Noncircular Pulley Research Articles

Development and Optimization of a Noncircular Pulley for Motion Decoupling in Cable-Driven Serial Robots

Abstract Cable-driven serial robots have emerged with high potential for wide applications due to their compact size and low inertia properties. However, developing this type of robot encounters a motion coupling issue that the movement of one joint leads to the motion of other joints, resulting in complex control. In this paper, we proposed a novel approach for motion decoupling based on a noncircular pulley. The length change of the driving cable caused by the motion coupling problem is resolved by using the noncircular pulley. The calculation process of the profile for the noncircular pulley is illustrated in detail. An optimization process based on the brute force method is presented to identify the optimal parameters to minimize the compensation error. A cable-driven serial robot based on the decoupling method is prototyped for assessments. Experiments are conducted to evaluate the performance of the proposed motion decoupling method. The results reveal that the proposed method can effectively resolve the motion coupling issue by maintaining almost constant cable length with a maximum accumulative error only as 0.086 mm, demonstrating the effectiveness of the method.

Application of Noncircular Pulleys to Straight-Fiber-Type Pneumatic Artificial Muscle Manipulator

This study proposes a method for improving the performance of a manipulator driven by pneumatic artificial muscles. Although the straight-fiber-type pneumatic artificial muscle (SF-PAM), a kind of pneumatic artificial muscle, is lightweight and exhibits high contractile force and contraction percentage, its contractile force decreases as contraction increases. To compensate for the decrease in the SF-PAM contractile force, we developed a noncircular pulley and integrated it into the manipulator driven by a wire pulley mechanism. Because this noncircular pulley is designed in accordance with the output characteristics of SF-PAM, the contraction force of SF-PAM can be converted into manipulator torque efficiently. In addition, the radius of the noncircular pulley is expressed as a function, which can be incorporated into a numerical model for the manipulator’s controller. Subsequently, simulation and experimentation to verify the proposed method showed that, when using the same actuator, the manipulator with a noncircular pulley can optimize both output torque and range of motion better than that with a conventional circular pulley. However, a few differences between simulation results and experimental results were observed. These differences were caused by SF-PAM stretching which was not considered in the model. This drawback can be overcome by improving the SF-PAM and the numerical model in future studies. We believe that this study will provide designers of robots that coexist with humans with a high degree of freedom.

Research and Test of Three-Pulley Noncircular Synchronous Pulley Transmission Mechanism with Minimum Slack

The noncircular synchronous belt drive mechanism has demonstrated certain achievements and has been used in special fields. Research regarding noncircular synchronous belt drive mechanisms has focused on optimization design and kinematic analysis in China, whereas two pulley noncircular synchronous belt transmissions have been developed overseas. However, owing to the noncircular characteristics of the belt pulley, the real-time variation in the belt length slack during the transmission of the noncircular synchronous belt is significant, resulting in high probabilities of skipping and vibration. In this study, a noncircular tensioning pulley is added to create a stable three-pulley noncircular synchronous belt driving mechanism and a good synchronous belt tensioning, with no skipping; hence, the non-uniform output characteristic of the driven pulley is consistent with the theoretical value. In the circular noncircular noncircular three-pulley noncircular synchronous belt mechanism, the pitch curve of the driving synchronous belt pulley is circular, whereas those of the driven synchronous belt and tensioning pulleys are noncircular. To minimize the slack of the belt length of the synchronous belt and the constraint of the concavity and circumference of the tensioning pulley, an automatic optimization model of the tensioning pulley pitch curve is established. The motion simulation, analysis, and optimization code for a three-belt-pulley noncircular synchronous belt drive mechanism is written, and the variation in belt length slack under different speed ratios is analyzed based on several examples. The testbed for a circular–noncircular–noncircular three-pulley noncircular synchronous belt transmission mechanism is developed. The test shows that the three-pulley noncircular synchronous belt drives well. This study proposes an automatic optimization algorithm for the tensioning pulley pitch curve of a noncircular synchronous belt transmission mechanism; it yields a stable transmission of the noncircular synchronous belt transmission mechanism as well as non-uniform output characteristics.

Design of Non-Circular Pulleys for Torque Generation: A Convex Optimisation Approach

Nowadays, robotic research focuses more and more on attaining energy-efficient and safe solutions. They are key-aspects of industrial robots, such as inspection and maintenance robots. The introduction of a mechanism that passively compensates the joint torque caused by the weight of the robot may offer a valid solution. Avoiding the need for actuators to balance gravity torques helps decrease the power consumption and the size of the actuators. Furthermore, a passive gravity compensation mechanism allows the robot to hold a static position without the need for an external power source, hence avoiding the risk of collapsing in case of failure of the actuators. This work focuses on designing a torque generator composed of a non-circular pulley and a spring, which, by solving a convex optimisation problem, offers a new methodology for creating any generic torque and thereby also succeeds in solving gravity compensation problems. This methodology guarantees the outcome of feasible non-circular pulleys which minimise the torque required to perform any specific task.

Differential Noncircular Pulleys for Cable Robots and Static Balancing

In this paper, we introduce a mechanism consisting of a pair of noncircular pulleys with a constant-length cable. While a single noncircular pulley is generally limited to continuously winding or unwinding, the differential cable routing proposed here allows to generate nonmonotonic motions at the output of the arrangement, i.e., the location of the idler pulley redirecting the cable. The equations relating its motion to rotation angles of the noncircular pulleys and to the cable length are presented in the first part of this paper. Next, we introduce a graphical method allowing us to obtain the required pulley profiles for a given output function. Our approach is finally demonstrated with two application examples: the guiding of a cable-suspended robot along a complex trajectory using a single actuator, and the static balancing of a pendulum with a 360 deg rotational range of motion.

Harmonious Cable Actuation Mechanism for Soft Robot Joints Using a Pair of Noncircular Pulleys

Various slim robots, such as surgical robots or humanoid robot fingers, are remotely actuated using transmission cables. If pull–pull drive is applied to actuate them using circular driving spools regardless of the shape of the joints, the tension of the driving cable becomes difficult to be maintained properly. Fortunately, it is possible to solve such a cable slack problem by providing an appropriate cable actuation length to the joint structure of the robot from the cable driving unit. Therefore, we propose a harmonious nonlinear cable actuation mechanism suitable for driving noncircular shaped joints. The proposed cable driver can mechanically provide the required cable actuation length to suit the angle change of the target joint using a pair of noncircular pulleys without increasing the number of actuators. In this paper, a design methodology of a noncircular pulley that can be applied to pulleyless rolling joints (PR joints) as well as pulleyless hinge joints is shown. Moreover, a practical cable driver is designed for actuating a hyper-redundant discrete bending joint composed of PR joints, and its effectiveness is verified through experiments. This novel cable actuation mechanism using noncircular pulleys or gears is expected to be applicable to various miniature robots such as surgical robots and animal robots of continuum structure in the future.

Design of Nonlinear Rotational Stiffness Using a Noncircular Pulley-Spring Mechanism

We present a new methodology for designing a nonlinear rotational spring with a desired passive torque profile by using a noncircular pulley-spring mechanism. A synthesis procedure for the shape of the noncircular pulley is presented. The method is based on an infinitesimal calculus approach that leads to an analytical solution, and the method is extended to address practical design issues related to the cable routing. Based on the synthesis method, an antagonistic spring configuration is designed for bilateral torque generation and is designed such that there is no slack in the routing cables. Two design examples are presented, namely, double exponential torque generation and gravity compensation for an inverted pendulum. Experiments with a mechanism for gravity compensation of an inverted pendulum validate our approach. We extend our approach to generate nonlinear torques at two joints by introducing the concept of torque decomposition. Experiments with a two-link robotic arm show that the gravitational forces from the masses on each link are accurately compensated for with our noncircular pulley-spring mechanisms.

Analytical Design Methods of The Force/Torque Profile Adjustment Mechanism with a Non-Circular Pulley

In this research, I investigated the design of non-circular pulley for a force/torque profile adjustment mechanism. I proposed the generalized analytical design method of the non-circular pulley applicable to the majority of structures. By using this design method, the torque acting on the non-circular pulley and the force acting on the flexible part twisted around the non-circular pulley can be converted mutually to obtain a desired torque/force profile. Also I demonstrated the design of the non-circular pulley for a spring balancer and for an arm weight compensation mechanism. Furthermore, I investigated the design limit of the non-circular pulley, and showed that too long effective radius, too long offset length, and too short radius of curvature cause the problem of impractical non-circular pulley shape. From the analysis of the occurrence condition of each case, it became clear that the derivative of the effective radius is important for avoiding too long offset length and that the effective radius and the second derivative of that are important for avoiding too short radius of curvature.

A Weight Compensation Mechanism with a Non-Circular Pulley and a Spring: Application to a Parallel Four-Bar Linkage Arm

We propose a new weight compensation mechanism with a non-circular pulley and a spring. We show the basic principle and a numerical design method to derive the shape of the non-circular pulley. Aft...

非円形プーリ‐バネ系による自重補償機構と４節平行リンク型アームへの適用

We propose a new weight compensation mechanism with a non-circular pulley and a spring. We show the basic principle and numerical design method to derive the shape of the non-circular pulley. After demonstration of the weight compensation for an inverted/ordinary pendulum system, we extend the same mechanism to a parallel four-bar linkage system, analyzing the required torques with transposed Jacobian matrices. Finally, we develop a 3 D.O.F manipulator with relatively small output actuators and verify that the weight compensation mechanism greatly contributes to decrease static torques to keep the same posture within manipulator's work space.

1A1-G20 非円形プーリーバネ系による自重補償機構 : パラレルリンクマニピュレータへの適用(映像,作業をするロボット)

We propose a new weight compensation mechanism with a non-circular pulley and a spring. We show the basic principle and numerical design method to derive the shape of the non-circular pulley. After demonstration of the weight compensation for an inverted/ordinary pendulum system, we extend the same mechanism to a parallel link manipulator, analyzing the required torques with Jacobian matrices. Finally, we carry out hardware experiments.