Disturbance-Observer-Based Dual-Position Feedback Controller for Precision Control of an Industrial Robot Arm

Recently, the fourth industrial revolution has accelerated the application of multiple degrees-of-freedom (DOF) robot arms in various applications. However, it is difficult to utilize robot arms for precision motion control because of their low stiffness. External loads applied to robot arms induce deflections in the joints and links, which deteriorates the positioning accuracy. To solve this problem, control methods using a disturbance observer (DOB) with an external sensory system have been developed. However, external sensors are expensive and have low reliability because of noise and reliance on the surrounding environment. A disturbance-observer-based dual-position feedback (DOB-DPF) controller is proposed herein to improve the positioning accuracy by compensating for the deflections in real time using only an internal sensor. The DOB was designed to derive the unpredictable disturbance torque applied to each joint using the command voltage generated by the position controller. The angular deflection of each joint was calculated based on the disturbance torque and joint stiffness, which were identified experimentally. The DPF controller was designed to control the joint motor while simultaneously compensating for angular deflection. A five-DOF robot arm testbed with a position controller was constructed to verify the proposed controller. The contouring performance of the DOB-DPF controller was compared with that of a conventional position controller with an external load applied to the end effector. The increases in the root mean square values of the contour errors were 1.71 and 0.12 mm with a conventional position controller and the proposed DOB-DPF controller, respectively, after a 2.2 kg weight was applied to the end effector. The results show that the contour error caused by the external load is effectively compensated for by the DOB-DPF controller without an external sensor.