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Haptic Control of Hydraulic Machinery Using Proportional Valves

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Haptic Control of Hydraulic Machinery Using Proportional Valves HAPTIC CONTROL OF HYDRAULIC MACHINERY USING PROPORTIONAL VALVES A Dissertation Presented to TheAcademicFaculty by Matthew E. Kontz In Partial Fulfillment of the Requirements for the Degree Doctor of Philosophy in the G.W. Woodruff School of Mechanical Engineering Georgia Institute of Technology December 2007 HAPTIC CONTROL OF HYDRAULIC MACHINERY USING PROPORTIONAL VALVES Approved by: Professor Wayne Book, Advisor Professor Amy Pritchett G.W. Woodruff School of Mechanical School of Aerospace / Industrial and Engineering Systems Engineering Georgia Institute of Technology Georgia Institute of Technology Professor Nader Sadegh Dr. Mark Evans G.W. Woodruff School of Mechanical Staff Engineer Engineering John Deere Commercial Products Georgia Institute of Technology Professor Kok-Meng Lee Date Approved: July 25, 2007 G.W. Woodruff School of Mechanical Engineering Georgia Institute of Technology To those who have encouraged me, believed in me and challenged me to do better. iii ACKNOWLEDGEMENTS My first acknowledge needs to go to my advisor, Wayne Book, whose guidance, sup- port and encouragement has been invaluable. Working in your research group has been a joy and privilege. Thanks to Nader Sadegh, Kok-Meng Lee, Amy Pritchett and Mark Evans for serving on my thesis committee. Thank to James Huggins for help developing the backhoe test-bed. You have also been a valuable sounding board for numerous ideas. Thanks to HUSCO International, John Deere and other supporting companies of the Fluid Power and Motion Control Center of Georgia Tech for supporting this work. A special thank to John Deere for donating the tractor, backhoe and numerous spare parts in additional to monetary support. A thanks is due to technical advice given by Shraham Tafazoli, Derek Eagles, Mark Evans, Bob Koski, Randy Bobbitt, Maria Cristina Herrera and Simon DiMaio. Thanks to expert operators Ron Faber, Gert Ploeg and Michael Bryson for taking the time to talk about backhoe/excavator operation. Your perspective was extremely valuable. I would also like to acknowledge comments and suggestions from anonymous reviewers who have critiqued some of the work presented in this document. I would like to acknowledge my mentors: Rod Heisler (Walla Walla College), Emmanuel Nwadiogbu (Honeywell) and Jeff Kuehn (Caterpillar). Thanks to all of my undergraduate engineering professors at Walla Walla College (Walla Walla University as of September 1, 2007) for encouraging me to pursue grad- uate school and for preparing me to do so. Thanks to all my teachers at the Lincoln City SDA School who taught me from third grade to my senior year of high school. Special thank to my parents who encouraged me to develop my strengths and iv work hard on my weaknesses. A special thanks is also due to my fianc´ee, Maria Cristina, for encouragement and for supplying incentive to finish. Since she has already completed her Ph.D., I am one of the few Ph.D. students who can say that his(her) girlfriend/fianc´ee/wife (boyfriend/fianc´e/husband) truly has empathy for the Ph.D. process. Laurel Dovich (Walla Walla College (University as of Sep 1, 2007) Civil/Structural Engineering Professor), you guided me from Civil Engineering with a structural em- phasis to Mechanical Engineering the first week of my junior year. Andrew Alleyne (UIUC Professor), you helped me to choose Dr. Book as my advisor and then less than two years later you helped me make the decision to stay for my Ph.D studies. Probably neither of you realizes the positive and important roles you played in these decisions. Thanks to all of my lab mates in the Intelligent Machines Dynamics Laboratory. It has been a pleasure working with all of you. Special thanks is due to Davin Swanson, L.J. Tognetti and Young Joon Lee for helping to teach me the ropes when I first started graduate school. A special acknowledge is also due to Joe Frankel. The quality and quantity of the work you put into your master’s thesis has been a real asset to my Ph.D. work. It was a pleasure working with you. In addition, I would like to acknowledge officemates Amir Shenouda and Scott Driscoll for allowing me to vent during the more frustrating periods of my Ph.D. journey. Lastly, I would like to thank all of the friends during my years at Georgia Tech who supplied the ridiculous moments to compliment my otherwise sublime life as a graduate student. v TABLE OF CONTENTS DEDICATION................................... iii ACKNOWLEDGEMENTS............................ iv LISTOFTABLES................................. ix LISTOFFIGURES................................ xi SUMMARY..................................... xiv I INTRODUCTION.............................. 1 II BACKGROUND.............................. 4 2.1Haptics................................. 4 2.2RoboticsExcavators.......................... 11 2.3Non-IdealFeaturesofHydraulicSystems............... 15 2.4HydraulicControl........................... 17 2.5Test-bed................................. 18 III KINEMATICS................................ 21 3.1Nomenclature.............................. 21 3.2 Joint-Space to Task-Space Kinematics . 23 3.2.1 Forward-Kinematics...................... 23 3.2.2 JacobianTransforms...................... 26 3.2.3 Inverse-Kinematics....................... 32 3.2.4 ConstrainedInverse-Kinematics................ 34 3.3 Cylinder-Space to Joint-Space Kinematics . 44 3.3.1 SwingCylinder......................... 44 3.3.2 BoomCylinder......................... 45 3.3.3 StickCylinder......................... 47 3.3.4 BucketCylinder........................ 48 3.4Summary................................ 50 vi IV HYDRAULICCONTROL......................... 52 4.1HydraulicsBackground........................ 53 4.2HydraulicSystem............................ 55 4.2.1 Proportional Directional Control Valves . 57 4.2.2 MainPressureRegulatorDesigns............... 61 4.3PumpPressureControl........................ 65 4.3.1 DynamicCoupling....................... 65 4.3.2 CylinderPositionControl................... 72 4.3.3 FlowLimiter.......................... 74 4.3.4 MaxPressureFilter...................... 81 4.4ActuatorFlowControl......................... 87 4.4.1 PressureCompensation.................... 87 4.4.2 Velcoity/FlowControlLaw.................. 92 4.4.3 Dead-band Transition . 99 4.4.4 CoordinatedMotion...................... 100 4.5Summary................................ 105 V BUCKETFORCE............................. 107 5.1PressureBasedForceEstimation................... 108 5.1.1 FrictionModels......................... 109 5.1.2 LS-Estimation......................... 111 5.2LoadCellMeasurement........................ 123 5.3LoadCellComparison......................... 127 5.4Summary................................ 130 VI VIRTUALBACKHOE........................... 131 6.1BackhoeModelandControl...................... 132 6.2SoilModel............................... 133 6.3Graphics................................ 137 6.4ComparisonPlots............................ 138 vii 6.5Summary................................ 142 VII HAPTIC CONTROL AND EVALUATION . 143 7.1CoordinatedHapticControl...................... 144 7.2ImpedanceShaping........................... 145 7.3HumanFactorsEvaluation....................... 151 7.3.1 Controller............................ 152 7.3.2 Procedure............................ 153 7.3.3 StatisticalAnalysis....................... 154 7.3.4 ForceonEnvironment..................... 154 7.3.5 DiggingProductivity...................... 159 7.3.6 Detection............................ 161 7.3.7 SubjectiveComments..................... 165 7.3.8 Learning............................ 169 7.4VirtualFixtures............................ 171 7.5PassiveEnergyBalanceMonitoring.................. 174 7.6Summary................................ 178 VIIICONTRIBUTIONSANDFUTUREWORK............... 180 8.1Summary................................ 180 8.2Contributions.............................. 181 8.3FutureWork.............................. 182 APPENDIX A SFUN BH C2J.C....................... 186 APPENDIX B LAGRANGIAN DYNAMICS . 195 APPENDIX C STATISTICS SUMMARY . 203 APPENDIX D HUMAN TESTING PROCEDURE . 210 REFERENCES................................... 213 VITA........................................ 226 viii LIST OF TABLES 3.1Denavit-Hartenbergparameters...................... 24 4.1Controllerparameters........................... 97 5.1 MSE for each degree-of-freedom. 121 5.2 Parameters from sequential LLS, concurrent LLS and CAD . 122 7.1 HEnRE and V-HEnRE digging force paired t-test . 155 7.2Diggingforcepeakspairedt-test..................... 157 7.3Averagediggingforcepairedt-test................... 157 7.4Largestforcepeaksonobjectpairedt-test................ 158 7.5Allforcepeaksonobjectpairedt-test.................. 158 7.6Diggingproductivitypairedt-test.................... 160 7.7Averagehapticforcepairedt-test.................... 161 7.8Numberofhitspairedt-test....................... 162 7.9 Success rate detecting the objects for different controllers. 163 7.10Detectiontimefromfirstnickpairedt-test............... 164 7.11 Detection time comparison paired t-test . 164 C.12 Confidence interval data for digging force . 204 C.13Pairedt-testdatafordiggingforce................... 204 C.14 Confidence interval data for digging force peaks . 205 C.15 Confidence interval data for average digging force . 205 C.16 Paired t-test data for digging force peaks . 205 C.17 Paired t-test data for average digging force . 205 C.18 Confidence interval data for the largest force peaks . 206 C.19 Confidence interval data for all force peaks on
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