Biomimetic Bi-Pedal Humanoid: Design, Actuation, and Control Implementation with Focus on Robotic Legs

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Biomimetic Bi-Pedal Humanoid: Design, Actuation, and Control Implementation with Focus on Robotic Legs Biomimetic Bi-Pedal Humanoid: Design, Actuation, and Control Implementation with Focus on Robotic Legs MICHAEL LOUIS OKYEN Thesis submitted to the faculty of the Virginia Polytechnic Institute and State University in partial fulfillment of the requirements for the degree of Master of Science In Mechanical Engineering Shashank Priya, Chair Steve Southward Alfred Wicks April 5, 2013 Blacksburg, VA Keywords: humanoid, biomimetic, legs, mechatronics, hydraulics Biomimetic Bi-Pedal Humanoid: Design, Actuation, and Control Implementation with Focus on Robotic Legs Michael Louis Okyen ABSTRACT The advancements made in technology over the past several decades have brought the field of humanoid robotics closer to integration into the everyday lives of humans. Despite these advances, the cost of these systems consistently remains high, thus limiting the environments in which these robots can be deployed. In this thesis, a pair of low-cost, bio-mimetic legs for a humanoid robot was developed with 12 degrees of freedom: three at the hip, one at the knee, and two at the ankle. Prior to developing the robot, a survey of the human-sized robotic legs released from 2006-2012 was conducted. The analysis included a summary of the key performance metrics and trends in series of human-sized robots. Recommendations were developed for future data reporting that will allow improved comparison of different prototypes. The design of the new robotic legs in this thesis utilized human anatomy data to devise performance parameters and select actuators. The developed system was able to achieve comparable ROM, size, weight, and torque to a six-foot tall human. Position and zero-moment point sensors were integrated for use in balancing, and a control architecture was developed. A model of the leg dynamics was created for designing balancing and walking algorithms. In addition, hydraulic actuators were evaluated for use in humanoid robotics, and testing was conducted in order to create a position control methodology. Finally, a predictive deadband controller was designed that was able to achieve accuracy of less than one degree using a valve with slow switching speed. Acknowledgements I need to thank everyone who has been a part of this great journey in my life. I certainly would not have made it through without the guidance, assistance, motivation, and friendship I received from the people I have worked with, especially Nick Thayer, Eric Baldrighi, Mike Stevens, Matthew Paluszek, Stephen Powell, and Noah Philipson. Working with 38 senior design students over the past three years has been one of the greatest experiences of my life. Thank you for the hard work, for all the late nights, for all the laughs, and for the friendships that will last a lifetime. I would also like to thank my advisor, Dr. Priya for giving me the opportunity to learn and grow into the engineer and person I am today. Despite all of your responsibilities, I always felt that you would make time for me, and I continually felt your trust in my judgment. I have never met anyone who is harder working, and I have no doubt that your research will continue to change the world! I have also been blessed with a wonderful family and friends who have supported me through every stage of my education. To my parents- thank you for everything you have done for me and given me as we’ve journeyed together through the past seven years. To my friends, thank you for all your encouragement and for all the joy you’ve brought to my life. Thank you everyone! iii Contents Chapter 1 1.1 Justification for Walking Robotics ................................................................................... 1 1.1.1 Establishing Criterion for Selection of Legged Robot ............................................ 2 1.1.2 Defining Stability ........................................................................................................ 2 1.1.3 Defining Wheeled vs. Legged Robots ........................................................................ 5 1.1.4 Justification for Two Legs over More Legs .............................................................. 7 1.1.5 Applications for Walking Robots .............................................................................. 9 1.1.6 Justification for the Presented Design .................................................................... 10 1.2 Survey of Full Size Bipedal Humanoid Robots ............................................................. 11 1.2.1 Criteria for Survey ................................................................................................... 11 1.2.2 Data Collection .......................................................................................................... 11 1.2.3 Survey Results ........................................................................................................... 16 1.2.3.1 Trends in Series of Robots ................................................................................ 21 1.2.4 Trends in Joint Design ............................................................................................. 24 1.2.4.1 Lower Back (Waist) .............................................................................................. 24 1.2.4.2 Hip Trends ......................................................................................................... 25 1.2.4.3 Knee Trends ....................................................................................................... 26 1.2.4.4 Foot and Ankle Trends ..................................................................................... 26 1.2.4.5 Walking/Running Capabilities ......................................................................... 26 1.2.5 Analysis of Survey Data ........................................................................................... 26 1.2.6 Suggestions for Future Data Reporting .................................................................. 32 1.2.7 Survey Conclusions................................................................................................... 33 1.2.8 Discussion of Future Biped Trends ......................................................................... 33 iv Chapter 2 2.1 Human Data Research ..................................................................................................... 35 2.1.1 Human Size and ROM ............................................................................................. 36 2.1.2 Human Joint Torques and Velocities...................................................................... 37 2.2 Overall Design Concepts and Actuator Selection ......................................................... 39 2.2.1 Actuator Selection..................................................................................................... 39 2.3 Hip Plate Design ............................................................................................................... 47 2.4 Upper Hip Design ............................................................................................................. 49 2.5 Lower Hip and Thigh Design .......................................................................................... 51 2.6 Knee Design ...................................................................................................................... 54 2.7 Lower Leg and Ankle Design .......................................................................................... 56 2.8 Lower Ankle and Foot Design ........................................................................................ 60 2.9 Overall Design Results ..................................................................................................... 64 2.10 Future Work ..................................................................................................................... 75 2.11 Overall Conclusion........................................................................................................... 75 Chapter 3 3.1 Introduction ...................................................................................................................... 76 3.2 Control and Feedback Components ............................................................................... 76 3.2.1 Motor Drivers ........................................................................................................... 76 3.2.2 Position Sensor .......................................................................................................... 78 3.3 ZMP Sensor ...................................................................................................................... 79 3.3.1 Calculating ZMP....................................................................................................... 79 3.3.2 ZMP Sensor ............................................................................................................... 80 3.3.3 ZMP Testing and Calibration ................................................................................. 84 3.4 Proposed Control Architecture ...................................................................................... 85 v 3.5 Balance Simulations ......................................................................................................... 86 3.6 Conclusions ....................................................................................................................... 89 Chapter 4 4.1 Introduction and Literature Review .............................................................................
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