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Design, Construction, and Testing of a Prototype Robotic Leg for Controls Experiments by Paula Marie Countouris Submitted to the Department of Mechanical Engineering in Partial Fulfillment of the Requirements for the degree of Bachelor of Science in Mechanical Engineering at the MASSACHUSETTS INSTITUTE OF TECHNOLOGY ARCHIVES MASSACHUSETTS INST UTE JUN 28 2012 [ LBRAES June 2012 © Massachusetts Institute of Technology 2012. All rights reserved. Author ...... .............. Department of Mechanical Engineering May 31, 2012 Certified by. .... . ............................ Russell L. Tedrake, PhD Associate Professor of Computer Science and Engineering Thesis Supervisor Accepted by.. ... ................................ ................... John H. Leinhard V Samuel C. Collins Professor of Mechanical Engineering Undergraduate Officer

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Page 1: Design, Construction, and Testing of a Prototype Robotic

Design, Construction, and Testing of a Prototype

Robotic Leg for Controls Experiments

by

Paula Marie Countouris

Submitted to the Department of Mechanical Engineeringin Partial Fulfillment of the Requirements for the degree of

Bachelor of Science in Mechanical Engineering

at the

MASSACHUSETTS INSTITUTE OF TECHNOLOGY

ARCHIVESMASSACHUSETTS INST UTE

JUN 28 2012

[ LBRAESJune 2012

© Massachusetts Institute of Technology 2012. All rights reserved.

Author ...... ..............Department of Mechanical Engineering

May 31, 2012

Certified by. .... . ............................Russell L. Tedrake, PhD

Associate Professor of Computer Science and EngineeringThesis Supervisor

Accepted by.. ... ................................ ...................John H. Leinhard V

Samuel C. Collins Professor of Mechanical EngineeringUndergraduate Officer

Page 2: Design, Construction, and Testing of a Prototype Robotic

2

Page 3: Design, Construction, and Testing of a Prototype Robotic

Design, Construction, and Testing of a Prototype Robotic

Leg for Controls Experiments

by

Paula Marie Countouris

Submitted to the Department of Mechanical Engineeringon May 31, 2012, in Partial Fulfillment of the

requirements for the degree ofBachelor of Science in Mechanical Engineering

Abstract

The complex underactuated legs used in the FastRunner robot, designed by theFlorida Institute for Human and Machine Cognition, are designed with multiple link-ages and nonlinear springs to exploit the natural dynamics of the system in order toachieve extraordinary agility and efficiency. One way to control such a complex, un-deractuated system is to use a model-based control design approach based on robustnonlinear control.

To develop a platform to test this physics based control design on the FastRunnerleg, a free swinging underactuated robot leg was designed and constructed for bench-top controls experiments. A stand with motor to actuate the leg and a basic controlsystem for the bench-top setup were also designed and implemented. To verify theperformance of the leg, actuation, and the control setup, an open-loop step response,sinusoidal response, and chirp response were executed on the prototype leg setup.

Future work includes redesign of the system electronics, construction of a systemof equations that describes the leg, and completion of system identification.

Thesis Supervisor: Russell L. Tedrake, PhDTitle: Associate Professor

3

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4

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Acknowledgments

This thesis could not have been completed without the help and support of the

following people and I am deeply grateful for your help.

To Russ Tedrake, for creating an incredible research lab, for the opportunity to

work on this really cool project, and for guidance throughout.

To Andy Barry, the invaluable code monkey who made all the sensing and software

a reality.

To Johnny Godowski for such amazing creativity and energy.

To Ron Wilken, Michael Posa, Ryuma Niiyama, Zachary Jackowski, the members

of the Locomotion Group and the IHMC team, who supplied invaluable knowledge,

experience, and an inspiring work environment.

5

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6

Page 7: Design, Construction, and Testing of a Prototype Robotic

Contents

Abstract .................. .... ................ .... 3

Acknowledgments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Table of Contents 7

List of Figures 9

1 Introduction 11

2 Leg Hardware 13

2.1 FastRunner Leg Design . . . . . . . . . . . . . . . . . . . . . . . . . . 13

2.2 Modified Leg Prototype . . . . . . . . . . . . . . . . . . . . . . . . . 14

2.2.1 Joints and Linkages . . . . . . . . . . . . . . . . . . . . . . . . 15

2.2.2 Hip and Pelvis . . . . . . . . . . . . . . . . . . . . . . . . . . 16

2.2.3 Achilles Linkage . . . . . . . . . . . . . . . . . . . . . . . . . . 17

3 Actuation Hardware 19

3.1 Motor Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

3.2 M otor M ount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

4 Control Hardware and Software 23

4.1 Motor Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

4.1.1 Pow er . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

4.2 Sensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

4.2.1 Optical Encoder . . . . . . . . . . . . . . . . . . . . . . . . . . 26

7

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4.2.2 Motion Capture. . . . . . . . . . . . . . . . . . . . . . . . . . 27

5 Testing 29

5.1 Open Loop Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

5.1.1 Step Input and System Delays . . . . . . . . . . . . . . . . . . 29

5.1.2 Continuous Sinusoidal Input . . . . . . . . . . . . . . . . . . . 30

5.1.3 Chirp Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

5.2 Proportional-Derivative (PD) Control . . . . . . . . . . . . . . . . . . 31

6 Conclusion 35

Bibliography . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

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Page 9: Design, Construction, and Testing of a Prototype Robotic

List of Figures

1-1 Proposed Rendering of FastRunner Robot designed by the IHMC

2-1 Linkages, Joints, and Spring Elements in the Prototype Leg Design

2-2 Prototype Leg Design . . . . . .

2-3 Modified Joint Design . . . . .

2-4 Hip Design . . . . . . . . . . . .

2-5 Achilles Linkage Design .....

Motor and Motor Mount Setup

Close-up of Motor Mount Setup

Leg Mount to Motor Shaft .

Control System Diagram.....

Millipak Sevcon Motor Controller

Power Elements Diagram . . . . .

4-4 Tether used to constrain Optical E

4-5 Optotrak Motion Capture Active-n

. . . . . . . . . . . . . . . . . . . . 19

. . . . . . . . . . . . . . . . . . . . 20

. . . . . . . . . . . . . . . . . . . . 2 1

. . . . . . . . . . . . . . . . . . . . 24

. . . . . . . . . . . . . . . . . . . . 25

. . . . . . . . . . . .. .. .. .. . 26

ncoder to Motor Mount . . . . . . 27

arkers . . . . . . . . . . . . . . . 28

System Response to Step Input . . . . . . . . . .

System Response to Continuous Sinusoidal Input

FastRunner Desired Foot Motion . . . . . . . . .

System Response to Chirp Signal . . . . . . . . .

30

32

. . . 33

. . . 34

9

11

13

. . . . . . . . . . . . . . 14

. . . . . . . . . . . . . . 15

. . . . . . . . . . . . . . 16

. . . . . . . . . . . . . . 1 7

3-1

3-2

3-3

4-1

4-2

4-3

5-1

5-2

5-3

5-4

Page 10: Design, Construction, and Testing of a Prototype Robotic

10

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Chapter 1

Introduction

The FastRunner Robot, a dynamic bipedal running robot designed by the Florida

Institute for Human and Machine Cognition, aims to mesh a biologically inspired

design with the capability of running in excess of 10 m/s.

1I 1

Figure 1-1: Proposed Rendering of FastRunner Robot designed by the IHMC. Imagereproduced with permission from IHMC1]

The complex underactuated legs used in the FastRunner robot are designed with

multiple linkages and nonlinear springs to exploit the natural dynamics of the system

11

Page 12: Design, Construction, and Testing of a Prototype Robotic

in order to achieve extraordinary agility and efficiency. One way to control such

a complex, underactuated system is to use a model-based control design approach

based on robust nonlinear control, a new control approach that extends the tools

from robust linear control to legged robots with nonlinear dynamics.

To develop a platform to test this physics based control design on the FastRunner

leg, a free swinging underactuated robot leg was designed and constructed for bench

top experiments. This thesis describes four components: designing and constructing

an improved copy a prototype robotic FastRunner leg, designing and constructing

a stand with motor to actuate the leg, designing and constructing a basic control

system for the bench-top setup, and testing the free swinging leg.

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Page 13: Design, Construction, and Testing of a Prototype Robotic

Chapter 2

Leg Hardware

2.1 FastRunner Leg Design

Pelvis(Hip

Knee

Ankte

Figure 2-1: Linkages, Joints, and Spring Elements in the Prototype Leg Design Blueelements represent links, green elements represent joints, and orange elements repre-sent springs.

The design of the FastRunner robot leg, based on the bone structure of an ostrich,

can be broken into various linkages joints, and spring members. Figure 2-1 shows the

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Page 14: Design, Construction, and Testing of a Prototype Robotic

basic design of the linkages in used in the leg prototypes.

The links, pictured in blue, include the pelvis/hip, thigh/femur, shin/tibia, cal-

caneal, foot, toes. The joints, pictured in green, starting from the top include the

hip, knee, and ankle. Spring members, pictured in orange include the Achilles link-

age, knee spring, and anti-gravity spring. The natural dynamics of these coupled

linkages and elastic elements enable the leg to efficiently swing and achieve a desired

foot motion. This planar model of the leg, which does not include the toes, has four

degrees of freedom.

A simple prototype based on these linkages, joints, and springs was designed and

constructed by John Godowoski. The prototype, shown in Figure 2-2a, was a 1/2

scale model and, when shaken by hand, achieved a desirable foot motion.

(a) Original (b) Modified

Figure 2-2: Prototype Leg Design

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Page 15: Design, Construction, and Testing of a Prototype Robotic

2.2 Modified Leg Prototype

For this thesis, a copy of the original prototype, shown in Figure 2-2b was designed

and machined to create a mountable test leg with a smooth, more repeatable motion.

Drawings and CAD model were constructed from the original prototype. The

revised prototype leg was constructed in the CSAIL machine shop using basic tools

and machines, including the mill, lathe, and computer controlled water jet. The

original prototype also included three foot joints and toes however the toe joints are

not included in the redesign.

2.2.1 Joints and Linkages

The most significant change on the modified design was the addition of ball bearings

and shafts at each joint and the redesign of the joints.

Figure 2-3: Modified Joint Design: Includes ball bearings, shoulder bolts, and sym-metric design to reduce bending moments in the joint shaft.

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Page 16: Design, Construction, and Testing of a Prototype Robotic

Addition of Bearings and Shafts

In the original prototype, each joint consisted of machine bolts rotating through holes

in the raw aluminum extrusion. Threads of the bolts rubbed wore against the holes

and increased friction in the joint. The screws of the joints did not have any locking

elements and were prone to vibrating loose and falling off as the leg was swung.

In the modified design, shown in Figure 2-3, ball bearings were placed on the

internal extrusion at each joint and the shoulder bolts press fit through the external

extrusion. Precision stainless steel shoulder bolts were used as the pivots for the

joints. These bolts provide a smooth surface for the bearings in the joints. The bolts

were shimmed to length and then preloaded with lock washers and nuts.

Symmetric Design and Decreasing Shaft Moment

In the original design, the two cut aluminum extrusion linkages which were joined were

offset from each other. This offset caused a moment in the shaft, further exacerbating

the friction and wear in each joint. In the modified design, linkages were designed

so that the extrusions nested within each other, also shown in Figure 2-3. This

symmetric design reduced the moment in the joint shaft, thus reducing friction and

wear.

2.2.2 Hip and Pelvis

In the original design, the hip was constructed using two 4inx1in aluminum extru-

sion pieces bolted together, shown in Figure 2-4a. The springs, mounted in blocks,

extruded out of the one side of the hip and rocked a lever back and forth. The hip

pieces could not be fully tightened together and the external lever posed difficulty for

mounting the leg at the hip to the actuator.

For the revised prototype, a sturdy, mountable hip was designed. The two main

plates of the hip, shown in Figure 2-4b were water-jetted out of 1/4" aluminum

plates, and separated with 1/2" bronze standoffs. The hip springs and hip lever were

captured between the plates and were chosen to have the same spring constant and

16

Page 17: Design, Construction, and Testing of a Prototype Robotic

(b) Modified Prototype

Figure 2-4: Hip Design

contact time as the springs in the original design. Use of two plates instead of the

extrusion results in a more robust design and allows the hip springs to be mounted

internally.

2.2.3 Achilles Linkage

In the original prototype, the Achilles linkage was constructed with two concentric

aluminum tubes sliding past one another. An external compression spring, shown in

Figure 2-5a, extends the linkage and is mounted in a way which makes it difficult to

change out the spring for springs of different spring constants.

The modified design, shown in Figure 2-5b, internalizes the spring and uses linear

ball bearings. Internalizing the spring keeps the spring concentric with the linkage

and allows to easily switch springs for those with different spring constants. The

linear bearings allow for up to a 2 degree misalignment between the shafts, reduces

friction in the linkage, and results in a more consistent motion. The linear bearings

are mounted in aluminum blocks and held with two aluminum plates. The shaft that

slides through the bearings is stepped such that the shaft limits the range of motion

of the linkage.

17

(a) Original Prototype

Page 18: Design, Construction, and Testing of a Prototype Robotic

(a) Original Prototype (b) Modified Prototype

Figure 2-5: Achilles Linkage Design

The modified linkage is assembled with four 2in long 4-40 flat head screws which

connect the bearing blocks with aluminum standoffs. In future designs, it is recom-

mended that the flat head screws are replaced with countersunk, hex head machine

screws for ease in assembly. It is also recommended that the shaft connection near

the ankle of the linkage is replaced with a more rigid connection.

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Page 19: Design, Construction, and Testing of a Prototype Robotic

Chapter 3

Actuation Hardware

In the bench-top setup, a high-torque motor swings the FastRunner bench-top leg,

as shown in Figure 3-1. The hip of the leg is mounted directly to the output shaft of

the motor and switches directions at a specified rate to swing the leg.

Figure 3-1: Motor and Motor Mount Setup

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Page 20: Design, Construction, and Testing of a Prototype Robotic

3.1 Motor Specifications

The motor used in the setup was a ME0709 a brush-type permanent magnet DC

motor manufactured by Motenergy Inc, Slinger, Wisconsin. At peak amperage, the

ME0709 is capable of supplying over 40Nm of torque, significantly higher than the

expected torque values for the system based on simulation[2].

Although using a gear reducer seems to be the natural choice for this high torque

low speed system, the disadvantages to gear reducers include high effective inertial

mass and errors due to backlash. Both of these are detrimental to physics based

control, and since size and weight were not main factors for this bench-top setup, a

large, direct drive DC motor was chosen.

3.2 Motor Mount

A motor mount was designed which connected the leg to the motor and cantilevered

the leg over the the edge of a 42" in high machine table. Figure 3-2 shows the motor

mount setup, which included a reinforced machine table, a bottom mounting plate,

two vertical motor mount plates, the four standoffs and the shaft coupling.

Figure 3-2: Close-up of Motor Mount Setup

The machine table purchased was a 42" high medium duty steel machine table.

The table was bolted to the floor using angle brackets and the sides of the table

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Page 21: Design, Construction, and Testing of a Prototype Robotic

were reinforced with diagonal braces. The height of the table allows for adequate leg

clearance off the ground, and also allows for the leg to be setup to run on the lab's

treadmill.

Bolted to the machine table was the bottom mounting plate. This plate was water-

jetted out of 1" thick aluminum with mounting holes to the table and mounting holes

to the vertical plates. The mounting holes to the vertical plates were counter-bored.

This plate was then cantilevered over the edge of the machine table to allow room for

the leg to swing freely.

The two vertical plates were water-jetted out of 1" thick 6061 Aluminum. Each

had 8 mounting holes for the motor and one center through-hole for the motor output

shaft. For the plate next to the motor, the center hole was recessed on the mill to

allow clearance for the shaft coupling. For the plate next to the leg, the bolt holes for

the standoffs were counter-bored so that the leg fit as closely to the plate as possible.

The plates were separated using four standoffs. 3/8-16" bolts extended from the plate

near the leg, through the standoffs, through the vertical plate near the motor, and

threaded onto the motor.

Figure 3-3: Leg Mount to Motor Shaft

A machinable bore shaft coupling was used to connect the 7/8" diameter output

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Page 22: Design, Construction, and Testing of a Prototype Robotic

shaft of the motor to the 3/4" diameter shaft of the leg and optical encoder. The

motor shaft mounts to the leg through a plate on the back of the leg. The motor

shaft is pinned to the leg with a set screw as well as a shaft collar locked between the

plate and the hip plates, shown in Figure 3-3.

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Page 23: Design, Construction, and Testing of a Prototype Robotic

Chapter 4

Control Hardware and Software

The control hardware and software are key parts to system which provide power,control the leg swing, and measure the system performance. Figure 4-1 shows the

general configuration for system control.

Motor Motor Swing LegTorque

Figure 4-1: Control System Diagram Blue elements represent the motor controllerand power components, the orange elements represent the system controller, and thegreen elements represent the sensing elements.

The boxes colored in blue represent the motor controller and power components;

their configuration is described in Section 4.1. The system controller, represented by

the orange box, and the sensing, the green boxes, is described in section 4.3.

23

Page 24: Design, Construction, and Testing of a Prototype Robotic

4.1 Motor Controller

The Millipak Sevcon DC motor controller, shown in Figure 4-2, is used to send mo-

tor commands to the hip actuator in the bench-top setup. The motor controller

was originally purchased for an autonomous forklift project, and was reused for this

project.

Figure 4-2: Millipak Sevcon Motor Controller The connector in the lower left handcorner connects the controller to the host computer and line contactor. The two

horizontal lines provide power to the motor. The red line at the bottom center is

connected to the power supply, and the black line at the top center is connected toground.

Three inputs control the leg movement: forward, reverse, and speed. The forward

and reverse are both binary analog inputs which control the direction of the motor.

The speed input to the controller is a voltage input and ranges from 0-5v [2]. The

minimum value supplied to the motor controller which swings the leg is 0.2V.

After testing with the Millipak M3, it was determined that the controller intro-

duced a hard coded delay on the order of 1 second into the system. Since such a large

delay is highly undesirable for this system, a Galil controller with Amtek amplifier

was chosen to reduce these delays in further testing. All tests performed for this

24

Page 25: Design, Construction, and Testing of a Prototype Robotic

thesis were performed using the Millipak M3 controller.

4.1.1 Power

Figure 4-4 shows setup of power elements to motor controller. The three key ele-

ments for the system include the power supply, the line contactor, the fuse, and the

emergency switch.

Figure 4-3: Power Elements Diagram

The power supply, a Sorensen 35V, 35A supply, provides power to the motor

controller, and thus to the actuator. The motor is connected to a 10OAmp fuse which

ensures that the system does not draw excessive current from the power supply.

The line contactor acts as a high current switch that cuts power to motor controller

if the input signals to the motor controller are incorrect or if the emergency stop is

activated. The emergency stop and the motor controller allow for monitoring of the

system and in cases where the motor becomes overly excited and loses control, power

is cut to the motor.

4.2 Sensing

To determine the input angle of the hip and the angles between each of the leg

linkages, two sensing techniques were used: optical encoding and motion capture.

The optical encoder measured the hip angle and the motion capture measured the

angles of the linkages.

25

Page 26: Design, Construction, and Testing of a Prototype Robotic

4.2.1 Optical Encoder

To determine the angular position input to the leg, an optical encoder was mounted

to the output shaft of the motor. An optical encoder is an electrical mechanical device

that converts rotary displacement into pulse signals.

The encoder used at the hip joint was a US digital HB6M quadrature optical

encoder with a resolution of 10,000 positions per 360 degree cycle of the output

shaft[3]. The HB6M encoder chosen featured a bronze hollow bore that slips over the

motor output shaft and locked into place with two 6-32 set screws.

Figure 4-4: Tether used to constrain Optical Encoder to Motor Mount

To fully constrain the encoder with respect to the shaft, a flexible anti-rotation

tether, shown in Figure 4-5, was mounted to the encoder and to a single point of

the motor mount. Rigidly mounting the encoder to the motor mount would over

constrain the system and introduce errors to the optical encoder measurements. The

flexible tether also compensates for shaft run out of up to 0.030" axial and 0.010"

total indicated run-out[3].

The output of the optical encoder was connected to the labjack and recorded on

the host computer.

26

Page 27: Design, Construction, and Testing of a Prototype Robotic

4.2.2 Motion Capture

Optotrak motion capture system was used to track the movements of the different

leg linkages throughout testing. The Optotrak 3D Investigator (manufactured by

Northern Digital Inc., Waterloo, Ontario, Canada) is a sophisticated position-sensing

camera, which uses three infrared-emitting diodes (IREDs) on active markers, shown

in Figure 4-5.

Figure 4-5: Optotrak Motion Capture Active-markers

These active markers are individually strobed at a high rate and their positions

measured by the trinocular camera system. The camera is connected to a control

unit which relays information between the markers to the camera sensor and relays

information to the host computer. The system used has an accuracy of up to 0.1 mm

and resolution of 0.01mm[5].

Five active markers were placed on the leg, to determine the linkage position and

joint angles of each linkage in the 4 DOF planar model, shown in Figure 2-1. The

trinocular camera was setup approximately 10ft from the leg, and was positioned such

that the markers were constrained to move in a 2D plane.

The software and setup of the Optotrak system was done by Andrew Barry, a

current PhD candidate in the Robot Locomotion group.

27

Page 28: Design, Construction, and Testing of a Prototype Robotic

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Page 29: Design, Construction, and Testing of a Prototype Robotic

Chapter 5

Testing

To verify the performance of the leg, actuation and the control setup and to determine

any problems with the setup, three open loop control tests and a simple PD control

test were executed on the prototype leg setup.

5.1 Open Loop Control

An open loop controller was written in MATLAB to swing the leg with various input

signals. Linkage angles, foot position, and hip angle, were recorded for each test to

determine system response and system delays. The data collected will be used for

system identification.

5.1.1 Step Input and System Delays

To determine delays in the system, a step voltage was supplied to the leg and the

system response was recorded. Figure 5-1 shows the system response in time to

various step signals. The leg was swung both forward and backward for each step

signal and similar results were reached for both directions.

Motor input voltages of less than 0.2V did not move the leg. For input signals of

greater than 0.7V, the leg swung past 90 degrees, would continue to rotate, and no

longer maintained a fixed position.

29

Page 30: Design, Construction, and Testing of a Prototype Robotic

-0.82

0 10 20 30 40 50 W0 70 80 WTime(s)

Figure 5-1: System Response to Step Input

The system shows a significant delay, on the order of 1-1.2 seconds compared to

the input signal, even for relatively low perturbations. Since the message rate of

the software in the host computer and the message rate of the Labjack both exceed

400Hz, the significant delays are likely due to hard coding and/or wiring of the motor

controller.

5.1.2 Continuous Sinusoidal Input

To simulate a more realistic driving torque at the hip, various sinusoidal inputs was

were tested on the leg. Figure 5-2 shows the system response in time to a selection

of sinusoidal inputs.

The range of optimal frequencies to drive the leg ranged from 4-9Hz and the range

of optimal voltages ranged from .65-1.2V. The tests shown in Figure 5-2, can be com-

pared to the desired foot trajectory, shown in Figure 5-3. For certain inputs, the

system response varied trial to trial for identical inputs and initial conditions. This

was most likely due to very slight inconsistencies in leg initialization and miscommu-

nication between the host computer and the leg.

30

Page 31: Design, Construction, and Testing of a Prototype Robotic

1

0.5 I

I0

-0.5

-1

-1-15

Time(s)

(a) Amplitude = 0.7V, Frequency = 4Hz, Offset = OV

1

0.5 [

0

-0.5 F

-1

-1

Time(s)

(b) Amplitude = 1.OV, Frequency = 7Hz, Offset = OV

1.5 -

1 1

0.5

-. 0 2 4 6 8 10 12 14Time(s)

1.5

1

0

i

-1

-1 -0.5 0U(M)

0.5 1 1.5

(c) Amplitude = 0.7V, Frequency = 7Hz, Offset = -0.4V

Figure 5-2: System Response to Continuous Sinusoidal Input: The plots on the left

compare changes in the input to changes in the motor output. The plots on the rightshow the x-y position of the leg's foot.

31

-1 -0.5 0 0.5 1 1.59(m)

-1 -0.5 0 0.5 19(m)

1.5

3 i i - I I

1

2 i i i i i i

i i

._5

0.5 [

%11-0.5

Page 32: Design, Construction, and Testing of a Prototype Robotic

0.5

0.4

0.3

0.2

0.1

0

-0.1

-0.2

-o.3

-0.4

-0.5

-0.4 -0.2 0 0.2U(.N)

- 0

Figure 5-3: FastRunner Desired Foot Motion: The FastRunner leg was swung by handon the test bench with the desired foot trajectory and the foot position was recorded.

5.1.3 Chirp Input

5 10Time(s)

15 20

aEl

a-=

1.5

1

.5

0

.5

-1

-1.-1.5 -1 -0.5 0 0.5y(m)

1 1.5

Figure 5-4: Systemof 0.5 V and ranged

Response to Chirp Signal: Input chirp signal had an amplitudein frequency from 0.5 Hz to 20 Hz.

To obtain data of the system performance to a varying input, a chirp signal with

constant amplitude and varying frequency was tested as an input to the leg. Figure

5-4 shows the system response in time to a chirp signal. Small sections of this data

32

1.5

1

0.5

0

-0.5

(-I)

C

-1

-1.5' I

0.4 0.6

Q4.0t jm

Page 33: Design, Construction, and Testing of a Prototype Robotic

will be used for system identification and modeling of the leg.

5.2 Proportional-Derivative (PD) Control

To implement a simple controller on the FastRunner leg, a proportional-derivative

(PD) controller was tested on the bench-top setup. The leg was swung by hand with

the desired motion, shown in Figure 5-3, and the hip angle was recorded with the

optical encoder. The PD control minimized the error between the desired hip motion

and actual hip motion.

The PD control was unsuccessful and the complex system did not produce signif-

icant results for a range of gains. For small gains, the system was unable to follow

the desired trajectory and for large gains, the system was highly unstable. The PD

control for the leg setup was not successful likely due to the long delay in the motor

controller.

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Chapter 6

Conclusion

The effort of this thesis was to to build and test a robotic leg for controls experiments

and a free swinging underactuated robot leg and test bench was successfully designed,

constructed, and tested.

Further steps are needed before a model-based control design approach based on

robust nonlinear control can be tested on this bench- top setup: redesign of the

system electronics, construction of a system of equations that describes the leg, and

completion of system identification. From the testing, it was determined that the

electronics used in the project, specifically the motor controller which was from a

previous project, were not appropriate for this application. The motor controller was

not purchased for the project, but was reused from a previous project. A proper motor

controller without hard coded delays will make a significant difference on the actuation

and control of the leg. A system of equations for the leg will be generated using a

model of the leg created in URDF, Unified Robot Description Format. Finally, system

identification will be performed on the leg to better estimate the inertial tensors and

joint frictions of the leg. With this system model, different robust nonlinear control

can be tested on the bench-top leg setup.

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Bibliography

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[2] Motenergy, "ME0709 Brush-Type DC Motor," Motenergy.com, 2011. [Online].Available:http://www.motenergy.com/me0709.html. [Accessed: May 10, 2012].

[3] Sevcon USA, Inc., Millipak 4QPM Controller Manual, Southborough, MA: SevconUSA, Inc., 2004.

[4] US Digital, "HB6M Hollow Bore Optical Encoder," US Digital, 2012. [Online].Available:http://www.usdigital.com/products/encoders/incremental/rotary/hollow-bore/hb6m. [Accessed: May 14, 2012].

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[6] S. Cotton, I. Olaru, M. Bellman, T. van der Ven, J. Godowski, and J. Pratt."FastRunner: A fast, efficient and robust bipedal robot. concept and planar sim-ulation." In Proceeding of the IEEE International Conference on Robotics andAutomation (ICRA), St. Paul, Minnesota. 2012

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