Development of the Humanoid Robot LOLA

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Applied Mechanics and Materials Vols. 5-6 (2006) pp 529-540 online at http://www.scientific.net (2006) Trans Tech Publications, Switzerland Online available since 2006/Oct/15 Development of the Humanoid Robot LOLA H. Ulbrich a, T. Buschmann b and S. Lohmeier c Institute of Applied Mechanics, Technical University Munich, 85747 Garching, Germany. a ulbrich@amm.mw.tum.de, b buschmann@amm.mw.tum.de, c lohmeier@amm.mw.tum.de Keywords: Humanoid robot, hardware design, control, simulation Abstract. This paper presents the performance enhanced humanoid robot LOLA which is currently being manufactured. Hardware design, controllers and simulation are based on experience gained during the development of the robot JOHNNIE. The objective of the current research project is to realize a fast, human-like and autonomous walking motion. To enable an optimal design of the robot with respect to lightweight construction, motor and drive sizing, an appropriate simulation model is required. Dynamics simulation is a key tool to develop the hardware and control design properly. For hardware design and detailed dynamic analysis a comprehensive model including motor and gear dynamics is required, while for controller design and stability analysis a simplified model for global system dynamics is sufficient. Both robots are characterized by a lightweight construction. In comparison to JOHNNIE, the new robot LOLA has a modular, multi-sensory joint design with brushless motors. Moreover, the previously purely central electronics architecture is replaced by a network of decentral joint controllers, sensor data acquisition and filtering units and a central PC. The fusion of motor, gear and sensors into a highly integrated mechatronic joint module has several advantages for the whole system, including high power density, good dynamic performance and reliability. Additional degrees of freedom are introduced in elbow, waist and toes. Linear actuators are used for the knee joints to achieve a better mass distribution in the legs. Introduction Significant advances in actuator and computer technology during the past years made the realization of sophisticated humanoid robots possible [1 6]. Bipedal walking is considered to be one of the core technologies for a humanoid robot. Almost every biped robot is able to achieve reliable dynamic walking, but compared with human beings, fast walking is still a challenge for most of them. Recently, ASIMO was reported to run as fast as 6km/h [7], but almost no details on the controller and hardware design have been published yet. However, ASIMO is the proof that the concept of a fully actuated biped with a stiff structure is capabale of fast locomotion. Other recent developments look very promising, too. The top speed of HRP-2 is 2.5km/h [4] and there are attempts to realize a running motion with both feet lifting off the ground [8]. Our robot JOHNNIE (Fig. 1(a)) has reached a maximum of 2.4km/h [9]. Based on the experiences with JOHNNIE the humanoid robot LOLA with enhanced performance is developed. The goal of our project is to realize a fast, human-like walking motion, i. e. a significant increase in walking speed, more flexible gait patterns and increased autonomy. Besides the challenging control problems inherent in fast walking, research effort is also required for the robot hardware. Obviously, the robot must be able to provide the required velocities at a high dynamic response. Then there is the important issue of choosing the best All rights reserved. No part of contents of this paper may be reproduced or transmitted in any form or by any means without the written permission of the publisher: Trans Tech Publications Ltd, Switzerland, www.ttp.net. (ID: 130.203.133.33-14/04/08,13:29:10)

530 Modern Practice in Stress and Vibration Analysis VI z yaw roll x y pitch (a) Biped robot JOHNNIE (b) CAD model and joint structure of the robot LOLA. The newly introduced DoF are marked in red. Fig. 1: Biped robots developed at the Institute of Applied Mechanics kinematic configuration. And, generally speaking, the weight of the robot has to be kept at a minimum which must be balanced with the requirements for powerful actuators and high structural stiffness. The paper is organized as follows. First, the kinematic structure of the robot is presented, emphasizing the new degrees of freedom. The following section gives a short overview of the dimensioning of the robot hardware including motor and gear selection. Next, the modular joint concept is introduced, followed by a brief overview of the simulation tool developed for the robot s hardware and controller design. Finally, the electronics concept using decentralized joint controllers is presented. Kinematic Structure of the Robot Our special interest is the realization of a fast, human-like walking motion. Therefore the kinematic configuration of the robot is mainly determined by the characteristics of human walking. The robot has 22 actuated degrees of freedom (DoF): 14 DoF (7 each) for the legs, 2 DoF for the torso and 6 (3 each) for the arms. Its physical dimensions are based on anthropometric data and correspond with an 180cm tall adult. The kinematic structure and the CAD model of the robot are shown in Fig. 1(b). Five new joints are introduced in addition to the 17 DoF of JOHNNIE elbow joints, a 2-DoF waist joint and toe joints. The axes of the 3-DoF hip joint intersect at one point which allows us to keep the anthropometric proportions of the robot including the height of the torso. For the knee joint, a linear actuator based on a ballscrew drive is proposed. The torque-speed characteristic of this actuator corresponds to the human knee, and despite its high performance the inertia of the shank remains acceptable. Elbow joint Especially at higher walking speeds a reciprocal arm swing is of great importance to reduce the yaw moment between foot and ground [10]. Arm motion is used only to avoid

Applied Mechanics and Materials Vols. 5-6 531 (a) Hip joint with intersecting axes (b) Knee joint with linear actuator Fig. 2: Hip joint and knee joint slipping, so full arms with hands are not needed but the arms are equipped with additional masses at their ends. However, introducing elbow joints is advantageous for fast walking, since they permit translational arm swing. This is more effective than a purely rotational motion. In addition, the moment of inertia of the arms is adjustable using the elbow and shoulder (roll axis) joints. 2-DoF waist Joint A 2-DoF waist allows torso and waist to roll and yaw independently which allows to increase step length and provides more mobility for lateral motions. The roll axis facilitates walking with a straight stance leg at nearly constant height of the center of gravity [10]. The yaw axis can further be used to compensate for the yaw moment between foot and ground. WABIAN-2 LL has a similar waist joint configuration [5]. Hip joint The 3-DoF hip joint is of particular interest since it connects leg and pelvis and its overall stiffness considerably influences the walking performance. The hip joint shown in Fig. 2(a) is actuated by three serial drives composing a spherical joint with axes intersecting at one point. Its compact design allows for keeping anthropometric proportions throughout the robot including the height of the torso. For better power distribution among the three hip drives, the yaw axis is inclined 15 to the vertical axis [11]. Knee joint with linear actuator Torques and velocities of knee and hip pitch axis are comparable, so that the intention of a modular design originally implied the use of identical drives. However, using the hip joint module for the knee is problematic because its mass would unacceptably increase the thigh moment of inertia. In turn a large part of the enhanced hip joint output would be spent on accelerating a heavier knee. Because of positive experience with ballscrews in the ankle joints of JOHNNIE [12] we went for the same actuation principle for the knees. The muscle-like mechanism is shown schematically on the left of Fig. 3, the actual mechanical configuration is depicted in Fig. 2(b). Thus, a better mass distribution in the hip-thigh area is achieved and LOLA s thigh s moment of inertia is only marginally higher than JOHNNIE s. Thus, the driving power of the knee could be enhanced without decreasing the hip joint s performance. The mechanism has nonlinear transfer behavior which is advantageous for typical gait patterns since the torque markedly depends on the link position and has its maximum at around 50. Fig. 3 shows the torque

532 Modern Practice in Stress and Vibration Analysis VI requirements in the knee for a walking speed of 5 km/h compared to the torque capacity of the drive and the velocity dependent capacity of the human knee. The trajectories were calculated with a method based on nonlinear parameter optimization [13]. The biped robot BIP 2000 [14] employs linear actuators in the knees, however, the kinematics are different from the proposed mechanism: A satellite roller screw is fixed to the shank, and connected to the knee with a steering rod. An additional linear bearing is required to keep the satellite roller screw free from radial loads. 7-DoF legs with toe joints Nearly all humanoid robots are designed with 6-DoF legs 3 DoF in the hip, one in the knee and two in the ankle. Each foot consists of one rigid body, therefore heel lift-off during terminal stance phase can hardly be realized. Even small disturbances lead to instabilities due to the line contact of the foot s leading edge with the floor. In human walking heel lift-off of the stance leg occurs during terminal swing, i. e. shortly before the swing leg has floor contact [10]. Biped robots with one-piece foot segments cannot perform forward roll across the forefoot. Especially for larger step lengths, this leads to an extended knee configuration at initial contact of the swing leg, resulting in large joint accelerations. Therefore an additional link between forefoot and heel equivalent to the human toes is proposed. Heel lift-off in the stance leg allows the swing leg to be in a more extended configuration. Area contact of the toe segment stabilizes the robot and facilitates forward roll across the forefoot which is expected to reduce the joint loads in hip and knee compared to a 6-DoF leg configuration. To our knowledge the only humanoids with actively driven toe joints are H6 and H7 [15], and there are only few robots with passive toe joints. Design of Robot Hardware Dimensioning of the robot hardware is an iterative process of mechanical design and extensive multibody simulations [16]. Kinematics, geometrical data and gear transmission ratios, together with body masses and inertia obtained from the 3D-CAD model of the robot serve as input parameters for the dynamic simulation of the system. The simulation itself is based on a comprehensive model of the robot taking into account rotor dynamics and nonlinear friction of Harmonic Drive gears. Special emphasis was devoted to model the contact situation between foot and ground, realized with spring-damper elements. Stiffness and damping characteristics were adjusted by experiments with the robot JOHNNIE, so that the computed results can be Hip Cardan joint Thigh Actuator Knee Shank Cardan joint Fig. 3: Left: Mechanism employed for the the knee joint. Right: Torque and speed requirements of knee joint, human torque capacity from [10]

Applied Mechanics and Materials Vols. 5-6 533 expected to be close to reality [17]. The most important parameters obtained from the simulation are the joint torques and velocities used for motor and gear selection, and the constraint forces of the links to be used for Finite Element simulations. Selection of the actuators is a demanding task because they must be able to move at high velocity while good dynamic performance is required to accelerate the links. On the other hand, for minimal weight of the robot it is essential not to oversize the drives while at the same time appropriate power reserves should be kept. Three major demands on the actuators are (1) high dynamic response, (2) high output axis speed and (3) high output axis torque over a large speed Fig. 4: Torque and speed requirements of the hip joint range. To achieve good dynamic behavior, minimizing rotor inertia will pitch axis and torque speed diagram of the motor theoretically maximize acceleration capabilities and increase the system bandwidth. An important parameter for motor sizing is the load to motor inertia ratio k = J L N 1, 2 J M which can be derived from the gear reduction ratio N at given load inertia J L and motor inertia J M. Maximum power transfer will occur at k = 1 which yields the best dynamic response and minimum motor acceleration torque [18]. In general, k = 1...3 is acceptable for highly dynamic drives. Fig. 4 exemplifies motor and gear selection for the hip joint pitch axis on basis of a stable gait pattern at a walking speed of 5km/h [13]. From the right hand plot it can be seen that the torque demands for gear ratios of N = 80 and N = 50 are similar. However, higher motor speed at N = 80 means that the motor torque is mainly spent on accelerating the motor shaft. For N = 50 a motor with less power (and weight) can be chosen, which is shown by the shaded areas representing the motor characteristic for continuous and intermittent operation. Thus, drive efficiency, denoted by the ratio of load moment and motor shaft acceleration torque, can be increased because the torque and speed bandwidths of the employed motors permit smaller gear ratios. Modular Joint Concept Obviously, a modular structure of the whole robot would be desirable from the manufacturing and maintenance point of view. However, a fully modular structure would lead higher weight and suboptimal mass distribution. The detailed analysis in [11] reveals that structural components contribute 43% to a humanoid robot s weight. With approximately 31% the drive chains make the second largest part 22.7% account for the motors and another 7.9% for the gears, making the development of compact and lightweight joint units a crucial factor. (1)

534 Modern Practice in Stress and Vibration Analysis VI The main structure of the robot is non-modular with joints that are built on the unit construction principle. They have identical structure with the sizes of gear and motor adapted to the requirements of each link. Many parts are standardized for all drives, but some housings are specialized to minimize weight and to achieve an optimal load spread and distribution. This turned out to be the most reasonable way to realize the robot at minimal weight while taking into account ease of manufacturing. There are only 7 different drives for the 22 actuated DoF. The main characteristics of the drives are listed in [21]. To realize such highly integrated joint units with maximum power density it is necessary to use the latest technologies in the field of electrical drives, gears and sensors. We are using high performance brushless motors from Parker Bayside because of their superior torque and speed capabilities. The motors come as frameless motors, which allows for an integrated design optimized for small space and low weight. Linear drives based on ballscrews are used in knee and ankle joint, all other joints employ Harmonic Drive gears as speed reducers. Each drive unit contains an incremental rotary encoder, an absolute angular encoder as link position sensor and a light barrier as limit switch. The fusion of motor, gear and sensors into a highly integrated, mechatronic joint module has several advantages for the whole system: High velocity range at good dynamic performance, high power density, i.e. high efficiency, comparatively small volume of the whole drive unit, reliability due to brushless design of the motors and the capability of self-monitoring and diagnosis. The robot SDR-4X has modular drive units, where gears, motor and electronics comprise intelligent servo actuators [3]. The units come in three different sizes and seem to be optimized for mass production. Brushless motors drive the joints presumably through a spur gearing, but unfortunately, only few details are published on the gear and the sensor systems. Motor technology Looking at current humanoid robot projects, the predominant actuation principle is a combination of Harmonic Drive gears and DC brush motors, mostly coupled with timing belts [2,4 6]. For ASIMO [7] and ETL-HUMANOID [19] both DC brush motors and DC brushless motors drive the joints through Harmonic Drive gears. JOHNNIE is actuated by DC brush motors and Harmonic Drive gears, except for the ankle joints that are driven by parallel mechanisms with ballscrews [12]. The robot BIP 2000 [14] is equipped with brushless motors and Harmonic Drive gears or satellite roller screws, respectively. A very interesting concept is realized in DLR s lightweight robot LWR-III, a torque-controlled 7-DoF robotic arm [20]. The joints are actuated with Harmonic Drive gears and very efficient motors called DLR RoboDrive. These sophisticated brushless motors with high pole count are optimized for the demands of robotic applications such as high torque capacity and minimal power consumption and losses at low and medium speeds. bil The main reasons for us to choose PMSM over DC brush motors are robustness, a significantly higher power density, and higher torque and speed bandwidths. Fig. 5 compares the performance data of commercially available DC brush motors and permanent magnet synchronous motors (PMSM). Obviously, PMSM are superior to DC brush motors in both specific peak and continuous torque. However, control algorithms and power electronics are more complex because of electronic commutation and three-phase design. PMSM permit larger stall

Applied Mechanics and Materials Vols. 5-6 535 Fig. 5: Comparing the power density of commercially available DC motors and PMSM torques for longer intervals than DC motors where mechanical commutation severely limits stall torque. This is especially important for slow motions or when the robot is standing, i.e. when the motors are in reversing operation around zero speed or joint positions are held for a certain time. A special type of PMSM are frameless motors which consist of a stator lamination stack with three-phase winding plus a rotor with permanent magnets bonded onto a ferrous tube. Motor shaft and bearing have to be custom-made which facilitates a space-saving integration directly into the joint. There is no need for couplings or timing belts, making the whole drive chain free from backlash and slip and, ultimately, increases stiffness and system bandwidth. For optimal heat transfer the joint housing has cooling fins and the stator is bonded into the housing with a thermally conductive adhesive. Additional forced ventilation is employed in the highly loaded knee and hip joints. The joint design is given in greater detail in [21]. Simulation Simulation System Design and sizing of the robot s mechanical and electronic components must be based on comprehensive simulation data. Similarly, development of the control and trajectory generation system and dynamics analysis require a simulation model capable of accurately predicting all physical phenomena of interest. To this end we implemented a modular simulation system that can be used to simulate various robot configurations during development. motor currents robot model (MBS) robot state power electronics (PWM) sensor models (noise, bandwidth etc.) virtual robot armature voltage trajectory generation and control sensor data control system Fig. 6: Schematic representation of the simulation system. Fig. 6 shows the logical structure of the simulation system. The modules shown in the top half of the diagram simulate the sensors, actuators, power electronics and dynamics, i.e. the robot hardware. The module trajectory generation and control implements the entire robot control. The simulation system and the real robot provide source-level compatible interfaces for sensor data acquisition and control commands. Thus the simulation environment provides the

536 Modern Practice in Stress and Vibration Analysis VI important facility of safely testing unmodified controller code in a virtual environment prior to conducting experiments. LOLA s and JOHNNIE s links are made of aluminum and designed for high stiffness. Therefore, the robot is modeled as a rigid multibody system (MBS). The equations of motion (EOM) are calculated in minimal coordinates using the Newton-Euler formalism (e.g. [22, 23]) and written in the following form: M q + h(q, q) = Q mot + Q gear + Q cont (2) Lİ = RI k M ϕ + U (3) where q are the generalized coordinates, M the mass matrix and h the vector of Coriolis forces, centrifugal forces etc. Therefore, the left hand side of (2) takes into account all effects due to rigid body mechanics, including nonlinear ballscrew drive mechanisms etc., while the remaining generalized forces are given on the right hand side. Q mot are the forces due to motor torques, Q gear generalized gear friction forces and Q kont forces due to foot-ground contact. Eq. (3) describes the electrical dynamics of the robot s motors. In case of PMSM motors, the equations hold for the coordinate system fixed to the motor shaft. L denotes the inductance, R the armature resistance, k M the torque constant, I the motor currents and U the applied voltage. The modeling procedure is explained in more detail in [17]. normal force [N] 100 0 100 200 300 400 500 600 0 1 2 3 4 5 6 time [sec] experiment reduced simulation detailed simulation Fig. 7: Normal force acting on JOHNNIE s right foot during an experiment and simulation results. Experimental Verification In order to verify modeling assumptions, we performed some walking experiments with JOHNNIE and implemented a simulation model using the software framework described above. Fig. 7 shows the normal reaction force acting on one foot measured during the experiment and the corresponding results from a detailed and a simplified simulation model. The detailed simulation includes nonlinear friction models for the Harmonic Drive gears and ballscrews, effects due to the nonlinear ballscrew drive mechanisms and the motor s electrical dynamics. Using this model, all relevant effects can be simulated accurately. In order to reduce simulation times, a simplified model with shorter integration times was implemented. The simplified model does not include such effects as drive friction, but still predicts global system dynamics quite accurately as shown in Fig. 7. More detail on the two simulation models is given in [17]. Modular computer system With 22 actuators and several sensors not mentioned above (e. g. force/torque sensors, attitude sensor) the overall system is quite complex. In consequence of the modular joint design, a decentral electronics architecture would be preferable in order to decrease complexity, to simplify

Applied Mechanics and Materials Vols. 5-6 537 first-time operation and to make the system expandable for additional degrees of freedom or sensors. While fully decentral controller architectures have been implemented successfully for many multi-legged walking machines, they are not suitable for humanoid robots the highly coupled kinematics and dynamics demand a central controller instance. However, it is possible and reasonable to shift low-level control of link positions and velocities to local controllers. The field-orientated control algorithms for brushless motors are computationally more expensive than controllers for DC motors. In our robot the central system controller is unloaded from these standard tasks, and motor control is executed in parallel on the embedded controllers. The proposed modular electronics system makes custom hardware necessary for the embedded controllers because of the combination of interfaces, comprising communication bus, absolute angular encoder and other sensors. However, off-the-shelf components will be used for the central system controller. An industrial PC board supplemented by an interface board for the communication bus turns out to be the most efficient solution, as it provides enough computational power and can be upgraded easily. For a decentral architecture, bus systems for both power and communication replace the complex, bulky cabling of a central system where cables contribute 4.7% to the total weight [11]. The major requirements on the communication bus employed between central system controller and local controllers include Real-time capability and a high level of determinism, guaranteed bandwidth with minimal protocol overhead. Compared to an IEEE 1394-based solution, different implementations of real-time Ethernet and CAN, a SERCOS-based system turned out to be the best solution. SERCOS is a digital communication interface for communication of standardized closed-loop data in real-time. It provides an accurately timed, high speed serial interface (max. 100 MBaud) and is adopted as an international standard [24]. The SERCOS protocol defines both cyclic communication within deterministic time slices for real-time communications and a non-cyclic channel for nonreal-time data transfers such as status and diagnostic messages. The non-cyclic channel also facilitates parameterization of the drives, switching between different operating modes and gain scheduling. Conclusion and Outlook Despite recent advances walking machines are still slow compared to biological systems and have limited autonomy. The intention of the research presented is to diminish this gap. In comparison to JOHNNIE, the new robot LOLA features a modular, multisensory joint design with brushless motors. The electronics architecture is designed as an intelligent sensor-actuator network with a central controller. The new decentral components increase the system s performance from a technological point of view. Additional DoFs are introduced to allow for more flexible and natural motions. The trajectory generation and control system is currently being developed, aiming for faster, more flexible and more robust walking patterns. The control system features a gait pattern adaptation scheme inspired by that observed in human walking. Nevertheless, we are just at the beginning of taking advantage of biological findings and transferring some of the observed principles to technological systems. This transfer promises significant advantages for the sciences involved. At the same time it poses a great challenge and requires further interdisciplinary research by scientists from biology, medicine and engineering.

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