Multivariable Frequency-Domain Identification of Industrial Robots

Industrial robots are today essential components in the manufacturing industry where they are used to save costs, increase productivity and quality, and eliminate dangerous and laborious work. High demands on accuracy and speed of the robot motion require that the mathematical models, used in the motion control system, are accurate. The models are used to describe the complicated nonlinear relation between the robot motion and the motors that cause the motion. Accurate dynamic robot models are needed in many areas, such as mechanical design, performance simulation, control, diagnosis, and supervision. A trend in industrial robots is toward lightweight robot structures, where the weight is reduced but with a preserved payload capacity. This is motivated by cost reduction as well as safety issues, but results in a weaker (more compliant) mechanical structure with enhanced elastic effects. For high performance, it is therefore necessary to have models describing these elastic effects. This thesis deals with identification of dynamic robot models, which means that measurements from the robot motion are used to estimate unknown parameters in the models. The measured signals are angular position and torque of the motors. Identifying robot models is a challenging task since an industrial robot is a multivariable, nonlinear, unstable, and resonant system. In this thesis, the unknown parameters (typically spring-damper pairs) in a physically parameterized nonlinear dynamic model are identified, mainly in the frequency domain, using estimates of the nonparametric frequency response function (FRF) in different robot configurations/positions. Each nonparametric FRF then describe the local behavior around an operating point. The nonlinear parametric robot model is linearized in the same operating points and the optimal parameters are obtained by minimizing the discrepancy between the nonparametric FRFs and the parametric FRFs (the FRFs of the linearized parametric robot model). Methods for estimating the nonparametric FRF from experimental data are analyzed with respect to bias, variance, and nonlinearities. In order to accurately estimate the nonparametric FRF, the experiments must be carefully designed. To minimize the uncertainty in the estimated parameters, the selection of optimal robot configurations/positions for the experiments is also part of the design. Different parameter estimators are compared in the thesis and experimental results show the usefulness of the proposed identification procedure. The identified nonlinear robot model gives a good global description of the dynamics in the frequency range of interest. The research work is also implemented and made easily available in a software tool for accurate estimation of nonparametric FRFs as well as parametric robot models.