator to control a robotic device has been developed and validated. It consists of the implementation of two control modules able to i) generate the predefined trajectory and ii) guarantee the path tracking, reducing unwanted effects. In this case a simple S-shaped path has been originated by the "trajectory generator module" as a reference movement to rehabilitate upper limb functionality. The numerical simulation and the results of preliminary tests show the efficacy of the proposed approach through the vibration smoothness appraisal associated with the motion profile.

Design and control of system for elbow rehabilitation: Preliminary findings.

BACKGROUND: The use of an exoskeleton elbow is considered an effective treatment in several pathologies, including post-stroke complications, traumatic brain injury (TBI) and spinal cord injury (SCI), as well as in patients with neurodegenerative disorders. The effectiveness of rehabilitation is closely linked to a suitably chosen therapy. The treatment can be performed only by specialized personnel, significantly supported by the use of automated devices. OBJECTIVES: The aim of this study was to present a novel exoskeleton for elbow rehabilitation without a complicated control system. MATERIAL AND METHODS: Single-degree-of-freedom (SDOF) solution in constructing the prototype of an elbow exoskeleton for rehabilitation purposes has been applied. The simplicity of the actuation mechanism was set as one of the priorities in the design; thus, a single-axis stepper motor with a controller was found to be adequate for providing a reliable and precise source of motion for the exoskeleton. RESULTS: Technological development may provide novel solutions, such as an exoskeleton - a wearable, external structure which supports or (in selected applications) even replaces the muscle actuation in the patient. The reported advantages of the proposed exoskeleton reflect current state-of-the-art. The proposed control strategy relies on closed-loop position control, performance, low manufacturing cost, and predicted performance in a rehabilitation scenario. All these factors play an important role in establishing the directions for further research, e.g., an integrated force sensor in the device, measurements of torque interactions on the elbow joint, and assessment and response to an overload of articulation. CONCLUSIONS: This study suggests not only the clinical but also the possible economic and logistical advantages offered by the portability of the system, and its effective support for therapists applying an elbow exoskeleton.

Vibration Damping Analysis of Lightweight Structures in Machine Tools.

The dynamic behaviour of a machine tool (MT) directly influences the machining performance. The adoption of lightweight structures may reduce the effects of undesired vibrations and increase the workpiece quality. This paper aims to present and compare a set of hybrid materials that may be excellent candidates to fabricate the MT moving parts. The selected materials have high dynamic characteristics and capacity to dampen mechanical vibrations. In this way, starting from the kinematic model of a milling machine, this study evaluates a number of prototypes made of Al foam sandwiches (AFS), Al corrugated sandwiches (ACS) and composite materials reinforced by carbon fibres (CFRP). These prototypes represented the Z-axis ram of a commercial milling machine. The static and dynamical properties have been analysed by using both finite element (FE) simulations and experimental tests. The obtained results show that the proposed structures may be a valid alternative to the conventional materials of MT moving parts, increasing machining performance. In particular, the AFS prototype highlighted a damping ratio that is 20 times greater than a conventional ram (e.g., steel). Its application is particularly suitable to minimize unwanted oscillations during high-speed finishing operations. The results also show that the CFRP structure guarantees high stiffness with a weight reduced by 48.5%, suggesting effective applications in roughing operations, saving MT energy consumption. The ACS structure has a good trade-off between stiffness and damping and may represent a further alternative, if correctly evaluated.

Functional Design in Rehabilitation: Modular Mechanisms for Ankle Complex.

This paper is aimed at presenting an innovative ankle rehabilitation device based on a parallel mechanism. A functional analysis and design are described to obtain a device able to guarantee ankle movement while patient's body remains stationary. Human ankle is a challenging context where a series of joints are highly integrated. The proposed rehabilitation device permits a patient with walking defects to improve his or her gait. The research focuses on plantar-flexion-dorsiflexion movement. The robust design starts from an accurate modelling of ankle movements during walking, assessing motion data from healthy individuals and patients. The kinematics analysis and functional evaluations lead the study and development of the articulated system. In particular, results of simulations support the effectiveness of the current design. A 3D prototype is presented highlighting that the ankle motion is successfully demonstrated.