ISSN 2658–5782

DOI 10.21662/mfs

☰
2025. Vol. 20. Issue 4, Pp. 208–216
URL: https://multiphasesystems.online/mfs2025.4.027,en
DOI: https://doi.org/10.21662/mfs2025.4.027
Integration of the smart drive into the drive unit of an atypical manipulator and its calibration
A.V. Ivachev1, O.V. Darintsev1 🖂, D.R. Bogdanov2
1Ufa University of Science and Technology, Ufa, Russia
2Ufa State Petroleum Technological University, Ufa, Russia

Abstract

Unlike traditional manipulators, one of the main problems of continuous manipulator control is the control of the shape of the links of the continuous manipulator, as it determines its operating point. This article presents the technological stage of the development of a draft design of a smart drive for atypical manipulators, designed to solve this problem. The control object is a continuous manipulator consisting of links based on rigid elements with a spherical surface, the rolling of which relative to each other determines the shape of the links. The elements are set in motion by means of cables passing through them, the length of which is changed by means of drives. In the previous article, the design stage of the work was described, which includes solving three tasks: designing an intake module based on a stepper motor with a cable tension and displacement sensor; developing an information system architecture; designing the internal structure of a programmable logic integrated circuit. At the current (technological) stage, presented in this article, the following tasks are being solved: creation of an experimental test bench for characterization of sensors; development of specialized software for characterization of sensors. The application software is implemented in the form of two interconnected modules — low-level and high- level. Low-level software is implemented in the field programmable gate array, it provides drive control, performs synchronous polling of sensors, interrupt processing, data filtering and execution of commands from a top-level computer. The windowed application for a top-level computer provides two modes of operation: manual and automatic control, intuitive user interface, and data visualization.The operability of the structure was confirmed by tests, the analysis of the data obtained confirmed the high accuracy of measurements and the linearity of the power characteristics of the tension sensor in the full operating range.

Citation

Ivachev AV, Darintsev OV, Bogdanov DR. Integration of the smart drive into the drive unit of an atypical manipulator and its calibration. Multiphase Systems. 2025;20(4):208–216 (in Russian).

Keywords

smart drive;
atypical manipulators;
cable tension and displacement sensor;
FPGAs;
stepper motors;
sensor calibration

Article outline

The development of atypical manipulators (continuous manipulators) also requires, due to the specifics of the design, special approaches to the synthesis of drives and the structure of it’s information system. Previously, the authors showed the original architecture of an adaptive and multiconnected control system based on the use of a smart drive with distributed data processing implemented through the use of FPGAs. This article shows the technology for implementing a drive that supports the smart drive paradigm at the hardware and software level. The proposed design implements feedback on the forces generated and the movement of the cable due to the organization of internal feedback loops, which significantly reduces the load on the multi-link manipulator control system and allows for coordinated control of four drives of one link.

Methods. To assemble the proposed smart drive, it is necessary to develop the correct manufacturing technology for individual components and synthesize a controlled assembly technique for both individual components and the entire complex, consisting of a stepper motor with a complete gearbox, a tension and cable displacement sensor, a driver, an ADC and a controller. The correctness of the synthesis of 3D models of the drive's structural elements is achieved through a competent selection of printing materials and the equipment on which it will be performed. The reliability and operability of the developed parts is confirmed by the results of a static analysis of the structure, with the identification of highly loaded nodes and stress concentration points. To process the data obtained, the main provisions of the theory of experimental planning and digital information processing were used.

Results. At the second (technological) stage, an experimental stand was made based on the previously presented draft design of a smart drive, which was used to conduct a series of experiments that confirmed the achievement of the planned functional and operational characteristics. Special attention was paid to the operation of the smart drive in real time when moving cables with current tension control, since the main task was to survey a large number of heterogeneous sensors in synchronous mode simultaneously with the preliminary processing of the received data. The implementation of the FPGA-based control system architecture has been verified, and a preliminary assessment has been made of the possibility of synthesizing a control system based on a single controller for all four actuators (smart drives) for a single manipulator link.

Conclusions. The results show that the proposed design of the smart drive makes it easy to scale the resulting solution by integrating feedback channels in the execution module. The prototype of the smart drive, the performance of which has been confirmed using a specialized experimental bench, is equipped with specialized software implemented on the basis of FPGAs, which makes it easy to modify the resulting code or structures for use in subsequent work, in the synthesis of adaptive or intelligent control systems for atypical manipulators.

References

  1. Webster RJ, Jones BA.Design and Kinematic Modeling of Constant Curvature Continuum Robots: A Review. The International Journal of Robotics Research. 2010;29(13):1661–1683.
    https://doi.org/10.1177/0278364910368147
  2. Сeccarelli M. Fundamentals of Mechanics of Robotic Manipulation (Mechanisms and Machine Science Book 112. Springer; 2022. 636 p.
  3. Yang J, Peng H, Zhou W, Zhang J, Wu Z. A modular approach for dynamic modeling of multisegment continuum robots. Mechanism and Machine Theory. 2021;165:104429.
    https://doi.org/10.1016/j.mechmachtheory.2021.104429
  4. Богданов ДР, Даринцев ОВ. Кинематика манипулятора с управляемым изгибом на базе твердых элементов со сферической поверхностью. Мехатроника, автоматизация, управление. 2015;16(10):671–678. https://doi.org/10.17587/mau.16.671-678
    Bogdanov DR, Darintsev OV. Kinematics of a Manipulator with a Controlled Bending on the Basis of Solid Elements with a Spherical Surface. Mekhatronika, Avtomatizatsiya, Upravlenie. 2015;16(10):671–678. (in Russian)
  5. Богданов ДP, Даpинцев ОВ. Конструктивные особенности манипуляторов с управляемым изгибом. Современные проблемы науки и образования. 2013;6:210. https://elibrary.ru/RVCQVR
    Bogdanov DR, Darintsev OV. Design features of manipulators with the controlled bend. Modern problems of science and education. 2013;6:210. (in Russian)
  6. Yang J, Pe\ na-Pitarch E, Potratz J, Beck S, Abdel-Malek K. Synthesis and analysis of a flexible elephant trunk robot. Advanced Robotics. 2006;20(6):631–659. https://doi.org/10.1163/156855306777361631
  7. Coulson R, Robinson M, Kirkpatrick M, Berg DR. Design and Preliminary Testing of a Continuum Assistive Robotic Manipulator. Robotics. 2019;8(4):84. https://doi.org/10.3390/robotics8040084
  8. Ивачев АВ, Даринцев ОВ, Богданов ДР. Специфика конструкторской проработки прототипа смарт-привода для нетипичных манипуляторов. Многофазные системы. 2025;20(3):153–164.
    https://doi.org/10.21662/mfs2025.3.020
    Ivachev AV, Darintsev OV, Bogdanov DR. Design development of a Smart Drive for Atypical Manipulators. Multiphase Systems. 2025;20(3):153–164 (in Russian).
  9. Насибуллаев ИШ, Даринцев ОВ. Разработка компьютерной модели подвижного элемента манипулятора. Вестник Башкирского университета. 2024;29(1):12–18. https://doi.org/10.33184/bulletin-bsu-2024.1.3
    Nasibullayev ISh, Darintsev OV. Development of a computer model of the moving element of the manipulator. Vestnik Bashkirskogo Universiteta. 2024;29(1):12–18. (in Russian)
  10. Насибуллаев ИШ, Даринцев ОВ. Моделирование качения подвижного элемента манипулятора в решателе Calculix. XVI Всероссийская мультиконференция по проблемам управления (МКПУ-2023): Материалы мультиконференции. В 4-х томах. Том 1. Волгоград: ВолГТУ; 2023. С. 86–89. https://elibrary.ru/QNYGOY
    Nasibullayev ISh, Darintsev OV. Modeling the Rolling Motion of a Manipulator's Movable Element in the Calculix Solver. XVI All-Russian Multi-Conference on Control Problems (MCCP-2023): Proceedings of the Multi-Conference. In 4 volumes. Volume 1. Volgograd: VolGTU; 2023. P. 86–89. (in Russian)
  11. Богданов ДР, Даринцев ОВ. Динамика (кинематика) звена манипулятора с управляемым изгибом. XII Всероссийский съезд по фундаментальным проблемам теоретической и прикладной механики: Сборник трудов. В 4-х томах. Том 1. Уфа: Башкирский государственный университет; 2019. С. 528–530. https://elibrary.ru/HIHAUL
    Bogdanov DR, Darintsev OV. Dynamics (kinematics) of a manipulator link with controlled bending. XII All-Russian Congress on Fundamental Problems of Theoretical and Applied Mechanics: Collection of Papers. In 4 volumes. Volume 1. Ufa: Bashkir State University; 2019. Pp. 528–530. (in Russian)
  12. AMS. Ams AS5048A High-Resolution Position Sensor. [online] https://look.ams-osram.com/m/287d7ad97d1ca22e/original/AS5048-DS000298.pdf (Accessed 22.09.2025).
  13. Intel. Intel\textregistered\, MAX\textregistered\, 10 FPGA Device Datasheet. [online] https://cdrdv2-public.intel.com/666319/m10_datasheet-683794-666319.pdf (Accessed 22.09.2025).
  14. Sensor Tension Testing 8mm External Diameter 3kg 5kg 10kg 20kg 50kg 100kg (3kg Range). [online] https://www.amazon.com/DYHW-108-Compression-Tension-External-Diameter/dp/B0C1NF3NVM?th=1 (Accessed 22.09.2025).
  15. Богданов ДР, УФИЦ РАН. Программа для моделирования и синтеза специализированного цифрового компонента ПЛИС опроса датчика магнитного энкодера AS5048A, версия 2. Свидетельство о государственной регистрации программы для ЭВМ № 2024617721. 2024. https://elibrary.ru/BSJRWM
    Bogdanov DR, UFRC RAS. Program for modeling and synthesizinga specialized digital FPGA component for polling the AS5048A magnetic encoder sensor, version 2. Certificate of state registration of the computer program No. 2024617721. 2024. (in Russian)
  16. Айвазян СА, Енюков ИС, Мешалкин ЛД. Прикладная статистика: Основы моделирования и первичная обработка данных. М.: Финансы и статистика; 2012. 323 с.
    Ayvazyan SA, Enyukov IS, Meshalkin LD. Applied statistics: Fundamentals of modeling and primary data processing. Moscow: Finance and statistics; 2012. 323 p.
  17. Буянкин ВМ. Интегральный пропорциональный дифференциальный нейрорегулятор. Вестник МГТУ им. Н.Э. Баумана. Серия «Естественные науки». 2006;(3(22)):56–61. https://elibrary.ru/HVHCTD
    Buyankin VM. Integral, Proportional, Differential Neuroregulator. Herald of the Bauman Moscow State Technical University. Series Natural Sciences. 2006;(3(22)):56–61. (in Russian)
  18. Буянкин ВМ. Синтез нейрорегуляторов для сложных технологических установок с применением бинарных нечетких отношений. Исследования наукограда. 2013;(1(3)):33–41. https://elibrary.ru/QAQWYL
    Bujankin VM. Synthesis neuralregulator for difficult technological installations with application of binary indistinct relations. The research of the science city. 2013;(1(3)):33–41. (in Russian)
  19. Кузнецов ЕА, Ульянов СВ. Разработка интеллектуальной системы управления многозвенным роботом манипулятором. Системный анализ в науке и образовании. 2022;(3):161–179.
    http://sanse.ru/download/477
    Kuznetsov EA, Ulyanov SV. Developing of intelligent control system for robotic manipulator with several freedom degrees. System analysis in science and education. 2022;(3):161–179. (in Russian)
  20. Гурский НН, Скудняков ЮА, Артющик ВС, Безручко АН. Управление мехатронной системой на базе многозвенных роботов-манипуляторов. Наука и Техника. 2019;18(4):350–354.
    https://doi.org/10.21122/2227-1031-2019-18-4-350-354
    Hurski NN, Skudnyakov YuA, Artsiushchyk VS, Bezruchko AN. Control of Mechatronic System Based on Multilink Robot-Manipulators. Science \& Technique. 2019;18(4):350–354. (in Russian)