Rigid and Flexible Structures Coupled System Study and Enhanced Vision-Aided Control for a Versatile Cable Winding Robot

It is challenging to model and control rigid and flexible structures coupled systems (RFSCS). This article presents an automated robot for drum-to-drum cable winding in industrial scenes. The cable winding process encounters unprecedented disturbances that induce tension vibrations and winding errors. We seek to stabilize cable tension with an underactuated serial manipulator, which forms an RFSCS with the cable and drum. The impedance control model further improves the tension response. The study explores the modeling, control, and stability analysis of the RFSCS. Additionally, the machine vision module is integrated to provide essential measurements and involve in coil forming control. The techniques of vision-encoder fusion and drum pose compensation improve the measurement accuracy. The vision-aided drum walking controller switches between two control modes for different winding states. The static tests in both simulation and experiment evaluated the merits of RFSCS against disturbances. The prototype can wind ordered coils from materials of varying sizes and stiffnesses. Our solution promotes the application of RFSCS and visual control systems in harsh industrial environments.