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In this paper a real-time seam tracking algorithm is proposed that can cope with the accuracy demands of robotic laser welding. A trajectory-based control architecture is presented, which had to be developed for this seam tracking algorithm. Cartesian locations (position and orientation) are added to the robot trajectory during the robot motion. In this way, sensor information obtained during the robot motion is used to generate the robot trajectory while moving. Experiments have been performed to prove the tracking capabilities of the seam tracking algorithm.

In this study, a modeling approach is developed to examine laminar flow effects on the rotordynamic behavior of high-speed mini rotating machinery with a moderate flow confinement. The existing research work mostly focuses on the flow-induced forces in small gap systems, such as bearings and seals, in which the flow is mostly laminar and inertia effects are ignored. In other studies, medium gap systems are analyzed, taking the inertia effects into consideration, but the surrounding flow is considered as turbulent. However, in high speed mini rotating machinery, the large clearances and the high speeds make the inertia effects significant, even in the laminar flow regime. In the current study, the flow-induced forces resulting from the surrounding fluid are analyzed and these models are combined with the structural finite element (FE) models for determining the rotordynamic behavior. The structure is analyzed with finite elements based on Timoshenko beam theory. Flow-induced forces, which include inertia effects, are implemented into the structure as added mass-stiffness-damping at each node in the fluid confinement. The shear stress is modeled with empirical and analytical friction coefficients, and the stability, critical speeds, and vibration response of the rotor is investigated for different friction models. In order to validate the developed modeling approach, experiments were conducted on a specially designed setup at different support properties. By comparing the experiments with the theoretical models, the applicability of the different friction models are examined. It was found that the dynamic behavior is estimated better with empirical friction models compared to using the analytical friction models.

Recently, there have been numerous research projects on the development of minirotating machines. These machines mostly operate at speeds above the first critical speed and have special levitation systems. Besides, the multiphysical effects become significant in small scale. Therefore, advanced modeling approaches should be developed and innovative experimental rigs with the foregoing requirements should be constructed in order to test the developed techniques. In the current study, the design of an experimental setup for testing the multiphysical effects has been outlined. First, the previously developed multiphysical models (Dikmen, E., van der Hoogt, P., de Boer, A., and Aarts, R., 2010, “Influence of Multiphysical Effects on the Dynamics of High Speed Minirotors—Part I: Theory,” J. Vibr. Acoust., 132, p. 031010; Dikmen, E., van der Hoogt, P., de Boer, A., and Aarts, R., 2010, “Influence of Multiphysical Effects on the Dynamics of High Speed Minirotors—Part II: Results,” J. Vibr. Acoust., 132, p. 031011) for the analysis of small scale rotors are described briefly for background information. Second, an analysis of the effect of the rotor parameters (diameter, length, rotation speed, etc.) on the dynamics of the rotor under multiphysical effects is presented. Afterward the design process which includes the design decisions based on these results, the availability, simplicity, and applicability of each component is presented in detail. Finally, the experimental results have been presented and the efficiency of the design has been evaluated. In summary, the design requirements for an experimental setup for testing multiphysical effects on minirotors have been analyzed. The design procedure and evaluation of the design have been presented.

In this study the temperature increase and heat dissipation in the air gap of a cylindrical mini rotor stator system has been analyzed. A simple thermal model based on lumped parameter thermal networks has been developed. With this model the temperature dependent air properties for the fluid-rotor interaction models have been calculated. Next the complete system has also been modeled by using computational fluid dynamics (CFD) with Ansys-CFX and Ansys. The results have been compared and the capability of the thermal networks method to calculate the temperature of the air between the rotor and stator of a high speed micro rotor has been discussed.

In this study, a flexible rotor with variable support stiffness has been analyzed. Simple support models consisting of mass, spring systems are extracted from modal analysis of the isolated support and by applying static loads to the finite element model of the supports. The derived equivalent models of the supports are then implemented in the finite element based structural model which predicts the dynamic behavior of the rotor. Finally experimental modal analysis of the rotor is performed with different support stiffnesses. The experimental and theoretical results have been compared and different support modeling approaches have been examined.

This paper presents a realistic dynamic simulation of the closed-loop tip motion of a rigid-link manipulator with joint friction. The results from two simulation techniques are compared with experimental results. A six-axis industrial Strobot is modelled. The LuGre friction model is used to account both for the sliding and pre-sliding regime. The manipulation task implies transferring a laser spot along a straight line with a trapezoidal velocity profile. Firstly, a non-linear finite element method is used to formulate the dynamic equations of the manipulator mechanism. In a closed-loop simulation the driving torques are generated by the control system. The computed trajectory tracking errors agree well with the experimental results. Unfortunately, the simulation is very time- consuming due to the small time step of the discrete-time controller. Secondly, a perturbation method has been applied. In this method the perturbed motion of the manipulator is modelled as a first-order perturbation of the nominal manipulator motion. Friction torques at the actuator joints are introduced at the stage of perturbed dynamics. A substantial reduction of the computer time is achieved without loss of accuracy.

This paper deals with modelling and identification of flexible-joint robot models that can be used for dynamic simulation and model based control of industrial robots. A nonlinear finite element based method is used to derive the dynamic equations of motion in a form suitable for both simulation and identification. The latter requires that the equations of motion are linear in the dynamic parameters. For accurate simulations of the robot tip motion the model should describe the relevant dynamic properties such as joint friction and flexibilities. Both the drive and the joint flexibilities are included in the model. Joint friction is described by means of a static friction model, including Coulomb and viscous friction components. The dynamic parameters describing mass, inertia, stiffness, damping and friction properties are obtained from a least squares solution of an over determined linear system assembled from closed loop identification experiments. In the identification experiment the robot moves along a prescribed trajectory while all joint angles, flexible deformations and driving torques are recorded. In order to excite joint vibrations during the identification feed forward torques at frequencies above the bandwidth of the control system are superposed on the joint torques. The applicability of the method is demonstrated in a numerical study of a four link industrial robot.

This paper deals with the modelling and identification of a six axes industrial Sta¨ubli RX90 robot. A non-linear finite element method is used to generate the dynamic equations of motion in a form suitable for both simulation and identification. The latter requires that the equations of motion are linear in the inertia parameters. Joint friction is described by a friction model that describes the friction behaviour in the full velocity range necessary for identification. Experimental parameter identification by means of linear least squares techniques showed to be very suited for identification of the unknown parameters, provided that the problem is properly scaled and that the influence of disturbances is sufficiently analysed and managed. An analysis of the least squares problem by means of a singular value decomposition is preferred as it not only solves the problem of rank deficiency, but it also can correctly deal with measurement noise and unmodelled dynamics.

This paper presents a trajectory generator, which generates a smooth robot trajectory in real-time. The trajectory generator is based on cubic interpolation, where Cartesian locations (position and orientation) can be added on-the-fly during the robot motion. This way sensor information obtained during the robot motion can be used to generate the robot trajectory. A general control architecture called trajectory-based control is presented in combination with this trajectory generator. Experiments have been carried out which show the capabilities of the trajectory generator to provide a smooth trajectory for the robot joint motion controller.