Ajay Proj Presentation 1

Modeling and Kinematic Analysis
of a 6 D.O.F. MOOG Motion Base using

Virtual Prototyping tools
Ajay D’Souza
Advisor : Dr. Venkat Krovi
Mechanical and Aerospace Engineering Department
State University of New York at Buffalo.
Ajay D’Souza
May 2, 2003
Slide 1 of 32 Automation, Robotics and Mechatronics Lab, SUNY at Buffalo
Agenda
Motivation
- Need for Virtual Prototyping
- Project Goals
Background
- Introduction to Robots
- Kinematics of Serial and Parallel Chain Manipulators
Implementation
- Modeling and Simulation of the System
- Tools Employed
Validation/Results
- Validation of the Virtual Model
- Virtual Test Setup
- Results of Simulations
Future Work / Conclusions

- GUI development
- Implications
Ajay D’Souza
May 2, 2003
Conventional Approach to Design
1. Conceptual Design $$$

2. Build Physical Prototype
3. Measure Performance and Test
No 4. Modify Physical
Criteria met? Prototype
Yes
5. Manufacture Product
Ajay D’Souza Motivation Background Implementation Validation/Results FutureWork

May 2, 2003
The Virtual Prototyping Alternative
1. Conceptual Design
2. Build Virtual Prototype

Less $$ !!!
3. Measure Performance and
Test by Simulation
No 4. Refine Virtual
Criteria met?
Prototype
Yes
5. Build Physical Prototype
6. Test Physically
No
Criteria met?
Yes
7. Manufacture Product

May 2, 2003
Ride Programming
Current Scenario
• Joystick based teach pendant method

saved as pre-programmed binary ride file
• API through which d.o.fs can be set for

each time step.
-Prescribing coupled Cartesian
motions tends to be difficult

May 2, 2003
Project Goals
Proposed Approach
• Creation of a detailed CAD model (Geometric

and Kinematic)
• Perform kinematic analyses (Inverse / Forward)
• Run validation tests on virtual models
• Use validated data for creating ride files

May 2, 2003
Introduction to Robots
Robotics Institute of America definition of ROBOT:
‘A re-programmable multi-functional manipulator designed to move material, parts,

tools or specialized devices, through variable programmed motions for the
performance of a variety of tasks.’
Structural Classification :
Serial manipulators
- Structure takes form of open articulated chain
i.e. one end of the manipulator is attached to the ground and the other end is free to move in space
Parallel manipulators
- Composed of one or more closed kinematic loops
i.e. Final link is grounded such that each link in the chain is connected to at least 2 other links

May 2, 2003
Serial and Parallel manipulators - At a glance
Serial Parallel
Workspace Large Small
Load Capacity Small Large
Precision Low High
Passive joints No Yes
FDA Simple, Unique solution Complex, Multiple solutions
RDA Complex, Multiple solutions Complex, Multiple solutions
Typical Welding, assembly, painting, Flight / ride simulator, machining,

Applications material handling, pick and entertainment, mining equipment,
place radar positioning
(Courtesy: Ebert-Uphoff, I., Class notes 2001)

May 2, 2003
Quadruped Walking Robot "Tekken-II
(Courtesy: University of Electro-
Communications Kimura Lab , Japan)
Orthoglide parallel kinematic m/c tool
(Courtesy: Institut de Recherche en
Communications et Cybernétique de Nantes) Applications of
Parallel
manipulators
Bicycle simulator
(Courtesy: Vibration Control Boeing 737 flight simulator
Laboratory, Korea Advanced (l to r: External and interior views)
Institute of Science and (Courtesy: Ansett flight simulator
Technology (KAIST)) centre, Melbourne Australia)

May 2, 2003
The MOOG motion base
F = l (n - j - 1) + Sfi
where,
F: degrees of freedom of the mechanism
fi: degrees of relative motion permitted by joint i
n: number of links in a mechanism, including the fixed
link
j: number of joints in a mechanism, assuming all the
joints are binary
Motion Base (Courtesy: MOOG Inc.) l: degrees of freedom of the space in which a
mechanism is intended to function (l=6 for spatial and
l=3 for planar and spherical mechanisms)
For the Moog Base we get,

Prismatic joint
Spherical joint
F = 6 (14 – 18 – 1) + [(2x6) + (1x6) + (3x6)]
= -30 + 36 = 6
Universal joint Degrees of Freedom = 6
More about Parallel Manipulators:

U-P-S Limb of the Base
www.parallemic.org

May 2, 2003
Kinematic Analyses
~
End-effector
Joint variables, Forward Kinematics
Cartesian coordinates,
~
X
End-effector
Cartesian coordinates, X Inverse Kinematics Joint variables, ~
~

May 2, 2003
Serial Manipulators
RRR Serial chain robot
• 3 Degrees of Freedom
• Planar robot
  1   2  3
End effector Forward Kinematic Analysis
Given 1 ,  2 , 3 to find ( x, y,  )
  1  2  3
a3
3 x  a1c1  a 2c12  a3c123
P
y  a1s1  a 2 s12  a3s123
a2 where,
Y 2
(c1, s1)  (cos  1,sin  1), (c12, s12)  (cos 1   2,sin 1   2), etc
a1
1
X
Result : Simple, Unique solution

May 2, 2003
Serial Manipulators
RRR Serial chain robot Inverse Kinematic Analysis
• 3 degrees of freedom
• Planar robot   1   2  3 Given ( x, y,  ) to find 1, 2 ,3
x  a3c  a1c1  a 2c12
End effector
y  a3s  a1s1  a 2 s12
Squaring each equation and adding them together
eliminates  1 . Solving for  2 yields,
a3
3 ( x  a 3c  ( y  a 3s   a12  a 2 2
c2 
P 2a1a 2
a2 s2   1  c22
Y 2  2 (  )  ATAN 2( s 2, c 2)
a1
1
a3
X 3
(+)
2 solutions for  2 exist in this
case leading to 2 configurations
3
2
(-)
3 yielding the same end-effector
a2
 2 (+)
location
 1 (-) a1 Indeterminacies exist

1 (+) 2
1 Result : Complicated, Multiple solutions !!

May 2, 2003
C
h
Parallel Manipulators h
h
 B
A
Planar 3-d.o.f, 3-RRR parallel robot b1
1
y a1 D
1
O
Inverse Kinematic Analysis x
For the inverse kinematics, xA, yA and  are given, P(xp,yp)
and the joint angles  1, 2, 3 are to be found.
Parallel robot to be modeled as 3 serial


robots and solved
Total of (23 ) eight possible manipulator
postures corresponding to a given end
effector location !
Indeterminacies exist
(Courtesy: Tsai, 1999)
Result : Complicated, Multiple solutions !!

Assumption:
AB=BC=AC=h and PQ=QR=RP=c

May 2, 2003
C
h
Parallel Manipulators h
h
 B
A
Planar 3-d.o.f, 3-RRR parallel robot
b1
1
Forward Kinematic Analysis
For the direct kinematics  1,  2,  3 are given and the position xA,yA y a1 D
and orientation angle  of the moving platform are to be found. 1
O
x
P(xp,yp)
Closed-form solution is an 8th degree polynomial.

Indeterminacies exist
Upto 8 possible manipulator configurations ! The analysis becomes more complicated as
we progress to spatial manipulators with
added degrees of freedom.
Result : Complicated, Multiple solutions !!
A General Stewart-Gough platform can have
upto 40 direct kinematics solutions! [1]
Detailed Kinematic Analysis for an interested reader :

Lung-Wen Tsai: Robot Analysis: The Mechanics of Serial
and Parallel Manipulators

May 2, 2003
Hence…
We propose:
Interlinking state-of-the-art CAD, Motion Simulation
and Analysis tools to create and validate a Virtual
Prototype of a 6 d.o.f Motion Base
Implications in Design:
Designer can focus totally on refining Control
Schema and Design Optimization. This can help in
cutting down concept-to-realization cycle times and
associated costs significantly !

May 2, 2003
Implementation Scheme
3-D CAD
SolidWorks Designer
Motion Simulation & Control
Visual Nastran
Simulink
User Interface
Matlab GUI
Customer / End user MOOG Programmer

May 2, 2003
CAD Modeling
Why SolidWorks ?
• 3-D parametric modeling software
• Ability to link to a variety of analysis modules
parametrically
• User-friendly

May 2, 2003
SolidWorks – Stages in the Modeling of the platform
Pin Joint Universal Joint
+ + +
Piston Cylinder Piston base Piston Lower Joint
Piston Assembly
Lower bracket Univ_Joint Piston Assembly Complete Leg Assembly

May 2, 2003
SolidWorks – Stages (contd.)
Base Plate Upper bkt LH
Top Plate Upper bkt RH
Complete Motion Base
Univ_Joint
Leg Assembly
May 2, 2003
SolidWorks – Stages (contd.)
Top and Front Views of the

completed SolidWorks model
of the platform

May 2, 2003
Motion Simulation
Why VisualNastran ?
- Enables computation of displacements, forces, torques,
velocity and acceleration anywhere on the model
- Can simulate contact and friction to yield more realistic
models
- Collision detection feature
- Automatic Constraint Mapping (ACM) technology translates
CAD parts, assemblies and assembly mate information.
- Full associative integration with SolidWorks and a host of
other traditional CAD modeling software
- Interactive input sliders to perform What-if ? analyses

May 2, 2003
Motion Simulation
Visual Nastran Interface
Input Slider Controls
Motion model
Import error
Output meters

May 2, 2003
VisualNastran – Grey Areas
Limitations of approach
Pathological examples:
1. Model imported from SolidWorks significantly over-constrained.
2. Part of a component (base bracket) could not be resolved in

VNastran. Complexity of part a factor in importing part geometry.
3. Simulation time required varies depending upon model complexity.

Extent of simplification is a trade-off between virtual realism and
simulation times.
Issues
1. Control for Orientation not yet included in present version of vNastran.

May 2, 2003
Validation of the Model
Simulink Block Diagrams
End effector Co-ords vNastran IK model Actuator leg lengths vNastran FK model
Set-up for Inverse Kinematics data generation for the Forward Kinematic set-up for validating results of
virtual motion base. the IK model.

May 2, 2003
IK Run – Random Input
Input Data Table
Degree of Constant value Varying value Amplitude Frequency

Freedom (mm) Wave Form (mm) (Hz)
X 0 Saw tooth 50 1
Y 0 Square 35 0.6
Z 900 Sine 200 0.25
Rx, Ry, Rz 0 - - -

May 2, 2003
Results
Error Std Deviation (mm)

X 10.91
Y 9.06
Z 11.78

May 2, 2003
Future Work
• Binary ride files from generated data for validation

on actual MOOG Motion Base
• Creation of a Graphical User Interface (GUI)
• Dynamic analysis of the System

May 2, 2003
Graphical User Interface
Advantages
• End user need not
know how to use
Simulink or Visual
Nastran to control the
virtual prototype
• Input data can be
normalized to within
the range of the
MOOG Base
specifications.

May 2, 2003
Bibliography
1. Tsai, Lung-Wen,1999, Robot Analysis: the mechanics of serial and parallel manipulators.
2. Ebert-Uphoff, I., 2001, Class notes: ‘ME 4451 Robotics’, Georgia Institute of Technology, Atlanta, Georgia.
3. Parenti-Castelli,V. and Venanzi, S., On the joint clearance effects in Serial and Parallel Manipulators,
Proceedings of the Workshop on Fundamental Issues and Future Research Directions for Parallel Mechanisms
and Manipulators, Oct 3–4, 2002, Quebec City, Quebec, Canada.
4. Krovi, V., 2002, Class notes: ‘MAE 412 Machines & Mechanisms II’, University at Buffalo, SUNY, Buffalo, New
York.
5. Tsai, Lung-Wen, Technical research report: ‘Systematic Enumeration of Parallel Manipulators’, T.R. 98-33,
Institute for Systems Research, University of Maryland, College Park, Maryland.
6. Tutorial Guide: ‘MSC.visualNastran Desktop’, MSC Software Corporation, California.
Internet :
7. MOOG Inc. website: www.MOOG.com
8. MSC.visualNastran website: www.vndesktop.com
9. MSC.ADAMS website: www.adams.com
10. ParallelMIC- the Parallel Mechanisms Information Center website: www.parallemic.org
11. MATLAB and Simulink website: www.mathworks.com
12. Article: ‘When to prototype, virtually’, http://www.manufacturing.net/contents/pdf/DNx020204sAUQA.pdf
13. Review: ‘Orthoglide: A 3-Axis Parallel Machine Tool for High-Speed Machining’, Chablat, D. et al.:
http://www.parallemic.org/Reviews/Review011.html
14. Laval University Robotics Laboratory website: http://wwwrobot.gmc.ulaval.ca/liens/liens_a.html
15. KUKA Roboter GmbH website: http://www.kuka-roboter.de
16. The New York State Center for Engineering Design and Industrial Innovation (NYSCEDII) website:
http://www.nyscedii.buffalo.edu
17. http://www.isr.umd.edu/Labs/ISL/Projects/Par_Manip/parmanip.html
Ajay D’Souza
May 2, 2003
Questions ?
Ajay D’Souza
May 2, 2003
Thank You !
Ajay D’Souza
May 2, 2003

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Modeling and Kinematic Analysis

of a 6 D.O.F. MOOG Motion Base using

Future Work / Conclusions

1. Conceptual Design $$$

3. Measure Performance and Test

Ajay D’Souza Motivation Background Implementation Validation/Results FutureWork

2. Build Virtual Prototype

Ajay D’Souza Motivation Background Implementation Validation/Results FutureWork

• Joystick based teach pendant method

• API through which d.o.fs can be set for

Ajay D’Souza Motivation Background Implementation Validation/Results FutureWork

• Creation of a detailed CAD model (Geometric

• Perform kinematic analyses (Inverse / Forward)

• Run validation tests on virtual models

• Use validated data for creating ride files

Ajay D’Souza Motivation Background Implementation Validation/Results FutureWork

Robotics Institute of America definition of ROBOT:

‘A re-programmable multi-functional manipulator designed to move material, parts,

Ajay D’Souza Motivation Background Implementation Validation/Results FutureWork

Load Capacity Small Large

Precision Low High

Passive joints No Yes

FDA Simple, Unique solution Complex, Multiple solutions

RDA Complex, Multiple solutions Complex, Multiple solutions

Typical Welding, assembly, painting, Flight / ride simulator, machining,

Ajay D’Souza Motivation Background Implementation Validation/Results FutureWork

Ajay D’Souza Motivation Background Implementation Validation/Results FutureWork

For the Moog Base we get,

Universal joint Degrees of Freedom = 6

More about Parallel Manipulators:

Ajay D’Souza Motivation Background Implementation Validation/Results FutureWork

Ajay D’Souza Motivation Background Implementation Validation/Results FutureWork

End effector Forward Kinematic Analysis

Ajay D’Souza Motivation Background Implementation Validation/Results FutureWork

 1 (-) a1 Indeterminacies exist

Ajay D’Souza Motivation Background Implementation Validation/Results FutureWork

Parallel robot to be modeled as 3 serial

Result : Complicated, Multiple solutions !!

Ajay D’Souza Motivation Background Implementation Validation/Results FutureWork

Closed-form solution is an 8th degree polynomial.

Detailed Kinematic Analysis for an interested reader :

Ajay D’Souza Motivation Background Implementation Validation/Results FutureWork

Ajay D’Souza Motivation Background Implementation Validation/Results FutureWork

Motion Simulation & Control

Customer / End user MOOG Programmer

Ajay D’Souza Motivation Background Implementation Validation/Results FutureWork

Ajay D’Souza Motivation Background Implementation Validation/Results FutureWork

Pin Joint Universal Joint

Lower bracket Univ_Joint Piston Assembly Complete Leg Assembly

Ajay D’Souza Motivation Background Implementation Validation/Results FutureWork

Base Plate Upper bkt LH

Top Plate Upper bkt RH

Complete Motion Base

Top and Front Views of the

Ajay D’Souza Motivation Background Implementation Validation/Results FutureWork

Ajay D’Souza Motivation Background Implementation Validation/Results FutureWork

Visual Nastran Interface

Input Slider Controls

Ajay D’Souza Motivation Background Implementation Validation/Results FutureWork

1. Model imported from SolidWorks significantly over-constrained.

2. Part of a component (base bracket) could not be resolved in

3. Simulation time required varies depending upon model complexity.

1. Control for Orientation not yet included in present version of vNastran.

Ajay D’Souza Motivation Background Implementation Validation/Results FutureWork