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A Nonlinear Elasticity Model and Feedforward Compensation Method to Increase Positioning Accuracy of Industrial Robots

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IEEE Transactions on Automation Science and engineering 2025年

作者： Dzubba, Marcel Neubauer, Michael Hinze, Christoph Lechler, Armin Verl, Alexander University of Stuttgart Institute for Control Engineering of Machine Tools and Manufacturing Units Stuttgart70174 Germany

Large industrial robots are inexpensive compared to their workspace. Due to flexibility, the positioning accuracy is compromised. This paper presents a simple yet effective static calibration method for robots using a laser tracker that can be applied to processes with no change in external load and without high processing forces. The calibration method is based on a novel elastokinematic model that captures the nonlinear gearbox and link compliance and also accounts for the effects of pose dependent joint friction and nonlinearities due to the gravity compensation mechanism. Furthermore, a feedforward concept is presented that separates kinematics from compliance to reduce computation time. The calibration method was implemented on industrial hardware and experimentally validated on a KUKA KR210–2. In comparison to state of the art compliance modeling, accuracy is improved by 23.1 %. Finally, the feedforward model reduces the mean positioning error in the entire workspace by 54.9% compared to the purely kinematically calibrated model, emphasizing the need for compliance compensation. © 2004-2012 IEEE.

关键词： Kinematics

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Modeling Load-, Velocity-, and Temperature-Dependent Transmission Errors of Cycloidal Drives for Industrial Robots Using Fourier Series

Modeling Load-, Velocity-, and Temperature-Dependent Transmi...

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IEEE International Conference on Industrial Technology (ICIT)

作者： Christian J. E. Bauer Valentin Kamm Marcel Dzubba Lukas Steinle Armin Lechler Alexander Verl Institute for Control Engineering of Machine Tools and Manufacturing Units (ISW) University of Stuttgart Stuttgart Germany

ISBN: (数字)9798331521950

ISBN: (纸本)9798331521967

Industrial robots are rarely used for machining tasks due to their limited path accuracy. This accuracy is mainly limited by inaccuracies in the drive trains. Compliance and transmission errors occur in the joint gearboxes. While transmission errors have been extensively studied for strain wave gears, there is little research on these errors in cycloidal drives. This gearbox type is commonly used in industrial robots for medium to heavy payloads. It is proposed to model the mainly periodic transmission errors using a Fourier series where amplitude and phase are defined as a polynomial function of the main influence factors load-torque, velocity, and temperature. Measurements of the transmission errors were conducted using an experimental setup representing a single robot joint. In the evaluation of the measurement data, harmonic frequencies were related to mechanical properties of the cycloidal drive. These frequencies were used to identify the parameters of the polynomial Fourier series model. Compared to validation measurements, the derived model shows an average root mean square error of 0.026 mrad. It is proposed to use the output of the resulting model in a feedforward control approach to compensate the transmission errors and to increase the path accuracy of industrial robots.

关键词： Temperature measurement Accuracy Temperature Gears Measurement uncertainty Industrial robots Polynomials Frequency measurement Fourier series Load modeling

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Offline and Online Energy Simulation using Virtual Commissioning Models with Extended Dynamical Behavior

Offline and Online Energy Simulation using Virtual Commissio...

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2025 IEEE/SICE International Symposium on System Integration, SII 2025

作者： Deubert, Darius Pfeifer, Denis Scheifele, Christian Fehr, Jorg Verl, Alexander Bosch Rexroth AG Lohr am Main97816 Germany Institute for Control Engineering of Machine Tools and Manufacturing Units University of Stuttgart Stuttgart70174 Germany ISG Industrielle Steuerungstechnik GmbH Stuttgart70563 Germany Institute of Engineering and Computational Mechanics University of Stuttgart Stuttgart70174 Germany

ISBN: (纸本)9798331531614

Considering energy consumption and dynamical behavior within the simulation of manufacturing systems emerges as an important objective for their development, commissioning, and operation. Currently, these aspects are often neglected in many fields including virtual commissioning. This work presents an approach to extend highly detailed virtual commissioning models of components from industrial automation by dynamics models for the calculation of energy consumption in an offline simulation and for reuse in an online simulation. To validate the presented approach, an exemplary offline virtual commissioning simulation of a pick-and-place robot application is implemented and subsequently transferred to an online simulation. The validation shows a good accuracy of the simulated energy consumption, enabling virtual commissioning engineers to analyze and optimize energy consumption already in the design phase of manufacturing systems. Additionally, the dynamical behavior was well reflected in the online simulation, contributing to the capability of simulation in the operation phase. © 2025 IEEE.

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Offline and Online Energy Simulation using Virtual Commissioning Models with Extended Dynamical Behavior

Offline and Online Energy Simulation using Virtual Commissio...

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IEEE/SICE International Symposium on System Integration

作者： Darius Deubert Denis Pfeifer Christian Scheifele Jörg Fehr Alexander Verl Bosch Rexroth AG 97816 Lohr am Main Germany and Institute for Control Engineering of Machine Tools and Manufacturing Units University of Stuttgart Stuttgart Germany Denis Pfeifer is with ISG Industrielle Steuerungstechnik GmbH 70563 Stuttgart and Institute of Engineering and Computational Mechanics University of Stuttgart Stuttgart Germany ISG Industrielle Steuerungstechnik GmbH Stuttgart Institute of Engineering and Computational Mechanics University of Stuttgart Stuttgart Germany Alexander Verl is with Institute for Control Engineering of Machine Tools and Manufacturing Units University of Stuttgart Stuttgart Germany

ISBN: (数字)9798331531614

ISBN: (纸本)9798331531621

关键词： Energy consumption Automation Accuracy Service robots System integration manufacturing systems

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Automatic preload adjustment for ball screw drives by means of a spring-loaded mechanism

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CIRP Annals 2025年

作者： A. Verl O. Jud Institute for Control Engineering of Machine Tools and Manufacturing Units (ISW) University of Stuttgart Stuttgart Germany

Preloaded ball screw drives are widely used in high-precision linear motion applications, particularly in machine tool feed drives. To compensate for the loss of preload due to wear over the service life and to maintain typical operational characteristics such as zero backlash and high rigidity, ball screws are usually preloaded to high values. However, this results in increased wear and friction, with a consequent increase in temperature. To address these issues, this paper introduces a novel double nut design for ball screws, featuring a passive preload adjustment mechanism, enabling reduced preload levels while enhancing operating characteristics and operational service life.

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Interoperable Digital Product Passports: An Event-Based Approach to Aggregate Production Data to Improve Sustainability and Transparency in the manufacturing Industry

Interoperable Digital Product Passports: An Event-Based Appr...

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2024 IEEE/SICE International Symposium on System Integration, SII 2024

作者： Ajdinović, Samed Strljic, Matthias Lechler, Armin Riedel, Oliver Institute for Control Engineering of Machine Tools and Manufacturing Units University of Stuttgart Germany

ISBN: (纸本)9798350312072

The manufacturing industry is increasingly focused on sustainability, requiring greater product transparency to meet sustainability targets. Digital Product Passports (DPPs) have emerged as a potential solution to improve recyclability and inform consumer purchasing decisions. However, there is a lack of methodology and digital representation for building DPPs, which hinders data linkage and sharing. In this paper, we propose an approach based on standardised data models and event sourcing to aggregate production data, using energy consumption as an example. We present a concept that captures and stores process information using event sourcing in Asset Administration Shells (AAS), and evaluate its feasibility through a manufacturing demonstrator. The results show that event-based aggregation facilitates the creation of DPPs, allowing different actors in the value chain to participate in an interoperable way. By leveraging a standardised and interoperable common data space, this approach improves product transparency, promotes recyclability and enables informed consumer choice in line with sustainability goals. © 2024 IEEE.

关键词： Transparency

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Remote Power control and Monitoring of Cross-Platform Devices Using Magic Packets Across Network Boundaries 3

Remote Power Control and Monitoring of Cross-Platform Device...

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3rd IEEE Industrial Electronics Society Annual On-Line Conference, ONCON 2024

作者： Von Arnim, Christian Dalkowski, Evelyn Bodamer, Tobias Selim, Ziya Ellwein, Carsten Wortmann, Andreas Institute for Control Engineering of Machine Tools and Manufacturing Units University of Stuttgart Germany

ISBN: (纸本)9798331540319

This paper compares online device discovery and remote startup and shutdown solutions for an enterprise network. As some of for these solutions do only work in a local network and the enterprise network consists of several subnetworks with different firewalls setting, a concept to communicate securely across subnetworks is required. For an evaluation, a prototype is implemented using Wake-on-Lan for startup, Address Resolution Protocol for online detection and Secure Shell for shutting down. Bridged MQTT-brokers are used to communicate across subnetwork with a service in every subnetwork. The central hosted prototype is able to switch on or off computers remotely in every subnetwork. © 2024 IEEE.

关键词： Remote control

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Towards an Implementation of Simulation Based Digital Twins in Cyber-Physical Production Systems Environments 28

Towards an Implementation of Simulation Based Digital Twins ...

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28th IEEE International Conference on Emerging Technologies and Factory Automation, ETFA 2023

作者： Fur, Shan Ajdinović, Samed Lechler, Armin Verl, Alexander Institute for Control Engineering of Machine Tools and Manufacturing Units University of Stuttgart Germany

ISBN: (纸本)9798350339918

The increasing digitization of the manufacturing industry offers a wide range of opportunities for the effective use of production data, which can lead to significant time and cost savings. One promising approach is the use of synchronous simulations during the actual operation of cyber-physical production systems (CPPS) to provide valuable insights into possible performance improvements and at the same time reduce the risk of costly downtime. This paper presents a novel concept that enables structured storage of CPPS production data as part of a digital twin that serves as a virtual replica of the physical production environment. In particular, this approach is based on the Asset Administration Shell (AAS), which provides a comprehensive framework for the management of production data and allows for a seamless integration with simulation models. Storing production data in a structured and standardized format can make data queries efficient, facilitate data processing, and provide a solid foundation for simulation model development, calibration, and validation. These simulation models can then be used to identify potential process improvements and test different scenarios, minimizing the risk of disruption to actual production. © 2023 IEEE.

关键词： Digital storage

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Research approaches enabling transformability for the metal forming industry

Research approaches enabling transformability for the metal ...

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2012 IFAC Workshop on Automation in the Mining, Mineral and Metal Industries, MMM 2012

作者： Birkhold, M. Verl, A. Institute for Control Engineering of Machine Tools Manufacturing Units Stuttgart BW 70174 Germany

ISBN: (纸本)9783902823120

In recent years manufacturers are faced with ever increasing volatile markets. To be able to react to new market situations, manufacturers need to develop production systems that are adaptable to these changes. In order to support research efforts concerning this challenge the Federal Ministry of Education & Research (BMBF) is funding joint projects of companies and research institutes. This paper describes the problems that the sheet metal forming industry is currently facing due to the market turbulences, how the BMBF-funded research project "Formäleon" will enable transformability in the sheet metal forming industry and the first results in the development of a new adaptive control system. © 2012 IFAC.

关键词： Flexible manufacturing systems

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control architecture for embedding reinforcement learning frameworks on industrial control hardware 2020

Control architecture for embedding reinforcement learning fr...

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3rd International Conference on Applications of Intelligent Systems, APPIS 2020

作者： Schmidt, Alexander Schellroth, Florian Riedel, Oliver Institute for Control Engineering of Machine Tools and Manufacturing Units University of Stuttgart Stuttgart Germany

ISBN: (纸本)9781450376303

Using reinforcement learning to find new control strategies for manufacturing processes is a promising approach. However, in order to use reinforcement learning in a manufacturing environment, industrial requirements must be met. In this paper, a new control architecture is proposed that allows reinforcement learning frameworks to be executed on programmable logic controllers, which implies requirements regarding real-time execution. An agent exchange module is presented, that allows to automatically load agents from a non real-time learning environment to a control program running in a real-time environment of a programmable logic controller. The proposed architecture is evaluated on an experimental setup with a non-linear process and commercial off-the-shelf control hardware, to meet industrial requirements. A genetic algorithm is used to learn new control strategies without having prior knowledge of the system. © 2020 ACM.

关键词： Genetic algorithms

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