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J. D. TEDFORD
Department of Mechanical Engineering, University of Auckland, Auckland, New
Zealand
(Received 14 February 1991; accepted 1 March 1991)
Abstract--The design of a two-jaw robot gripper using a D.C. servomotor with optical encoder is
described. Force control of the gripper is achieved using armature current sensing as a means of
detecting motor torque and hence the force applied between the gripper jaws.
The motor was modelled mathematically to obtain the second order equation relating armature
current to the applied motor voltage. This relationship was used to develop a proportional plus
integral digital control algorithm enabling force feedback to be achieved.
Two-way communication between the ASEA robot controller and the IBM-XT gripper controller
enables a range of gripping forces to be accessed throughout the robot programme cycle, any one of
which may be selected at a particular time. Anticipated problems associated with the thermal drift
and transient responses have largely been overcome by repeatedly recalibrating the gripper
throughout a work shift.
INTRODUCTION
311
312 J.D. TEDFORD
gripping force. The ultimate aim was to achieve this variability in gripping force from
within the robot control system itself through the use of a force feedback controlled
electro-mechanical gripper [5].
M E C H A N I C A L DESIGN
ASEA
Robot
cantroLLer
Positionfeedback
r
Forcefeedback
Fig. 3. Overall system block diagram.
~ Gripper
motor
( H-Bridge
ampLifier Resistor
(force
sensor)
Differential
amplifier ~ Feedback signal )
e-~
RI R2 +SV
O
I0 NF +SV +SV IO NF
D3 ) I::~I/M
D7 D 8 ~~L .
IK | RI2/ IK
RI4 R32
RII 0 22 l ]RI3 4,7
22K JIK5 RI8 4,7
47
Fig. 5. H - B r i d g e amplifier. ~
316 J.D. TEDFORD
The closed-loop transfer function for the force control is of the proportional plus
integral type, namely
D ( z ) - -
M(Z)
- -
g p ( 1 + ki) z
{ '/
(1 + g i )
E(z) z - 1
for which the constants Kp and K i can be determined for the specific sample and rise
times implemented in the controller. The equivalent time-domain equation for the
controller output is given by
m K = K p x K i e K -- Kpe K 1 + mK-1,
DIGITAL INTERFACE
Electronic hardware was required to provide the interface between the microcom-
puter, the H C T L 1000 motor controller, the A - D converter and A S E A robot
controller. A schematic of the interface is shown in Fig. 6. In addition to providing
the control signal interface between the various devices, the microcomputer executes
the software algorithm needed to achieve the force feedback control.
ock generator J
HCTLIO00
Address Address j Motor
Lines
decoding controLLer
~ [ Motor P W M ) / gripper
I B M PC
Data
N Lines f ASEA
Robot
controLLer
The H C T L 1000 provides the servomotor with the appropriate PWM drive signal
when requested to do so and keeps track of the motor's position from the optical
encoder.
The A - D converter uses a 12-bit AD7572 chip in its "Slow Memory" mode.
Although this causes the microcomputer to halt while conversion takes place, no
significant time penalty was experienced in practice.
The A S E A robot controller has eight data lines available for communication with
external devices. Four of these are used for exclusive read while the other four are
used for write. Thus a total of 16 different instructions can be written to or read from
the robot controller. The 24 V logic of the robot controller needed to be isolated
from the microcomputer, this was achieved by the use of appropriate opto-couplers.
A PCB containing the necessary components for digital control and interface was
designed using "Protel". This board was housed in one of the expansion slots of the
microcomputer, with all external connections being made via a DB37 pin connector.
CONTROL SOFTWARE
The control software was written in Turbo Pascal 4.0 to perform the following
functions.
(i) Read and Write to the H C T L 1000 registers to enable the operating mode of
the IC to be changed, and to set the PWM duty-cycle for variable force control.
(ii) Read from and Write to the robot controller to initiate and acknowledge
specific gripping actions at appropriate points in the robot programme cycle.
(iii) Calibrate the gripper periodically by generating an unloaded velocity profile, for
subsequent use in detecting the presence of an object between the gripper jaws.
(iv) Open or close the gripper to any desired position.
(v) Close the gripper on an object and hold it with a predetermined force.
At the beginning of each work shift and periodically throughout it, a gripper
calibration cycle would be called for. This calibration cycle essentially establishes the
fully open position for the gripper in terms of optical encoder counts. It then
generates a velocity profile for the gripper in terms of encoder counts versus time by
gradually increasing the PWM duty-cycle until mechanical friction is overcome and
the jaws close smoothly. Once closed, the maximum PWM duty-cyle is momentarily
applied and the corresponding A D C value noted and normalised to scale the
feedback signal. Repeating this calibration routine periodically throughout the work
shift accounts for any performance changes resulting from temperature variations or
static friction, and the accuracy of the force control is maintained.
When the robot programme calls for a close gripper action, the force with which it
closes on the object is specified by a four-bit input to the microcomputer. Thus any
one of 16 different gripping forces, expressed as a percentage of the maximum force,
can be applied. As the jaws close on the object, the velocity profile of the gripper is
noted and compared with the stored profile. The tactile sensitivity of the gripper is
preset to ensure that fragile objects are undamaged during this phase of the gripper's
operation. When contact with the object is detected by a change in the velocity
318 J. D. TEDFORD
Force = 20%
Kp: 0.00010 K I = 660
80
6O
20
u_ 0
-20
-40 - -
Time
CONCLUSIONS
Acknowledgements--The author wishes to acknowledge the financial support provided by the Auckland
University Research Grants Committee to make this project feasible.
REFERENCES
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3. Tedford J. D. and Wong L. S., Compliant robot grippers. Proceedings of the 22nd Annual Conference of
the Ergonomics Society of Australia and New Zealand, December 1985, pp. 70-76 (1985).
4. Caporali M. and Shahinpoor M., Design and construction of a five-fingered robotic hand. Robotics Age
February 14-20 (1984).
5. Lawrence A. M. (and Goodwin D.), Force feedback and position control of a manufacturing robotic
gripper. Electrical and Electronic Engineering Dept, University of Auckland, Report No EE 88/36
(1988).