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8th CIRP Conference on High Performance Cutting (HPC 2018)

8th CIRP Conference on High Performance Cutting (HPC 2018)
Cartesian Stiffness Optimization for Serial Arm Robots
Cartesian
28thStiffness
CIRP DesignOptimization
Conference, May for
2018,Serial
Nantes,Arm
FranceRobots
Huseyin Celikaga,a,*, Neil D. Simsaa, Erdem Ozturkbb
A new Industrial Doctorate Centre in Machining Science, The University of Sheffield, Mappin Street, Sheffield S1 3JD,architecture
a
methodology to analyze
Huseyin Celikag *, the functional
Neil and physical
D. Sims , Erdem Ozturk
United Kingdom
of
existing products
Industriala
Doctorate
AMRC b
forin The
withCentre
Boeing,
b
anUniversity
assembly
Machining Science,
of Sheffield, oriented
The University
Wallis of Sheffield,
Way, product
Mappin
Catcliffe, Street,
Rotherham S60 family
Sheffield identification
S1 3JD,
5TZ, United United Kingdom
Kingdom
AMRC with Boeing, The University of Sheffield, Wallis Way, Catcliffe, Rotherham S60 5TZ, United Kingdom
* Corresponding author. Tel.: +44 (0) 114 222 7700. E-mail address: hcelikag1@sheffield.ac.uk
* Corresponding author. Tel.: +44 (0) 114 222 7700. E-mail address: hcelikag1@sheffield.ac.uk
Paul Stief *, Jean-Yves Dantan, Alain Etienne, Ali Siadat
École Nationale Supérieure d’Arts et Métiers, Arts et Métiers ParisTech, LCFC EA 4495, 4 Rue Augustin Fresnel, Metz 57078, France
Abstract
Abstract
*Recently,
Corresponding
serialauthor. Tel.: +33
arm robots 3 87attention
drew 37 54 30;of E-mail address: paul.stief@ensam.eu
the machining industry due to their high dexterity, large workspace and ability to conduct various
Recently,
tasks, withserial arm robots
a reduced capitaldrew
cost attention
comparedoftothe machining
machine tools.industry
However, duetheir
to their
poorhigh
anddexterity, large workspace
varying rigidity, and abilityare
and low precision, to the
conduct
mainvarious
factors
tasks, withtheir
impeding a reduced capital
application to cost
hardcompared to machineoperations.
material machining tools. However,
Propertheir poor and of
development varying rigidity,
stiffness and lowmodels
and dynamic precision, are thetomain
is crucial factors
predict and
impeding
compensate their
theapplication to hardunder
tool deflections material machining
cutting forces.operations.
However, this Proper development
is only of stiffness
part of the solution,and anddynamic
there ismodels
a needisforcrucial to predict
Cartesian and
stiffness
Abstract
compensate
enhancement.the toolcan
This deflections
be achieved under cutting forces.
by utilizing However,redundant
the functionally this is only part of
degree offreedom
the solution,
(DoF)and therethe
around is tool
a need
axisfor
thatCartesian stiffness
is available when
enhancement.
employing a 6-DoF This can be achieved
serial arm robot by for
utilizing
5-axisthemachining
functionally redundantIndegree
operations. of freedom
this paper, (DoF) around
the stiffness the tool
of a serial armaxis that was
robot is available
optimized whento
Inemploying
today’s business
a 6-DoF environment, the trend
for atowards more product variety and customization the isstiffness
unbroken. of aDue to this development, the need of
minimize the possibleserial arm robot
deflections during 5-axis machining
milling operation.operations.
The machining In this paper,
table surface with a fixed serial
height arm
was robot
divided wasinto
optimized
a mesh of to
agile and reconfigurable
minimize the possible productionduringsystemsa emerged to cope with various products and product
withfamilies.
fixed To designwasand optimize production
evenly spaced points deflections
with the tool alignment milling operation.
perpendicular The
to itsmachining
surface. table
The surface
functionally aredundant height
degree divided
of freedom intowas
a mesh of
varied
systems
evenly as
sequentially,well
spaced andas to choose
points
robot with the optimal
the
configurations productthe
tool alignment
achieving matches,
desiredproduct
perpendicular poses analysis
to were methods
its surface.
determined are needed.
Thethrough
functionally
inverse Indeed,
redundant mostdegree
kinematics of
forthe known
of
each freedommethods
scenario. aim
was inverse
The to
varied
analyze
of a product
sequentially,
Cartesian stiffnessor
and robot one product family
configurations
matrix, on the
achieving
(the Cartesian physical level.
the desired
Compliance Different
poses
matrix) were
of the product families,
determined
robot was thenthroughhowever,
computed may
inverse differ
kinematics
for every largely in terms
for eachand
configuration, of the
scenario. number
the oneThe and
inverse
having the
nature
optimumof components.
of Cartesian
Cartesian This fact
stiffnesscompliance
matrix, impedes
(theparameter
Cartesian anin efficient
Compliance comparison
an arbitrary matrix) of and
direction the
was choice
robot wasof then
selected. appropriate
computed
Consequently, product
for family
every
a map thecombinations
ofconfiguration,
optimum and for
the the
Cartesian production
onecompliance
having the
system.
optimum A new
parameter overmethodology
Cartesian
the surface ofisthe
compliance proposed
parameter
machining to analyze
intable existing
an arbitrary
was products
direction
obtained which incan
was view
be of
selected.
used their functional
Consequently,
for and
a map
static deflection physical
of thearchitecture.
compensation optimum The aim iscompliance
and, Cartesian
potentially to cluster
for chatter
these products
parameter
avoidance overinthe
new
in robotic assembly
surface
milling oriented
ofoperations.
the product
machining Thetable families
work was for the
thatoptimization
obtained
suggests which can beof
a significant usedexistinginassembly
for static
increase linesofcompensation
thedeflection
stiffness and
thethe creation
robot beofobtained
canand, future reconfigurable
potentially byfor chatter
using this
assembly
avoidancesystems.
method. in roboticBased on Datum
milling FlowThe
operations. Chain,workthesuggests
physicalthatstructure of the products
a significant increase inis analyzed.
the stiffnessFunctional
of the robotsubassemblies are identified,
can be obtained by using and
this
amethod.
functional analysis is performed. Moreover, a hybrid functional and physical architecture graph (HyFPAG) is the output which depicts the
similarity
© 2018 The between
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Published by providing
by Elsevier Ltd. Thisdesign
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CC BY-NC-ND product designers. An illustrative
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Peer-review
Selection under
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peer-review under ofresponsibility
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of the International Scientific 8ththe
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CIRP approach.
Conference
of the 8th CIRP on High Performance
Conference Cutting
on High (HPC
Performance
©2018).
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responsibility byof Elsevier
the B.V.
International Scientific Committee of the 8th CIRP Conference on High Performance Cutting (HPC
Cutting (HPC
Peer-review 2018).
under responsibility of the scientific committee of the 28th CIRP Design Conference 2018.
2018).
Keywords: Stiffness optimisation, functional redundancy, machining robot.
Keywords:Assembly;
Keywords: Design method;
Stiffness optimisation, Familyredundancy,
functional identification
machining robot.

1. Introduction Cartesian stiffness properties. These disadvantages deteriorate

1. Introduction
1. Introduction of thequality
Cartesian
the product andrange
stiffness and characteristics
properties.
dimensional These
accuracy manufactured
disadvantages and/or
of the enddeteriorate
product.
Serial arm type industrial manipulators are able to adapt to assembled
the quality and
Furthermore, in this system.
the dimensional In
dynamic nature this context,
accuracy the main challenge
of the forces
of the cutting end product. in
results
Due
various to the
Serialoperations
arm type and fast development
industrial
reach manipulators in
large workspace the domain
are volumes.
able to adapt of
Theseto modelling
Furthermore,
in and analysis
the dynamic
excessive vibration, is
causingnow
naturenot only to
of theissues
further cope
cutting
with with
forces single
results
the product
communication
various operations
are excellent andand anreach
ongoing
characteristics large
when trend
workspaceof digitization
coping volumes.
with and
the These
latest products,
in excessive
quality. a limited product
vibration,
Therefore the causing range
proper or existing
further issuesproduct
development with thefamilies,
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of manipulator
digitalization,
are excellent manufacturing
requirements characteristics
of enterprises
when coping
extreme responsiveness areand
facing
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the latest
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quality.
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andable to the
stiffnessanalyzeproper
models and and
to compare
development products
consequently, to define
of manipulator
application
challenges
requirements
production lines in today’s
of [1].
extreme market environments:
For thisresponsiveness
reason, using serial a continuing
and flexibility
manipulators in new product
kinematic
of families. It
and stiffness models
error compensation can be observed
techniques that
and consequently, classical
becomes necessary existing
applicationfor
tendency
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for towards
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[1]. For thishas product
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the potential times
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10.1016/j.procir.2018.08.222
 Huseyin Celikag et al. / Procedia CIRP 77 (2018) 566–569 567
2 Huseyin Celikag/ Procedia CIRP 00 (2018) 000–000

There has been some previous work on stiffness
optimization, taking advantage of the redundancy of the
manipulator. For example, the Cartesian stiffness control of a
redundant manipulator was studied by utilizing Stiffness
Feasibility Ellipsoids and reconfiguring the manipulator to
acquire desired Cartesian stiffness for an external force [2].
For a robotic drilling application, posture optimization was
conducted by taking advantage of redundancy around tool axis
and optimizing stiffness by implementing Jacobian based
reconfiguration [3]. The redundancy around tool axis was also
used for stability prediction and optimization in robotic
milling [4,5] and singularity avoidance [6] as well. However,
along with stiffness optimization, application of combination
of deflection compensation and stability prediction are
necessary for meeting better accuracy requirements which
hasn’t been addressed yet.
In this paper, the Cartesian compliance parameter of an
industrial serial arm machining robot was aimed to be
optimized by utilizing functional redundancy around the tool
axis in a 5-Dof milling operation with analytical inverse
kinematics for error compensation and machining stability
enhancement purposes.
Nomenclature
T 4 × 4 Homogeneous transformation matrix
 Link twist (°)
a Link length (m)
d Link offset (m)
n Number of joints/ degrees of freedom in joint space
q Actuating joint variable (°)
 Ac Virtual joint variable (°)
inverse kinematics computation. The nominal DH parameters
of the robot can be obtained from the manufacturer, but these
parameters do not accurately represent the position and
orientation of the end effector due to dimensional
inaccuracies, tolerances and assembly processes [8]. For this
reason, kinematic calibration is crucial to obtain accurate
representation of the pose of the end effector of the modelled
manipulator. In pursuit of acquiring better representation of
the robot kinematics, within the entire DH parameter table,
only the link length and link offset can be optimized from a
pragmatic perspective. This is because the analytical inverse
kinematic solution of industrial manipulators becomes
impossible if the assumption of a mechanical arm and
spherical wrist combination is broken which hinders the
decoupling of orientation and position to reach a pose.
Consequently the present study used the Self-Adaptive
Differential Algorithm (SADE) [9] to identify the true DH
parameters from experimental data. The link length and link
offset parameters were optimized by minimizing the
normalized error between different measurements (each
obtained with a laser tracker) and modelled poses. The
optimized DH parameters are shown in Table 1. As it can be
seen from the table, the optimized parameters can have up to
22mm difference compared to their nominal values.
Table 1: Optimized DH Parameters of ABB IRB6640. Nominal values are
shown in parenthesis.
Link Link Twist Link Length Link Offset Joint Angle
i  i (°) ai (m) di (m) i (°)
1 (-90) 0.324, (0.320) 0.768, (0.780) ( 1 )
2 (0) 1.284, (1.280) (0) (  2 - 90)

 
Aggregated joint variable (°),  q  
i i
Ac
3
4
(-90)
(-90)
0.178, (0.200)
(0)
(0)
1.145, (1.142)
( 3 )
(  4 +180)
X ,Y , Z Global base frame 5 (90) (0) (0) ( 5 )
x, y, z Cartesian coordinates (m) 0.199, (0.200)
6 (0) (0) ( 6 )
r , r , r Rotation around X, Y and Z axes (rad)
2.2. Manipulator Stiffness/ Compliance Model

Based on the Virtual Joint Method (VJM) with enhanced

stiffness modelling [10], links are assumed to be rigid and the
control loop stiffness of actuated joints were modelled as
Z virtual springs. The pose of the tool with respect to the base
can be presented as derived in [11] but omitting link
flexibility as;
 n i 
Tool
TBase  TBase    i

TJo int qi   Ac i
 TLink   TTool (1)
 i 1 
Y X
where  represents the overall joint variable after application
of external loading. The geometric model defining pose of the
Figure 1: Photo of ABB IRB6640 tool with respect to base frame can be represented as:
2. Manipulator Kinematic and Compliance Model t  f  q, Ac  (2)

2.1. Kinematic Model Calibration

The industrial machining robot, ABB IRB6640, is a 6-axis
serial arm type manipulator (Figure 1). The Denavit
Hartenberg (DH) [7] convention was used to parameterize the
robot into a kinematic model in order to enable forward and

where the vector t  x, y, z, r , r , r  represents the end
effector position and orientation. In the frame of these
notations, let us first define the linear transformation which
maps joint speeds to Cartesian speeds of the manipulator. This
is called the Jacobian, J , and can be represented as;
t J   (3)
568 Huseyin Celikag et al. / Procedia CIRP 77 (2018) 566–569
Huseyin Celikag/ Procedia CIRP 00 (2018) 000–000
The relationship between Cartesian, joint and complementary
stiffness matrix of the manipulator, K c , K and K f , can be
represented as in [10];
 
Kc JT K  K f J1  (4)
Current work is still performing the joint stiffness parameter
identification for the ABB IRB6640 robot, based on the
combination of methodologies developed by [8,12]. For this
reason, the present study relies on the results obtained for
ABB IRB6660, using model parameters as defined in [13].
3. Cartesian Compliance Parameter Optimization
A manipulator becomes redundant when it is able to reach
more degrees of freedom than that of needed for a realized
task to be executed. This makes the manipulator able to reach
a particular pose with a theoretically infinite number of
configurations. Considering a robotic 5-axis (5-DoF) milling
operation, there are 5-DoFs in operational space compared to
6-DoFs in task space of the robot. This results in functional
redundancy [4]. The redundancy is the rotational DoF around
tool axis which makes no effect on the execution of the task
no matter its value. This is the foundation of Cartesian
Compliance parameter optimization.
For the sake of simplicity in the manipulator compliance
model, the external forces due to cutting process are ignored
for the time being, (i.e. K f  0 ), and posture dependent
manipulator compliance is considered. As a result, (4) can be
represented as conventional stiffness formulation or in terms
of Cartesian and joint compliance parameters, Cc and C ;
T
Cc  J C J (5)
Since manipulator deflection under a force lower than its
payload is linearly related, the Cartesian compliance matrix
can be used to analyze the effect of each force on the
deflection of the manipulator at each DoF by expanding the
Hooke’s Law in terms of compliance parameters. The first
equation describing deflection in X-axis becomes;
x cxx Fx  cxy Fy   cx F  cx F (6)
In order to define the optimization problem, the plane and
the Cartesian coordinates of the 5-DoF poses of a trajectory
need to be defined as in (2). As the redundancy is the
rotational DoF around the tool axis, the rotation around the
local Z-axis is defined as a variable and the other degrees of
freedom are accepted as constant for a 5-DoF pose. Recalling
the fact that 0  r  2 , the rotation around tool axis, r ,
can be discretized between its lower and upper limits into
evenly spaced vector by defining a resolution as r as;
T
r  1r , 2r ,3r , , N r  (7)
where N represents number of increments and therefore,
number of 6-DoF poses created from a single 5-DoF pose. For
every 6-DoF pose for the same 5-DoF pose, joint angles are
computed with analytical inverse kinematics and the Jacobian
matrix is computed based on (3). To eliminate the
configurations close to or at singularity, the condition number
of Jacobian at each configuration was computed based on
Frobenius norm. The product of Frobenius (Euclidean) norm
of the Jacobian and its inverse was used to obtain the
3
condition number. This quantifies the sensitivity of the
Jacobian with respect to joint variables, indicating the
manipulability and the distance of the manipulator from a
singularity. The configurations away from singularities were
selected and the Cartesian compliance matrices of the
manipulator were computed based on (5). The elements
within the Cartesian compliance matrix play an important role
on the deflection of the robot and hence the redundant degree
of freedom can be used to select the robot’s configuration that
will result in an optimum stiffness or compliance.
It should be noted that a similar formulation can be
developed whereby the Cartesian stiffness matrix is
considered instead of the Cartesian compliance matrix. Whilst
this might have advantages in terms of its practical
significance, the compliance matrix can be more easily related
to the deflection of the tool in each degree of freedom for an
input of a force in a particular direction.
4. Methodology and Preliminary Results
Initially, we investigate the manipulator stiffness along the
X-axis, assuming an applied force in the X direction only. The
2D surface of the machining table at 0.5m height was
discretized into evenly spaced (1cm) points in the X & Y-axes
(Figure 2), with tool alignment perpendicular to the surface.
The redundant DoF around the tool axis, (r ) , was discretized
with a resolution of 0.01rad and the cxx parameter was
optimized over the machining table.
4.1. Maximized Compliance Parameter, cxx
The manipulator configurations acquiring maximum
possible cxx values were obtained and the value of cxx over the
machining table was plotted as shown in Figure 2a.
a) b)
Figure 2: (a) Maximised (b) Minimised cxx parameter over machining table
It was observed that as the manipulator moves along the
positive X-axis, the maximum possible cxx parameter tends to
decrease. This means that the stiffness of the manipulator
along the X-axis (when subject to a hypothetical force in X
direction) tends to increase. This is due to inevitable
alignment of joints along the X-axis. As the tool center point
(TCP) deviates from the X-axis, the cxx parameter tends to
increase, making the manipulator more compliant to a force in
X direction due to development of larger torques at joints.
 Huseyin Celikag et al. / Procedia CIRP 77 (2018) 566–569
4 Huseyin Celikag/ Procedia CIRP 00 (2018) 000–000
4.2. Minimized Compliance Parameter, cxx
Similarly, the manipulator configurations acquiring
minimum possible cxx were obtained and value of cxx over the
machining table was plotted in Figure 2b. In this case, a
similar trend to maximized cxx parameter was observed except
the region close to the manipulator base. In this region, the
manipulator configures itself to lower the torque at joints 3
and 5, resulting in the manipulator being stiffer in the
direction of the force.
4.3. Ratio of Maximized to Minimized Compliance Parameter,
cxx
In order to estimate the improvability of the stiffness of the
manipulator along the X-axis to a force applied parallel to X-
axis, the ratio of maximized to minimized cxx parameter over
the machining table was taken as shown in Figure 3.
Figure 3: Ratio of maximised to minimised cxx parameter
It was observed that manipulator cxx parameter can be
optimized to a maximum of 161% compared to its minimum
value around the region close to its base. The parameter can
change by a minimum of 58% at (1.2, 0, 0.5)m coordinates in
Figure 3 which indicates the lowest stiffness improvability
over the table.
5. Conclusion
In conclusion, the manipulator stiffness along X-axis for a
force applied in X-direction can be improved by optimizing
Cartesian compliance parameter, cxx . For the scenarios
considered it has been shown that the compliance can vary by
between 58% and 161% simply by utilizing the redundant
degree of freedom of the robot. In this way, stiffness
improvements can be made in order to acquire better accuracy
in robotic machining operations. However, further work is
needed to consider the true forces that arise during milling, to
see how the performance can be illustrated using the stiffness
and compliance matrix approach, and to combine this with a
stability estimation for chatter avoidance.
6. Acknowledgements
The authors acknowledge funding provided by EPSRC for
Industrial Doctorate Centre in Machining Science
569
(EP/L016257/1) and the European Commission under the
Horizon 2020 COROMA project (723853).
References
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modular compensation," Springer, April 2014.
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Role of Robot Configuration in Cartesian Stiffness
Control," in IEEE International Conference on Robotics
and Automation (ICRA), Seattle, Washington, May 2015.
[3] Y. Guo, H. Dong, and Y. Ke, "Stiffness-oriented posture
optimization in robotic machining applications,"
Elsevier, Robotics and Computer-Integrated
Manufacturing, vol. 35, pp. 69-76, February 2015.
[4] S. Mousavi, V. Gagnol, B. C. Bouzgarro, and P. Ray,
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