WO2021102506A1 - Control systems and controllers for remote control of one or more mechanisms - Google Patents

Control systems and controllers for remote control of one or more mechanisms Download PDF

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Publication number
WO2021102506A1
WO2021102506A1 PCT/AU2020/051267 AU2020051267W WO2021102506A1 WO 2021102506 A1 WO2021102506 A1 WO 2021102506A1 AU 2020051267 W AU2020051267 W AU 2020051267W WO 2021102506 A1 WO2021102506 A1 WO 2021102506A1
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WO
WIPO (PCT)
Prior art keywords
controller
members
control system
peripheral
module
Prior art date
Application number
PCT/AU2020/051267
Other languages
French (fr)
Inventor
Paul Michael Phillips
Mark Creighton Sproule SPROULE
Original Assignee
The Blueprint Laboratory Pty Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from AU2019904481A external-priority patent/AU2019904481A0/en
Application filed by The Blueprint Laboratory Pty Ltd filed Critical The Blueprint Laboratory Pty Ltd
Publication of WO2021102506A1 publication Critical patent/WO2021102506A1/en

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Classifications

    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B19/00—Programme-control systems
    • G05B19/02—Programme-control systems electric
    • G05B19/42—Recording and playback systems, i.e. in which the programme is recorded from a cycle of operations, e.g. the cycle of operations being manually controlled, after which this record is played back on the same machine
    • G05B19/427—Teaching successive positions by tracking the position of a joystick or handle to control the positioning servo of the tool head, master-slave control
    • G—PHYSICS
    • G06—COMPUTING; CALCULATING OR COUNTING
    • G06F—ELECTRIC DIGITAL DATA PROCESSING
    • G06F3/00—Input arrangements for transferring data to be processed into a form capable of being handled by the computer; Output arrangements for transferring data from processing unit to output unit, e.g. interface arrangements
    • G06F3/01—Input arrangements or combined input and output arrangements for interaction between user and computer
    • G06F3/016—Input arrangements with force or tactile feedback as computer generated output to the user
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B25—HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
    • B25J—MANIPULATORS; CHAMBERS PROVIDED WITH MANIPULATION DEVICES
    • B25J13/00—Controls for manipulators
    • B25J13/006—Controls for manipulators by means of a wireless system for controlling one or several manipulators
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B25—HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
    • B25J—MANIPULATORS; CHAMBERS PROVIDED WITH MANIPULATION DEVICES
    • B25J13/00—Controls for manipulators
    • B25J13/02—Hand grip control means
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B25—HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
    • B25J—MANIPULATORS; CHAMBERS PROVIDED WITH MANIPULATION DEVICES
    • B25J13/00—Controls for manipulators
    • B25J13/06—Control stands, e.g. consoles, switchboards
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B25—HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
    • B25J—MANIPULATORS; CHAMBERS PROVIDED WITH MANIPULATION DEVICES
    • B25J13/00—Controls for manipulators
    • B25J13/06—Control stands, e.g. consoles, switchboards
    • B25J13/065—Control stands, e.g. consoles, switchboards comprising joy-sticks
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B25—HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
    • B25J—MANIPULATORS; CHAMBERS PROVIDED WITH MANIPULATION DEVICES
    • B25J9/00—Programme-controlled manipulators
    • B25J9/16—Programme controls
    • B25J9/1679—Programme controls characterised by the tasks executed
    • B25J9/1689—Teleoperation
    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05D—SYSTEMS FOR CONTROLLING OR REGULATING NON-ELECTRIC VARIABLES
    • G05D1/00—Control of position, course or altitude of land, water, air, or space vehicles, e.g. automatic pilot
    • G05D1/0011—Control of position, course or altitude of land, water, air, or space vehicles, e.g. automatic pilot associated with a remote control arrangement
    • G05D1/005—Control of position, course or altitude of land, water, air, or space vehicles, e.g. automatic pilot associated with a remote control arrangement by providing the operator with signals other than visual, e.g. acoustic, haptic
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K5/00—Casings, cabinets or drawers for electric apparatus
    • H05K5/0021—Side-by-side or stacked arrangements
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K7/00—Constructional details common to different types of electric apparatus
    • H05K7/02—Arrangements of circuit components or wiring on supporting structure
    • H05K7/10—Plug-in assemblages of components, e.g. IC sockets
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K7/00—Constructional details common to different types of electric apparatus
    • H05K7/14—Mounting supporting structure in casing or on frame or rack
    • H05K7/1462—Mounting supporting structure in casing or on frame or rack for programmable logic controllers [PLC] for automation or industrial process control
    • H05K7/1481—User interface, e.g. status displays; Programming interface, e.g. connector for computer programming; Monitoring
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B25—HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
    • B25J—MANIPULATORS; CHAMBERS PROVIDED WITH MANIPULATION DEVICES
    • B25J11/00—Manipulators not otherwise provided for
    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B2219/00—Program-control systems
    • G05B2219/30—Nc systems
    • G05B2219/37—Measurements
    • G05B2219/37138—Encoder and gear and absolute coder, give together absolute position of rotation
    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B2219/00—Program-control systems
    • G05B2219/30—Nc systems
    • G05B2219/40—Robotics, robotics mapping to robotics vision
    • G05B2219/40099—Graphical user interface for robotics, visual robot user interface
    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B2219/00—Program-control systems
    • G05B2219/30—Nc systems
    • G05B2219/40—Robotics, robotics mapping to robotics vision
    • G05B2219/40123—Indicate, select features on display, remote manipulator will execute
    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B2219/00—Program-control systems
    • G05B2219/30—Nc systems
    • G05B2219/40—Robotics, robotics mapping to robotics vision
    • G05B2219/40298—Manipulator on vehicle, wheels, mobile
    • G—PHYSICS
    • G06—COMPUTING; CALCULATING OR COUNTING
    • G06F—ELECTRIC DIGITAL DATA PROCESSING
    • G06F3/00—Input arrangements for transferring data to be processed into a form capable of being handled by the computer; Output arrangements for transferring data from processing unit to output unit, e.g. interface arrangements
    • G06F3/01—Input arrangements or combined input and output arrangements for interaction between user and computer
    • G06F3/03—Arrangements for converting the position or the displacement of a member into a coded form
    • G06F3/033—Pointing devices displaced or positioned by the user, e.g. mice, trackballs, pens or joysticks; Accessories therefor
    • G06F3/0346—Pointing devices displaced or positioned by the user, e.g. mice, trackballs, pens or joysticks; Accessories therefor with detection of the device orientation or free movement in a 3D space, e.g. 3D mice, 6-DOF [six degrees of freedom] pointers using gyroscopes, accelerometers or tilt-sensors
    • G—PHYSICS
    • G08—SIGNALLING
    • G08C—TRANSMISSION SYSTEMS FOR MEASURED VALUES, CONTROL OR SIMILAR SIGNALS
    • G08C2201/00—Transmission systems of control signals via wireless link
    • G08C2201/90—Additional features
    • G08C2201/93—Remote control using other portable devices, e.g. mobile phone, PDA, laptop
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R11/00—Individual connecting elements providing two or more spaced connecting locations for conductive members which are, or may be, thereby interconnected, e.g. end pieces for wires or cables supported by the wire or cable and having means for facilitating electrical connection to some other wire, terminal, or conductive member, blocks of binding posts
    • H01R11/11—End pieces or tapping pieces for wires, supported by the wire and for facilitating electrical connection to some other wire, terminal or conductive member
    • H01R11/30—End pieces held in contact by a magnet
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
    • H01R13/46—Bases; Cases
    • H01R13/52—Dustproof, splashproof, drip-proof, waterproof, or flameproof cases
    • H01R13/5219—Sealing means between coupling parts, e.g. interfacial seal
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
    • H01R13/62—Means for facilitating engagement or disengagement of coupling parts or for holding them in engagement
    • H01R13/6205—Two-part coupling devices held in engagement by a magnet

Definitions

  • the present disclosure relates, generally, to control systems and controllers for facilitating remote control of one or more mechanisms, and, particularly, to control systems and controllers for enabling control of robotic manipulators, such as an articulated limb.
  • UUVs unmanned underwater vehicles
  • Some unmanned underwater vehicles have one or more articulated limbs to allow performing tasks underwater, such as repairing a structure, or defusing a mine. These limbs are configured for remote control by a user located above- water.
  • Control of remotely-located mechanisms can be facilitated by a range of devices, such as a joystick, game controller (such as is used to control video games),
  • 3D mouse or a master controller, being an articulated device configured to represent the mechanism being controlled to provide a master/slave relationship.
  • Such devices are typically configured as a peripheral connectable to a computer, typically via a USB connector, to allow controlling the remote mechanism. Where remote control of multiple mechanisms simultaneously is required, this typically involves connecting a corresponding multiple peripherals to the computer. This can require a substantial amount of space and often proves inconvenient and cumbersome.
  • Control of remotely-located manipulators is increasingly performed using a master controller due to allowing a greater degree of precision and freedom of movement than alternative controllers.
  • Some master controllers provide sophisticated movements however are heavy, non-portable and/or expensive.
  • Other, inexpensive devices are driven entirely by user input and consequently lack sophistication.
  • a modular control system for facilitating remote control of one or more mechanisms.
  • the modular control system includes: a base module defining opposed sides, each side having a first electrical connector, the base module including a communications unit; at least one peripheral module operable to translate user input to input signals, the, or each, peripheral module having a second electrical connector and configured to be releasably securable to one of the opposed sides to electrically couple the first and second electrical connectors to allow communicating input signals to the communications unit; and a controller communicatively connected with the one or more mechanisms and the communications unit, the controller configured so that responsive to receiving an input signal from the communications unit, the controller effects control of the one or more mechanisms.
  • the system may include a plurality of the peripheral modules, where securing a pair of the peripheral modules to each of the opposed sides and operating the pair of peripheral modules to generate input signals causes the controller to effect control of a pair of the mechanisms simultaneously.
  • Each peripheral module may be configured to be releasably securable to either of the opposed sides.
  • Each peripheral module may be configured to be releasably securable to either of the opposed sides in one of two mirrored orientations relative to the base module.
  • Each peripheral module may be configured to be manually press-fit to one of the opposed sides.
  • Each opposed side and each peripheral module may have complementary retention elements arranged to retain the peripheral module to the base module.
  • Each retention element may be a magnetic member.
  • Each opposed side and each peripheral module may have complementary locating formations arranged to engage to secure the peripheral module to the base module.
  • Each of the opposed sides may have a seal arranged to seal against one of the peripheral modules.
  • the base module may be connectable to a power supply, and each first electrical connector be configured to supply power to one of the peripheral modules.
  • the controller may be configured as an application executable on a computing device, and the communications unit be configured to communicate with the computing device.
  • the controller may be configured to cause the computing device to operate a screen to display at least one of a video feed and graphics relating to the one or more mechanisms. This may involve causing the computing device to display graphical user interface (GUI) elements relating to settings for any of the one or more mechanisms and the, or each, peripheral module, and, responsive to a user operating the GUI elements to select settings, the controller be configured to effect the selected settings.
  • GUI graphical user interface
  • the system may include the computing device configured as a tablet computer securable to the base module.
  • the tablet computer may be housed within the base module.
  • the base module may be configured for use on a user’s lap.
  • a control system for facilitating remote control a manipulator.
  • the control system includes: a peripheral controller including a pair of members rotatably connected about an axis, at least one of the members arranged to be movable by a user to cause relative rotation of the members, a direct drive mechanism drivingly engaged with at least one of the members, the direct drive mechanism being operable to apply torque to the members in either direction about the axis, and an encoder arranged to measure an angular position of the members relative to each other and a relative velocity of the members; and a controller communicatively connected to the direct drive mechanism, the encoder and the manipulator, the controller configured to effect control of the motor.
  • the controller may be configured such that responsive to the encoder measuring relative velocity about the axis in a first direction exceeding a velocity threshold, the controller operates the direct drive mechanism to apply torque in a second, opposite direction to inhibit relative rotation of the members.
  • the controller may be configured such that responsive to the encoder measuring relative position of the members at or exceeding a first position threshold, the controller operates the direct drive mechanism to substantially constrain relative rotation of the members.
  • the controller may be configured such that responsive to the encoder measuring relative position of the members at or exceeding a second position threshold, the controller operates the direct drive mechanism to cause relative rotation of the members to bias the members.
  • the controller may be configured such that responsive to the controller determining one of a position of the manipulator is at or exceeding a third position threshold, and a force exerted on the manipulator exceeds a force threshold, the controller operates the direct drive mechanism to apply torque in alternating directions to cause the members to vibrate.
  • the controller may be configured such that responsive to determining a force exerted on the manipulator exceeds a force threshold, the controller operates the direct drive mechanism to substantially constrain relative rotation of the members.
  • the controller may be configured such that responsive to determining a position of the manipulator, the controller operates the direct drive mechanism to cause relative rotation of the members to arrange the members in a complementary position.
  • the controller may be configured as an application executable by a computing device.
  • the direct drive mechanism may be a brushless torque motor.
  • a peripheral controller for facilitating remote control of a manipulator, the peripheral controller including at least one pair of members rotatably connected about an axis, at least one of the members arranged to be movable by a user to cause relative rotation of the members, the, or each pair, being associated with an encoder arranged to measure an angular position of the members relative to each other and a relative velocity of the members, and a direct drive mechanism drivingly engaged with at least one of the members to allow applying torque to the members in either direction about the axis.
  • the peripheral controller may include a plurality of pairs of the members (each associated with an encoder and direct drive mechanism), the pairs arranged to define a complementary more than one degree of freedom.
  • the peripheral controller may be configured as a master controller to drive the manipulator as a slave mechanism.
  • embodiments may comprise steps, features and/or integers disclosed herein or indicated in the specification of this application individually or collectively, and any and all combinations of two or more of said steps or features.
  • Figure 1 is a perspective view of an unmanned underwater vehicle having two robotic manipulators mounted to a front region;
  • Figure 2 is a perspective view of a modular control system for facilitating remote control of one or more mechanisms, such as the manipulators shown in Figure 1, the modular control system shown in a first configuration with two peripheral modules secured to opposed sides of a base module;
  • Figure 3 is a perspective view of the modular control system shown in Figure 1 in a second configuration with one of the peripheral modules removed from the base module;
  • FIG. 4 is a schematic view of graphical user interface (GUI) elements displayed on a screen of the base module shown in Figures 2 and 3;
  • GUI graphical user interface
  • Figure 5 is a perspective view of one of peripheral modules shown in Figure 2;
  • Figure 6 is a perspective view of a cover securable to the base module shown in Figures 2 and 3;
  • Figure 7 is a perspective view of the other peripheral module shown in Figure
  • Figure 8 is a perspective view of the peripheral module shown in Figure 7 configured as a stand-alone master controller.
  • Figure 9 is an exploded perspective view of a sub-assembly of the master controller shown in Figures 7 and 8.
  • reference numeral 10 generally designates a modular control system 10 (Fig. 2) for facilitating remote control of one or more mechanisms.
  • the system 10 includes: a base module 12 defining opposed sides 14, each side 14 having a first electrical connector 16, the base module 12 including a communications unit 18; at least one peripheral module 20 operable to translate user input to input signals, the, or each, peripheral module 20 having a second electrical connector 22 and configured to be releasably securable to one of the opposed sides 14 to electrically couple the first and second electrical connectors 16, 22 to allow communicating input signals to the communications unit 18; and a controller 24 communicatively connected with the one or more mechanisms and the communications unit 18, the controller 24 configured so that responsive to receiving an input signal from the communications unit 18, the controller 24 effects control of the one or more mechanisms.
  • Figure 1 shows an unmanned underwater vehicle 26 carrying the one or more mechanisms, in the form of two manipulators 28, 30, suitable for being controlled remotely by the modular control system 10.
  • the first manipulator 28 includes three actuators to allow operation of an opposable claw 32, and rotation of the claw 32 about two axes.
  • the second manipulator 30 includes five actuators to allow operation of an alternative opposable claw 34 and movement of the claw 34 about four axes.
  • the vehicle 26 also includes a plurality of cameras 36 arranged to record footage of the manipulators 28, 30 during use.
  • the manipulators 28, 30 are merely exemplary of the types of mechanisms the modular control system 10 is configurable to control and that the system 10 may be configured to control operation of a wide range of other mechanisms.
  • the modular control system 10 is configured to control other vehicles and associated manipulators, such as a ground rover or aerial drone.
  • the modular control system 10 is configured to control other mechanisms, such as a camera gimbal, or a crane movable across a gantry system, such as employed in a packing warehouse or factory.
  • FIGs 2 and 3 show alternative configurations of the modular control system 10.
  • the system 10 has a pair of the peripheral modules 20, in the forms of a 3D mouse 201 and a master controller 202, secured to the opposed sides 14.
  • This configuration allows the user to operate each of the peripheral modules 201, 202 simultaneously to generate input signals to cause the controller 24 to effect simultaneous control of two remotely-located mechanisms, such as both of the manipulators 28, 30, or one of the manipulators 28, 30 and the vehicle 26.
  • the 3D mouse 201 and master controller 202 are examples of a range of different peripheral modules 20 securable to the base module 12.
  • the system 10 is shown with the master controller 202 removed exposing one of the electrical connectors 16 to allow an alternative peripheral module 20 or a cover 36 (Fig. 6) to be secured to the side 14.
  • each peripheral module 20 is configured to be manually press-fit to one of the sides 14 to mechanically secure and electrically couple the peripheral module 20 to the base module 12, and be removable by manually applying force perpendicular to the side 14.
  • the base module 12 has a locating formation, in the form of a projection 38 extending from the side 14, which is engageable with a complementary locating formation of the peripheral module 20, in the form of a recess 40 (Fig. 5).
  • a locating formations When the locating formations are engaged, at least one retention element of the base module 12, in the form of a pair of spaced magnetic members 42 recessed into the side 14, cause a retention element of the peripheral module 20, in the form of a pair of spaced magnetic members 44 (Fig.
  • the modules 12, 20 have alternatively configured locating formations, such as tapered pins and complementary apertures, and have alternatively configured retention elements, such as deformable clips securable to a complementary rim.
  • Each peripheral module 20 is typically configured to be releasably securable to either side 14 of the base module 12, most typically by being configured to be reversible to allow the peripheral module 20 to be secured to the base module 12, and be operable, in one of two mirrored orientations relative to the base module 12. This means that any peripheral module 20 can be mounted and be operable at either side 14 of the base module 12. This usefully allows a peripheral module 20 to be secured to the base module 12 in an orientation to correspond with that of the controlled mechanism, such as one of the manipulators 18, 30 relative to the vehicle 26.
  • a complementary five-axis master controller 202 is securable to the left-hand side 14 (as viewed by the user) of the base module 12. This allows the modular control system 10 to be configured to emulate the arrangement of the controlled mechanisms, consequently enhancing control of the mechanisms by the user.
  • Each electrical connector 16, 20 includes a plurality of contacts, the first connectors 16 having an array of pads 46 and the second connectors 20 having an array of depressible (“pogo”) pins 48.
  • Mounting a peripheral module 20 to one of the sides 14 of the base module 12 causes the pins 48 to couple with the pads 46 to allow power to be supplied from the base module 12 to the peripheral module 20, and data to be communicated between the peripheral module 20 and the base module 12.
  • the base module 12 is connectable to a power supply (not shown).
  • the base module 12 includes a battery to power the base module 12 and any connected peripheral module 20, meaning that the system 10 is entirely wireless. It will be appreciated that in such embodiments each peripheral module 20 may also include a battery.
  • Each side 14 of the base module 12 includes a circumferential seal 50 arranged about the projection 38.
  • the seal 450 is positioned to be compressed by a peripheral module 20 secured to the side 14 to sealingly engage the peripheral module 20 and the base module 12.
  • the seal 50 is arranged within the recess 40 of the peripheral module 20 to achieve the sealing engagement.
  • the controller 24 is typically configured as an application executable on a computing device, including a remote server, laptop computer, tablet computer, and smartphone.
  • the base module 12 houses the communications module 18 to allow communicating input signals received from the peripheral modules 20 to the controller 24, as well as communicating settings signals, and other instructions, from the controller 24 to the peripheral modules 20.
  • the communications module 18 is configurable for wireless communications, such as according to WiFi and/or Bluetooth standards, and/or wired communications, such as via an Ethernet cable.
  • the base module 12 houses a tablet computer 52 which includes processing components and a touch screen 54 operable to receive haptic user input.
  • the tablet computer 52 is configured to execute the controller 24 application and cooperate with the communications module 18 to allow communicating with, and effecting control of, the one or more mechanisms, such as the manipulators 28, 30 and/or the vehicle 26.
  • Configuring the base module 12 in this way allows the base module 12 with two peripheral modules 20 (as shown in Fig. 1) secured to the sides 14 to be comfortably supported and operated on a user’s lap.
  • the tablet computer 52 is separate and securable to the base module 12, such as to a mount structure. These embodiments allow a user to select the tablet computer 52 from a range of different models suitable to execute the controller 24 application.
  • the base module 12 is configured to only define mounts for the peripheral modules 20 and communicate with an external computing device, such as a remote server, executing the controller 24 module. These embodiments allow the controller 24 to effect control a large-scale monitor.
  • the controller 24 is configured to operate the screen 54 of the tablet computer 52 to display a video feed relating to the controlled mechanisms, such as received from the cameras 36 mounted to the vehicle 26, and/or graphics relating to the peripheral modules 20 and/or controlled mechanisms.
  • the controller 24 is also configured to operate the screen 54 to display graphical user interface (GUI) elements relating to the peripheral modules 20 and/or controlled mechanisms.
  • GUI graphical user interface
  • FIG 4 is a screenshot of the screen 54 displaying settings for the manipulators 28, 30 and the peripheral modules 201, 202 connected to the base module 12 (as shown in Fig. 1).
  • Various GUI elements are also displayed to allow a user to define settings by touching the GUI elements on the screen 54.
  • Examples of user definable settings for the manipulators 28, 30 include: force limits; position limits; velocity limits; grip force limits; workspace boundaries; stow preset positions; and deploy preset positions.
  • Examples of user definable settings for the peripheral modules 20 include: force feedback (e.g. vibrations, spring dampener); assign button operations; adjust movement scaling (e.g. 10 degrees rotation by the peripheral module 20 equates to 2 degrees of rotation of the manipulator 28, 30); operation modes (e.g. kinematics, manual); dial control options. It will be appreciated that these are merely exemplary and the controller 24 is configurable to operate the screen 54 to display, and operate the controlled mechanisms and/or peripheral modules 20 to effect, a wide range of setting options.
  • FIGS 5 and 7 show the peripheral modules 20, configured as 3D mouse 201 and master controller 202, in isolation.
  • Each of the peripheral modules 20 is configured to receive user input and translate this into input signals which are communicated to the base module 12 via the connector 22.
  • the 3D mouse 201 includes a cap 56 which is movable by a user in six degrees of freedom to provide the user input.
  • the master controller 202 includes an end effector handle 58 and joystick 59 which, together, are movable by a user in six degrees of freedom to provide the user input.
  • Each module 201, 202 includes one or more buttons 60 operable to provide additional user input.
  • Figure 6 shows the cover 36 in isolation.
  • the cover 36 is securable to either side 14 of the base module 12, in the same way as the peripheral modules 20, to sealingly enclose the electrical connector 16.
  • Figure 8 shows the master controller 202 configured as a stand-alone peripheral having a connector cap 62 secured across the recess 40.
  • the connector cap 62 includes one of the first connectors 16 (not visible) arranged to couple the second connector 22 of the master controller 202 with a third connector 64 defining two ports 66 arranged to allow a wired connection to a controller, such as configured as an application executed by a computing device (not shown).
  • the master controller 202 includes a plurality of members 68 rotatably secured to each other to provide four of the six degrees of freedom.
  • a first member 681 is secured to a mount 70 to allow relative rotation about a first axis A.
  • a second member 682 is secured to the first member 681 to allow relative rotation about a second axis B.
  • a third member 683 is secured to the second member 682 to allow relative rotation about a third axis C.
  • the end effector handle 58 is secured to the third member 683 to allow relative rotation about a fourth axis D.
  • each junction (joint) between the members 681, 682, 683, the mount 70 and the handle 58 includes a direct drive mechanism, in the illustrated embodiment in the form of a brushless direct drive motor 72, and an encoder 74.
  • the motor 72 is drivingly engaged with at least one of the members 681, 682, 683, handle 58, or mount 70, and is operable to apply torque in either direction about the axis.
  • the encoder 74 is arranged to measure an angular position of the members 681, 682, 683, handle 58, or mount 70, relative to each other, and measure a relative velocity of the members 681, 682, 683, handle 58, or mount 70.
  • the motor 72 and encoder 74 are typically communicatively connected to a controller, such as the controller 24 which is part of the system 10, or a microcontroller associated with the joint (discussed below).
  • the motor 72 is typically configured to communicate positional and velocity feedback to the controller to facilitate affecting operation of the motor 72 by the controller.
  • Figure 9 illustrates the joint between the first member 681 and the second member 682. It will be appreciated that this joint is exemplary and that each joint of the master controller 202 comprises the same features.
  • the first member 681 housing 76 is shaped to partially receive the motor 72.
  • the second member 682 housing 78 is shaped to partially receive the motor 72 in one side, and receive the encoder 74 and a PCB 80 in the other side.
  • the PCB 80 is communicatively connected with the motor 72 and the encoder 74 to allow communicating positional and velocity measurements obtained by the encoder 74 or motor 72 to the controller 24, and communicate control signals from the controller 24 to the motor 72 to effect control of (commutate) the motor 72.
  • the PCB 80 is configurable to communicate with an alternative controller (not illustrated), typically being an application executed by a computing device.
  • the master controller 202 and alternative controller together form an alternative control system for facilitating remote control of a mechanism, such as one of the manipulators 28, 30.
  • the PCB 80 carries a microcontroller which facilitates the controller function, thereby forming a stand-alone control system within each joint of the master controller 202.
  • the microcontroller receives and processes the measurements from the encoder 74 to commutate the motor 72.
  • the end effector handle 58 is configured to be manually moved by a user to allow providing the user input. Moving the handle 58 causes relative rotation between at least some of the members 681, 682, 683, handle 58, and mount 70, consequently causing one or more of the encoders 74 to measure positional translation, and/or relative velocity, and the measurements to be communicated to the controller 24. Depending on the measurement received, the controller 24 is configured to effect control of one or more of the motors 72 to convey the haptic feedback.
  • the settings for the manipulator 30 define a velocity threshold and the user operates the master controller 202 to rotate the members 682
  • the controller 24 is configured to operate the motor 72 drivingly engaged with these member 682, 683 to apply torque in an opposite, second direction to inhibit relative rotation of the members 682, 683. This is achieved by the controller 24 setting current drawn by the motor 72 to a defined value. This effectively dampens relative rotation of the members 682, 683 by increasing friction between the members 682, 683, prompting the user to reduce input force and consequently reduce speed of the master controller 202.
  • the controller 24 is configured to operate the motor 72 drivingly engaged with the members 682, 683 to substantially constrain relative rotation of the members 682, 683. This effectively rotationally locks the members 682, 683 to prompt the user to stop applying input force.
  • the controller 24 determines, from measurements from a sensor (not illustrated) operatively connected to the manipulator 30, that force exerted on the manipulator 30, such as due to colliding with an object, has exceeded a defined threshold.
  • the controller is configured to operate the motor 72 to apply torque in alternating directions to cause the members 682, 683 to vibrate. This is achieved by applying alternating voltages to the motor 72.
  • the settings for the master controller 202 define a positional bias, for example, to bias the first member 681 towards a defined position relative to the mount 70 so that the first member 681 is orientated as shown in Fig. 7, and the user operates the master controller 202 to rotate the member 681 to generate an input signal which defines a position not corresponding with the defined position
  • the controller 24 is configured to operate the motor 72 drivingly engaged with the first member 681 to rotate the member 681 to the defined position. This applies a spring effect to the member 681 to return the member 681 to the defined rotational position relative to the mount 70, consequently re-centering the first member 681.
  • the controller 24 is configurable to drive any of the motors 72 to position the members 681, 682, 683 or handle 58 in a defined position relative to each other, responsive to encoder 74 or other sensor measurements. For example, this may be to arrange the master controller 202 to emulate a current arrangement of the manipulator 30. This approach is particularly useful where the master controller 202 is configured to define the same degrees of freedom as the manipulator 30, providing an exact master/slave relationship between the master controller 202 and the manipulator 30.
  • Use of the modular control system 10 involves the user selecting appropriate peripheral modules 20 to control one or more mechanisms, such as the manipulators 28, 30, the user manually securing the selected peripheral modules 20 to the sides 14 of the base module 12 by pressing the peripheral modules 20 onto the projections 38, causing the electrical connectors 16, 22 to couple, powering the base module 12 causing power to be supplied to the connected peripheral modules 20, operating the base module 20 to establish a connection between the controller 24 and each connected peripheral module 20, and each controlled mechanism, and the user operating the peripheral modules 20 to provide user input, causing each peripheral module 20 to communicate input signals, via the base module 12 and communications unit 18, to the controller 24, causing the controller 24 to effect control of the mechanisms.
  • the manipulators 28, 30 the user manually securing the selected peripheral modules 20 to the sides 14 of the base module 12 by pressing the peripheral modules 20 onto the projections 38, causing the electrical connectors 16, 22 to couple, powering the base module 12 causing power to be supplied to the connected peripheral modules 20, operating the base module 20 to establish a connection between the controller 24 and each connected peripheral module 20, and each
  • an alternative peripheral module 20 is required, for example, which is more suitable for controlling an alternative mechanism, the user may manually remove one of the peripheral modules 20 from the base module 12 and secure an alternative peripheral module 20, as described above.
  • Use of the master controller 202 involves the user gripping the end effector handle 58 and moving the handle 58 through space. This causes at least some of the members 681, 682, 683 to rotate relative to each other, the handle 58 and/or the mount 70. The relative rotation causes at least one of the encoders 74 to measure a change in relative position and/or velocity, and communicate this to the controller 24, via the associated PCB 80. Should the measurement be at, above or below a defined threshold, the controller 24 causes at least one of the motors 72 to apply torque to the associated members 681, 682, 683 to communicate haptic feedback to the user.
  • the modular control system 10 is a readily reconfigurable system which allows two of a potentially wide range of peripheral modules 20 to be rapidly secured to the base module 12, without requiring tools, and operated to control two remotely- located mechanisms simultaneously. This means that the system 10 can be set up to complement the arrangement of the controlled mechanisms to enhance precision of control and provide an intuitive user experience. Furthermore, the simultaneous coupling of the peripheral modules 20 and associated electrical connectors 22 with the base module 12 and associated electrical connectors 16 simplifies assembling the system 10 and minimises cabling required by the system 10.
  • the arrangement of the members 681, 682, 683 and associated direct drive mechanisms, such as the motors 72, avoids requiring any gearing or gearbox between the motors 72 and the members 681, 682, 683. This minimises components required to drive relative rotation of the members 681, 682, 683 consequently enhancing reliability. This arrangement also advantageously minimises the bulk, weight, power consumption, cost and/or complexity of the joints between the members 681, 682, 683. Furthermore, the inclusion of the encoder 74 in each joint allows driving the motors 72 to communicate haptic feedback to the user.
  • Each direct drive motor 72 employed within the joints between members 681, 682, 683 provides bearings, a shaft and mounting features. This reduces or avoids requiring tolerance bearing fits between other mechanical components, such as the housings 76, 78, which further reduces complexity and cost of the joint.

Abstract

Modular control system for facilitating remote control of one or more mechanisms. The system includes a base module, at least one peripheral module, and a controller. The base module defines opposed sides, each having a first electrical connector, and includes a communications unit. The at least one peripheral module is operable to translate user input to input signals. The, or each, peripheral module has a second electrical connector and is configured to be releasably securable to one of the opposed sides to electrically couple the first and second electrical connectors to allow communicating input signals to the communications unit. The controller is communicatively connected with the one or more mechanisms and the communications unit. The controller is configured so that responsive to receiving an input signal from the communications unit, the controller effects control of the one or more mechanisms.

Description

"Control systems and controllers for remote control of one or more mechanisms" Cross-reference to Related Applications
[0001] This application claims priority from Australian Provisional Patent Application No. 2019904481, filed on 27 November 2019, the content of which is incorporated herein by reference.
Technical Field
[0002] The present disclosure relates, generally, to control systems and controllers for facilitating remote control of one or more mechanisms, and, particularly, to control systems and controllers for enabling control of robotic manipulators, such as an articulated limb.
Background
[0003] Remote controlled operation of a mechanism is often employed to allow a user to operate the mechanism in an environment which is inaccessible or dangerous to the user. For example, some unmanned underwater vehicles (UUVs) have one or more articulated limbs to allow performing tasks underwater, such as repairing a structure, or defusing a mine. These limbs are configured for remote control by a user located above- water.
[0004] Control of remotely-located mechanisms can be facilitated by a range of devices, such as a joystick, game controller (such as is used to control video games),
3D mouse, or a master controller, being an articulated device configured to represent the mechanism being controlled to provide a master/slave relationship. Such devices are typically configured as a peripheral connectable to a computer, typically via a USB connector, to allow controlling the remote mechanism. Where remote control of multiple mechanisms simultaneously is required, this typically involves connecting a corresponding multiple peripherals to the computer. This can require a substantial amount of space and often proves inconvenient and cumbersome.
[0005] Control of remotely-located manipulators, such as robotic arms, is increasingly performed using a master controller due to allowing a greater degree of precision and freedom of movement than alternative controllers. Some master controllers provide sophisticated movements however are heavy, non-portable and/or expensive. Other, inexpensive devices are driven entirely by user input and consequently lack sophistication.
[0006] Any discussion of documents, acts, materials, devices, articles or the like which has been included in the present specification is not to be taken as an admission that any or all of these matters were common general knowledge in the field relevant to the present disclosure as it existed before the priority date of each of the appended claims.
Summary
[0007] According to some disclosed embodiments there is provided a modular control system for facilitating remote control of one or more mechanisms. The modular control system includes: a base module defining opposed sides, each side having a first electrical connector, the base module including a communications unit; at least one peripheral module operable to translate user input to input signals, the, or each, peripheral module having a second electrical connector and configured to be releasably securable to one of the opposed sides to electrically couple the first and second electrical connectors to allow communicating input signals to the communications unit; and a controller communicatively connected with the one or more mechanisms and the communications unit, the controller configured so that responsive to receiving an input signal from the communications unit, the controller effects control of the one or more mechanisms. [0008] The system may include a plurality of the peripheral modules, where securing a pair of the peripheral modules to each of the opposed sides and operating the pair of peripheral modules to generate input signals causes the controller to effect control of a pair of the mechanisms simultaneously.
[0009] Each peripheral module may be configured to be releasably securable to either of the opposed sides.
[0010] Each peripheral module may be configured to be releasably securable to either of the opposed sides in one of two mirrored orientations relative to the base module.
[0011] Each peripheral module may be configured to be manually press-fit to one of the opposed sides.
[0012] Each opposed side and each peripheral module may have complementary retention elements arranged to retain the peripheral module to the base module. Each retention element may be a magnetic member.
[0013] Each opposed side and each peripheral module may have complementary locating formations arranged to engage to secure the peripheral module to the base module.
[0014] Each of the opposed sides may have a seal arranged to seal against one of the peripheral modules.
[0015] The base module may be connectable to a power supply, and each first electrical connector be configured to supply power to one of the peripheral modules.
[0016] The controller may be configured as an application executable on a computing device, and the communications unit be configured to communicate with the computing device. [0017] The controller may be configured to cause the computing device to operate a screen to display at least one of a video feed and graphics relating to the one or more mechanisms. This may involve causing the computing device to display graphical user interface (GUI) elements relating to settings for any of the one or more mechanisms and the, or each, peripheral module, and, responsive to a user operating the GUI elements to select settings, the controller be configured to effect the selected settings.
[0018] The system may include the computing device configured as a tablet computer securable to the base module. In such embodiments, the tablet computer may be housed within the base module.
[0019] The base module may be configured for use on a user’s lap.
[0020] According to other disclosed embodiments there is provided a control system for facilitating remote control a manipulator. The control system includes: a peripheral controller including a pair of members rotatably connected about an axis, at least one of the members arranged to be movable by a user to cause relative rotation of the members, a direct drive mechanism drivingly engaged with at least one of the members, the direct drive mechanism being operable to apply torque to the members in either direction about the axis, and an encoder arranged to measure an angular position of the members relative to each other and a relative velocity of the members; and a controller communicatively connected to the direct drive mechanism, the encoder and the manipulator, the controller configured to effect control of the motor.
[0021] The controller may be configured such that responsive to the encoder measuring relative velocity about the axis in a first direction exceeding a velocity threshold, the controller operates the direct drive mechanism to apply torque in a second, opposite direction to inhibit relative rotation of the members.
[0022] The controller may be configured such that responsive to the encoder measuring relative position of the members at or exceeding a first position threshold, the controller operates the direct drive mechanism to substantially constrain relative rotation of the members.
[0023] The controller may be configured such that responsive to the encoder measuring relative position of the members at or exceeding a second position threshold, the controller operates the direct drive mechanism to cause relative rotation of the members to bias the members.
[0024] The controller may be configured such that responsive to the controller determining one of a position of the manipulator is at or exceeding a third position threshold, and a force exerted on the manipulator exceeds a force threshold, the controller operates the direct drive mechanism to apply torque in alternating directions to cause the members to vibrate.
[0025] The controller may be configured such that responsive to determining a force exerted on the manipulator exceeds a force threshold, the controller operates the direct drive mechanism to substantially constrain relative rotation of the members.
[0026] The controller may be configured such that responsive to determining a position of the manipulator, the controller operates the direct drive mechanism to cause relative rotation of the members to arrange the members in a complementary position.
[0027] The controller may be configured as an application executable by a computing device.
[0028] The direct drive mechanism may be a brushless torque motor.
[0029] According to further disclosed embodiments, there is provided a peripheral controller for facilitating remote control of a manipulator, the peripheral controller including at least one pair of members rotatably connected about an axis, at least one of the members arranged to be movable by a user to cause relative rotation of the members, the, or each pair, being associated with an encoder arranged to measure an angular position of the members relative to each other and a relative velocity of the members, and a direct drive mechanism drivingly engaged with at least one of the members to allow applying torque to the members in either direction about the axis.
[0030] Where the manipulator defines more than one degree of freedom, the peripheral controller may include a plurality of pairs of the members (each associated with an encoder and direct drive mechanism), the pairs arranged to define a complementary more than one degree of freedom.
[0031] The peripheral controller may be configured as a master controller to drive the manipulator as a slave mechanism.
[0032] Throughout this specification the word "comprise", or variations such as "comprises" or "comprising", will be understood to imply the inclusion of a stated element, integer or step, or group of elements, integers or steps, but not the exclusion of any other element, integer or step, or group of elements, integers or steps.
[0033] It will be appreciated embodiments may comprise steps, features and/or integers disclosed herein or indicated in the specification of this application individually or collectively, and any and all combinations of two or more of said steps or features.
Brief Description of Drawings
[0034] Embodiments will now be described by way of example only with reference to the accompany drawings in which:
[0035] Figure 1 is a perspective view of an unmanned underwater vehicle having two robotic manipulators mounted to a front region;
[0036] Figure 2 is a perspective view of a modular control system for facilitating remote control of one or more mechanisms, such as the manipulators shown in Figure 1, the modular control system shown in a first configuration with two peripheral modules secured to opposed sides of a base module;
[0037] Figure 3 is a perspective view of the modular control system shown in Figure 1 in a second configuration with one of the peripheral modules removed from the base module;
[0038] Figure 4 is a schematic view of graphical user interface (GUI) elements displayed on a screen of the base module shown in Figures 2 and 3;
[0039] Figure 5 is a perspective view of one of peripheral modules shown in Figure 2;
[0040] Figure 6 is a perspective view of a cover securable to the base module shown in Figures 2 and 3;
[0041] Figure 7 is a perspective view of the other peripheral module shown in Figure
2;
[0042] Figure 8 is a perspective view of the peripheral module shown in Figure 7 configured as a stand-alone master controller; and
[0043] Figure 9 is an exploded perspective view of a sub-assembly of the master controller shown in Figures 7 and 8.
Description of Embodiments
[0044] In the drawings, reference numeral 10 generally designates a modular control system 10 (Fig. 2) for facilitating remote control of one or more mechanisms. The system 10 includes: a base module 12 defining opposed sides 14, each side 14 having a first electrical connector 16, the base module 12 including a communications unit 18; at least one peripheral module 20 operable to translate user input to input signals, the, or each, peripheral module 20 having a second electrical connector 22 and configured to be releasably securable to one of the opposed sides 14 to electrically couple the first and second electrical connectors 16, 22 to allow communicating input signals to the communications unit 18; and a controller 24 communicatively connected with the one or more mechanisms and the communications unit 18, the controller 24 configured so that responsive to receiving an input signal from the communications unit 18, the controller 24 effects control of the one or more mechanisms.
[0045] Figure 1 shows an unmanned underwater vehicle 26 carrying the one or more mechanisms, in the form of two manipulators 28, 30, suitable for being controlled remotely by the modular control system 10. The first manipulator 28 includes three actuators to allow operation of an opposable claw 32, and rotation of the claw 32 about two axes. The second manipulator 30 includes five actuators to allow operation of an alternative opposable claw 34 and movement of the claw 34 about four axes. The vehicle 26 also includes a plurality of cameras 36 arranged to record footage of the manipulators 28, 30 during use.
[0046] It will be appreciated that the manipulators 28, 30 are merely exemplary of the types of mechanisms the modular control system 10 is configurable to control and that the system 10 may be configured to control operation of a wide range of other mechanisms. For example, in some embodiments (not shown), the modular control system 10 is configured to control other vehicles and associated manipulators, such as a ground rover or aerial drone. In yet other embodiments (not shown), the modular control system 10 is configured to control other mechanisms, such as a camera gimbal, or a crane movable across a gantry system, such as employed in a packing warehouse or factory.
[0047] Figures 2 and 3 show alternative configurations of the modular control system 10. In Figure 2, the system 10 has a pair of the peripheral modules 20, in the forms of a 3D mouse 201 and a master controller 202, secured to the opposed sides 14. This configuration allows the user to operate each of the peripheral modules 201, 202 simultaneously to generate input signals to cause the controller 24 to effect simultaneous control of two remotely-located mechanisms, such as both of the manipulators 28, 30, or one of the manipulators 28, 30 and the vehicle 26. It will be appreciated that the 3D mouse 201 and master controller 202 are examples of a range of different peripheral modules 20 securable to the base module 12. In Figure 3, the system 10 is shown with the master controller 202 removed exposing one of the electrical connectors 16 to allow an alternative peripheral module 20 or a cover 36 (Fig. 6) to be secured to the side 14.
[0048] In the illustrated embodiment, each peripheral module 20 is configured to be manually press-fit to one of the sides 14 to mechanically secure and electrically couple the peripheral module 20 to the base module 12, and be removable by manually applying force perpendicular to the side 14. The base module 12 has a locating formation, in the form of a projection 38 extending from the side 14, which is engageable with a complementary locating formation of the peripheral module 20, in the form of a recess 40 (Fig. 5). When the locating formations are engaged, at least one retention element of the base module 12, in the form of a pair of spaced magnetic members 42 recessed into the side 14, cause a retention element of the peripheral module 20, in the form of a pair of spaced magnetic members 44 (Fig. 5) extending from within the recess 40, to retain the modules 12, 20 together. In some embodiments (not shown), the locating formations are absent so that the modules 12, 30 are secured only by the retention elements. In other embodiments (not shown), the modules 12, 20 have alternatively configured locating formations, such as tapered pins and complementary apertures, and have alternatively configured retention elements, such as deformable clips securable to a complementary rim.
[0049] Each peripheral module 20 is typically configured to be releasably securable to either side 14 of the base module 12, most typically by being configured to be reversible to allow the peripheral module 20 to be secured to the base module 12, and be operable, in one of two mirrored orientations relative to the base module 12. This means that any peripheral module 20 can be mounted and be operable at either side 14 of the base module 12. This usefully allows a peripheral module 20 to be secured to the base module 12 in an orientation to correspond with that of the controlled mechanism, such as one of the manipulators 18, 30 relative to the vehicle 26. For example, where a five-axis robotic arm is mounted to a left-hand side of the vehicle 26, a complementary five-axis master controller 202 is securable to the left-hand side 14 (as viewed by the user) of the base module 12. This allows the modular control system 10 to be configured to emulate the arrangement of the controlled mechanisms, consequently enhancing control of the mechanisms by the user.
[0050] Each electrical connector 16, 20 includes a plurality of contacts, the first connectors 16 having an array of pads 46 and the second connectors 20 having an array of depressible (“pogo”) pins 48. Mounting a peripheral module 20 to one of the sides 14 of the base module 12 causes the pins 48 to couple with the pads 46 to allow power to be supplied from the base module 12 to the peripheral module 20, and data to be communicated between the peripheral module 20 and the base module 12. Typically, the base module 12 is connectable to a power supply (not shown). In some embodiments, the base module 12 includes a battery to power the base module 12 and any connected peripheral module 20, meaning that the system 10 is entirely wireless. It will be appreciated that in such embodiments each peripheral module 20 may also include a battery.
[0051] Each side 14 of the base module 12 includes a circumferential seal 50 arranged about the projection 38. The seal 450 is positioned to be compressed by a peripheral module 20 secured to the side 14 to sealingly engage the peripheral module 20 and the base module 12. In other embodiments (not shown), the seal 50 is arranged within the recess 40 of the peripheral module 20 to achieve the sealing engagement.
[0052] The controller 24 is typically configured as an application executable on a computing device, including a remote server, laptop computer, tablet computer, and smartphone. The base module 12 houses the communications module 18 to allow communicating input signals received from the peripheral modules 20 to the controller 24, as well as communicating settings signals, and other instructions, from the controller 24 to the peripheral modules 20. The communications module 18 is configurable for wireless communications, such as according to WiFi and/or Bluetooth standards, and/or wired communications, such as via an Ethernet cable. [0053] In the illustrated embodiment, the base module 12 houses a tablet computer 52 which includes processing components and a touch screen 54 operable to receive haptic user input. The tablet computer 52 is configured to execute the controller 24 application and cooperate with the communications module 18 to allow communicating with, and effecting control of, the one or more mechanisms, such as the manipulators 28, 30 and/or the vehicle 26. Configuring the base module 12 in this way allows the base module 12 with two peripheral modules 20 (as shown in Fig. 1) secured to the sides 14 to be comfortably supported and operated on a user’s lap.
[0054] In other embodiments (not shown), the tablet computer 52 is separate and securable to the base module 12, such as to a mount structure. These embodiments allow a user to select the tablet computer 52 from a range of different models suitable to execute the controller 24 application. In yet other embodiments (not shown), the base module 12 is configured to only define mounts for the peripheral modules 20 and communicate with an external computing device, such as a remote server, executing the controller 24 module. These embodiments allow the controller 24 to effect control a large-scale monitor.
[0055] The controller 24 is configured to operate the screen 54 of the tablet computer 52 to display a video feed relating to the controlled mechanisms, such as received from the cameras 36 mounted to the vehicle 26, and/or graphics relating to the peripheral modules 20 and/or controlled mechanisms. In the illustrated embodiment, the controller 24 is also configured to operate the screen 54 to display graphical user interface (GUI) elements relating to the peripheral modules 20 and/or controlled mechanisms.
[0056] Figure 4 is a screenshot of the screen 54 displaying settings for the manipulators 28, 30 and the peripheral modules 201, 202 connected to the base module 12 (as shown in Fig. 1). Various GUI elements are also displayed to allow a user to define settings by touching the GUI elements on the screen 54. Examples of user definable settings for the manipulators 28, 30 include: force limits; position limits; velocity limits; grip force limits; workspace boundaries; stow preset positions; and deploy preset positions. Examples of user definable settings for the peripheral modules 20 include: force feedback (e.g. vibrations, spring dampener); assign button operations; adjust movement scaling (e.g. 10 degrees rotation by the peripheral module 20 equates to 2 degrees of rotation of the manipulator 28, 30); operation modes (e.g. kinematics, manual); dial control options. It will be appreciated that these are merely exemplary and the controller 24 is configurable to operate the screen 54 to display, and operate the controlled mechanisms and/or peripheral modules 20 to effect, a wide range of setting options.
[0057] Figures 5 and 7 show the peripheral modules 20, configured as 3D mouse 201 and master controller 202, in isolation. Each of the peripheral modules 20 is configured to receive user input and translate this into input signals which are communicated to the base module 12 via the connector 22. The 3D mouse 201 includes a cap 56 which is movable by a user in six degrees of freedom to provide the user input. The master controller 202 includes an end effector handle 58 and joystick 59 which, together, are movable by a user in six degrees of freedom to provide the user input. Each module 201, 202 includes one or more buttons 60 operable to provide additional user input.
[0058] Figure 6 shows the cover 36 in isolation. The cover 36 is securable to either side 14 of the base module 12, in the same way as the peripheral modules 20, to sealingly enclose the electrical connector 16.
[0059] Figure 8 shows the master controller 202 configured as a stand-alone peripheral having a connector cap 62 secured across the recess 40. The connector cap 62 includes one of the first connectors 16 (not visible) arranged to couple the second connector 22 of the master controller 202 with a third connector 64 defining two ports 66 arranged to allow a wired connection to a controller, such as configured as an application executed by a computing device (not shown).
[0060] The master controller 202 includes a plurality of members 68 rotatably secured to each other to provide four of the six degrees of freedom. A first member 681 is secured to a mount 70 to allow relative rotation about a first axis A. A second member 682 is secured to the first member 681 to allow relative rotation about a second axis B. A third member 683 is secured to the second member 682 to allow relative rotation about a third axis C. The end effector handle 58 is secured to the third member 683 to allow relative rotation about a fourth axis D.
[0061] Best shown in Figure 9, each junction (joint) between the members 681, 682, 683, the mount 70 and the handle 58, includes a direct drive mechanism, in the illustrated embodiment in the form of a brushless direct drive motor 72, and an encoder 74. The motor 72 is drivingly engaged with at least one of the members 681, 682, 683, handle 58, or mount 70, and is operable to apply torque in either direction about the axis. The encoder 74 is arranged to measure an angular position of the members 681, 682, 683, handle 58, or mount 70, relative to each other, and measure a relative velocity of the members 681, 682, 683, handle 58, or mount 70. The motor 72 and encoder 74 are typically communicatively connected to a controller, such as the controller 24 which is part of the system 10, or a microcontroller associated with the joint (discussed below). The motor 72 is typically configured to communicate positional and velocity feedback to the controller to facilitate affecting operation of the motor 72 by the controller.
[0062] Figure 9 illustrates the joint between the first member 681 and the second member 682. It will be appreciated that this joint is exemplary and that each joint of the master controller 202 comprises the same features. The first member 681 housing 76 is shaped to partially receive the motor 72. The second member 682 housing 78 is shaped to partially receive the motor 72 in one side, and receive the encoder 74 and a PCB 80 in the other side. The PCB 80 is communicatively connected with the motor 72 and the encoder 74 to allow communicating positional and velocity measurements obtained by the encoder 74 or motor 72 to the controller 24, and communicate control signals from the controller 24 to the motor 72 to effect control of (commutate) the motor 72. This arrangement allows the controller 24 to operate the motor 72 to effect relative rotation of the members 681, 682 to convey haptic feedback to a user. [0063] It will be appreciated that where the master controller 202 is used in the stand alone configuration, the PCB 80 is configurable to communicate with an alternative controller (not illustrated), typically being an application executed by a computing device. In such embodiments, the master controller 202 and alternative controller together form an alternative control system for facilitating remote control of a mechanism, such as one of the manipulators 28, 30. In yet other embodiments (not illustrated), the PCB 80 carries a microcontroller which facilitates the controller function, thereby forming a stand-alone control system within each joint of the master controller 202. In such embodiments, the microcontroller receives and processes the measurements from the encoder 74 to commutate the motor 72.
[0064] The end effector handle 58 is configured to be manually moved by a user to allow providing the user input. Moving the handle 58 causes relative rotation between at least some of the members 681, 682, 683, handle 58, and mount 70, consequently causing one or more of the encoders 74 to measure positional translation, and/or relative velocity, and the measurements to be communicated to the controller 24. Depending on the measurement received, the controller 24 is configured to effect control of one or more of the motors 72 to convey the haptic feedback.
[0065] For example, where the settings for the manipulator 30 define a velocity threshold and the user operates the master controller 202 to rotate the members 682,
683 in a first direction to generate an input signal defining a velocity which exceeds the threshold, the controller 24 is configured to operate the motor 72 drivingly engaged with these member 682, 683 to apply torque in an opposite, second direction to inhibit relative rotation of the members 682, 683. This is achieved by the controller 24 setting current drawn by the motor 72 to a defined value. This effectively dampens relative rotation of the members 682, 683 by increasing friction between the members 682, 683, prompting the user to reduce input force and consequently reduce speed of the master controller 202.
[0066] Similarly, where the settings for the manipulator 30 define a positional threshold, such as a workspace boundary, and the user operates the master controller 202 to rotate the members 682, 683 to generate an input signal to define a position which would move the manipulator 30 to, or beyond, the positional threshold, the controller 24 is configured to operate the motor 72 drivingly engaged with the members 682, 683 to substantially constrain relative rotation of the members 682, 683. This effectively rotationally locks the members 682, 683 to prompt the user to stop applying input force. The same effect may be caused where the controller 24 determines, from measurements from a sensor (not illustrated) operatively connected to the manipulator 30, that force exerted on the manipulator 30, such as due to colliding with an object, has exceeded a defined threshold. Alternatively, prompted by the same encoder 74 or other sensor measurements, the controller is configured to operate the motor 72 to apply torque in alternating directions to cause the members 682, 683 to vibrate. This is achieved by applying alternating voltages to the motor 72.
[0067] Furthermore, where the settings for the master controller 202 define a positional bias, for example, to bias the first member 681 towards a defined position relative to the mount 70 so that the first member 681 is orientated as shown in Fig. 7, and the user operates the master controller 202 to rotate the member 681 to generate an input signal which defines a position not corresponding with the defined position, the controller 24 is configured to operate the motor 72 drivingly engaged with the first member 681 to rotate the member 681 to the defined position. This applies a spring effect to the member 681 to return the member 681 to the defined rotational position relative to the mount 70, consequently re-centering the first member 681. Similarly, the controller 24 is configurable to drive any of the motors 72 to position the members 681, 682, 683 or handle 58 in a defined position relative to each other, responsive to encoder 74 or other sensor measurements. For example, this may be to arrange the master controller 202 to emulate a current arrangement of the manipulator 30. This approach is particularly useful where the master controller 202 is configured to define the same degrees of freedom as the manipulator 30, providing an exact master/slave relationship between the master controller 202 and the manipulator 30.
[0068] Use of the modular control system 10 involves the user selecting appropriate peripheral modules 20 to control one or more mechanisms, such as the manipulators 28, 30, the user manually securing the selected peripheral modules 20 to the sides 14 of the base module 12 by pressing the peripheral modules 20 onto the projections 38, causing the electrical connectors 16, 22 to couple, powering the base module 12 causing power to be supplied to the connected peripheral modules 20, operating the base module 20 to establish a connection between the controller 24 and each connected peripheral module 20, and each controlled mechanism, and the user operating the peripheral modules 20 to provide user input, causing each peripheral module 20 to communicate input signals, via the base module 12 and communications unit 18, to the controller 24, causing the controller 24 to effect control of the mechanisms.
[0069] During use, if an alternative peripheral module 20 is required, for example, which is more suitable for controlling an alternative mechanism, the user may manually remove one of the peripheral modules 20 from the base module 12 and secure an alternative peripheral module 20, as described above.
[0070] Use of the master controller 202 involves the user gripping the end effector handle 58 and moving the handle 58 through space. This causes at least some of the members 681, 682, 683 to rotate relative to each other, the handle 58 and/or the mount 70. The relative rotation causes at least one of the encoders 74 to measure a change in relative position and/or velocity, and communicate this to the controller 24, via the associated PCB 80. Should the measurement be at, above or below a defined threshold, the controller 24 causes at least one of the motors 72 to apply torque to the associated members 681, 682, 683 to communicate haptic feedback to the user.
[0071] The modular control system 10 is a readily reconfigurable system which allows two of a potentially wide range of peripheral modules 20 to be rapidly secured to the base module 12, without requiring tools, and operated to control two remotely- located mechanisms simultaneously. This means that the system 10 can be set up to complement the arrangement of the controlled mechanisms to enhance precision of control and provide an intuitive user experience. Furthermore, the simultaneous coupling of the peripheral modules 20 and associated electrical connectors 22 with the base module 12 and associated electrical connectors 16 simplifies assembling the system 10 and minimises cabling required by the system 10.
[0072] The arrangement of the members 681, 682, 683 and associated direct drive mechanisms, such as the motors 72, avoids requiring any gearing or gearbox between the motors 72 and the members 681, 682, 683. This minimises components required to drive relative rotation of the members 681, 682, 683 consequently enhancing reliability. This arrangement also advantageously minimises the bulk, weight, power consumption, cost and/or complexity of the joints between the members 681, 682, 683. Furthermore, the inclusion of the encoder 74 in each joint allows driving the motors 72 to communicate haptic feedback to the user.
[0073] Each direct drive motor 72 employed within the joints between members 681, 682, 683 provides bearings, a shaft and mounting features. This reduces or avoids requiring tolerance bearing fits between other mechanical components, such as the housings 76, 78, which further reduces complexity and cost of the joint.
[0074] It will be appreciated by persons skilled in the art that numerous variations and/or modifications may be made to the above-described embodiments, without departing from the broad general scope of the present disclosure. The present embodiments are, therefore, to be considered in all respects as illustrative and not restrictive.

Claims

CLAIMS:
1. A modular control system for facilitating remote control of one or more mechanisms, the system including: a base module defining opposed sides, each side having a first electrical connector, the base module including a communications unit; at least one peripheral module operable to translate user input to input signals, the, or each, peripheral module having a second electrical connector and configured to be releasably securable to one of the opposed sides to electrically couple the first and second electrical connectors to allow communicating input signals to the communications unit; and a controller communicatively connected with the one or more mechanisms and the communications unit, the controller configured so that responsive to receiving an input signal from the communications unit, the controller effects control of the one or more mechanisms.
2. The modular control system of claim 1 including a plurality of the peripheral modules, wherein securing a pair of the peripheral modules to each of the opposed sides and operating the pair of peripheral modules to generate input signals causes the controller to effect control of a pair of the mechanisms simultaneously.
3. The modular control system of claim 1 or 2, wherein each peripheral module is configured to be releasably securable to either of the opposed sides.
4. The modular control system of claim 3, wherein each peripheral module is configured to be releasably securable to either of the opposed sides in one of two mirrored orientations relative to the base module.
5. The modular control system of any one of the preceding claims, wherein each peripheral module is configured to be manually press-fit to one of the opposed sides.
6. The modular control system of claim 5, wherein each opposed side and peripheral module has complementary retention elements arranged to retain the peripheral module to the base module.
7. The modular control system of claim 6, wherein each retention element is a magnetic member.
8. The modular control system of any one of the claims 5 to 7, wherein each opposed side and peripheral module has complementary locating formations arranged to engage to secure the peripheral module to the base module.
9. The modular control system of any one of the preceding claims, wherein each of the opposed sides has a seal arranged to seal against one of the peripheral modules.
10. The modular control system of any one of the preceding claims, wherein the base module is connectable to a power supply, and wherein each first electrical connector is configured to supply power to one of the peripheral modules.
11. The modular control system of any one of the preceding claims, wherein the controller is configured as an application executable on a computing device, and wherein the communications unit is configured to communicate with the computing device.
12. The modular control system of claim 11, wherein the controller is configured to cause the computing device to operate a screen to display at least one of a video feed and graphics relating to the one or more mechanisms.
13. The modular control system of claim 12, wherein the controller is configured to cause the computing device to display graphical user interface (GUI) elements relating to settings for any of the one or more mechanisms and the, or each, peripheral module, and wherein responsive to a user operating the GUI elements to select settings the controller is configured to effect the selected settings.
14. The modular control system of any one of claims 11 to 13 further including the computing device configured as a tablet computer securable to the base module.
15. The modular control system of claim 14, wherein the tablet computer is housed within the base module.
16. The modular control system of any one of the preceding claims, wherein the base module is configured for use on a user’s lap.
17. A control system for facilitating remote control a manipulator, the control system including: a peripheral controller including: a pair of members rotatably connected about an axis, at least one of the members arranged to be movable by a user to cause relative rotation of the members; a direct drive mechanism drivingly engaged with at least one of the members, the direct drive mechanism being operable to apply torque to the members in either direction about the axis; an encoder arranged to measure an angular position of the members relative to each other and a relative velocity of the members; and a controller communicatively connected to the direct drive mechanism, the encoder and the manipulator, the controller configured to effect control of the motor.
18. The control system of claim 17, wherein the controller is configured so that responsive to the encoder measuring relative velocity about the axis in a first direction exceeding a velocity threshold, the controller operates the direct drive mechanism to apply torque in a second, opposite direction to inhibit relative rotation of the members.
19. The control system of claim 18 or 19, wherein the controller is configured so that responsive to the encoder measuring relative position of the members at or exceeding a first position threshold, the controller operates the direct drive mechanism to substantially constrain relative rotation of the members.
20. The control system of any of claims 17 to 19, wherein the controller is configured so that responsive to the encoder measuring relative position of the members at or exceeding a second position threshold, the controller operates the direct drive mechanism to cause relative rotation of the members to bias the members.
21. The control system of any of claims 17 to 20, wherein the controller is configured so that responsive to determining one of a position of the manipulator is at or exceeding a third position threshold, and a force exerted on the manipulator exceeds a force threshold, the controller operates the direct drive mechanism to apply torque in alternating directions to cause the members to vibrate.
22. The control system of any of claims 17 to 20, wherein the controller is configured so that responsive to determining a force exerted on the manipulator exceeds a force threshold, the controller operates the direct drive mechanism to substantially constrain relative rotation of the members.
23. The control system of any of claims 17 to 22, wherein the controller is configured so that responsive to determining a position of the manipulator, the controller operates the direct drive mechanism to cause relative rotation of the members to arrange the members in a complementary position.
24. The control system of any of claims 17 to 22, wherein the controller is configured as an application executable by a computing device.
25. The control system of any one of claims 17 to 24, wherein the direct drive mechanism comprises a brushless torque motor.
26. A peripheral controller for facilitating remote control of a manipulator, the peripheral controller including at least one pair of members rotatably connected about an axis, at least one of the members arranged to be movable by a user to cause relative rotation of the members, the, or each pair, being associated with an encoder arranged to measure an angular position of the members relative to each other and a relative velocity of the members, and a direct drive mechanism drivingly engaged with at least one of the members to allow applying torque to the members in either direction about the axis.
27. The peripheral controller of claim 26 wherein the manipulator defines more than one degree of freedom, and including a plurality of pairs of the members, the pairs arranged to define a complementary more than one degree of freedom.
28. The peripheral controller of claim 26 or 27 configured as a master controller to drive the manipulator as a slave mechanism.
PCT/AU2020/051267 2019-11-27 2020-11-23 Control systems and controllers for remote control of one or more mechanisms WO2021102506A1 (en)

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Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20050255915A1 (en) * 2004-05-11 2005-11-17 Riggs Andrew J Game controller with interchangeable controls
US20110105231A1 (en) * 2009-11-04 2011-05-05 Valve Corporation Video game controller having user swappable control components
US20170315586A1 (en) * 2011-12-20 2017-11-02 Wikipad, Inc. Combination computing device and game controller with flexible bridge and supporting a transaction apparatus

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20050255915A1 (en) * 2004-05-11 2005-11-17 Riggs Andrew J Game controller with interchangeable controls
US20110105231A1 (en) * 2009-11-04 2011-05-05 Valve Corporation Video game controller having user swappable control components
US20170315586A1 (en) * 2011-12-20 2017-11-02 Wikipad, Inc. Combination computing device and game controller with flexible bridge and supporting a transaction apparatus

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