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Industrial robots are extensively used in the robotic assembly of rigid objects, whereas the assembly of flexible objects using the same robot becomes cumbersome and challenging due to transient disturbance. The transient disturbance causes vibration in the flexible object during robotic manipulation and assembly. This is an important problem as the quick suppression of undesired vibrations reduces the cycle time and increases the efficiency of the assembly process. Thus, this study aims to propose a contactless robot vision-based real-time active vibration suppression approach to handle such a scenario.

A robot-assisted camera calibration method is developed to determine the extrinsic camera parameters with respect to the robot position. Thereafter, an innovative robot vision method is proposed to identify a flexible beam grasped by the robot gripper using a virtual marker and obtain the dimension, tip deflection as well as velocity of the same. To model the dynamic behaviour of the flexible beam, finite element method (FEM) is used. The measured dimensions, tip deflection and velocity of a flexible beam are fed to the FEM model to predict the maximum deflection. The difference between the maximum deflection and static deflection of the beam is used to compute the maximum error. Subsequently, the maximum error is used in the proposed predictive maximum error-based second-stage controller to send the control signal for vibration suppression. The control signal in form of trajectory is communicated to the industrial robot controller that accommodates various types of delays present in the system.

The effectiveness and robustness of the proposed controller have been validated using simulation and experimental implementation on an Asea Brown Boveri make IRB 1410 industrial robot with a standard low frame rate camera sensor. In this experiment, two metallic flexible beams of different dimensions with the same material properties have been considered. The robot vision method measures the dimension within an acceptable error limit i.e. ±3%. The controller can suppress vibration amplitude up to approximately 97% in an average time of 4.2 s and reduces the stability time up to approximately 93% while comparing with control and without control suppression time. The vibration suppression performance is also compared with the results of classical control method and some recent results available in literature.

The important contributions of the current work are the following: an innovative robot-assisted camera calibration method is proposed to determine the extrinsic camera parameters that eliminate the need for any reference such as a checkerboard, robotic assembly, vibration suppression, second-stage controller, camera calibration, flexible beam and robot vision; an approach for robot vision method is developed to identify the object using a virtual marker and measure its dimension grasped by the robot gripper accommodating perspective view; the developed robot vision-based controller works along with FEM model of the flexible beam to predict the tip position and helps in handling different dimensions and material types; an approach has been proposed to handle different types of delays that are part of implementation for effective suppression of vibration; proposed method uses a low frame rate and low-cost camera for the second-stage controller and the controller does not interfere with the internal controller of the industrial robot.

A new cutting tool is always well-defined and sharp at the onset of the metal cutting process and gradually losses these properties as the machining process advances. Similarly, at the beginning of the machining process, amplitude of tool vibrations is considerably low and it increases gradually and peaks at the end of the service period of the cutting tool while machining. It is significant to provide a corresponding real-time varying damping to control this chatter, which directly influences accuracy and quality of productivity. This paper aims to review the literature related to the application of smart fluid to control vibration in metal cutting and also focused on the challenges involved in the implementation of active control system during machining process.

Smart dampers, which are used as semi-active and active dampers in metal cutting, were reviewed and the research studies carried out in the field of the magnetorheological (MR) damper were concentrated. In smart materials, MR fluids possess some disadvantages because of their sedimentation of iron particles, leakage and slow response time. To overcome these drawbacks, new MR materials such as MR foam, MR elastomers, MR gels and MR plastomers have been recommended and suggested. This review intents to throw light into available literature which exclusively deals with controlling chatter in metal cutting with the help of MR damping methods.

Using an MR damper popularly known for its semi-active damping characteristics is very adaptable and flexible in controlling chatter by providing damping to real-time amplitudes of tool vibration. In the past, many researchers have attempted to implement MR damper in metal cutting to control vibration and were successful. Various methods with the help of MR fluid are illustrated.

A new cutting tool is always well-defined and sharp at the onset of metal cutting process and gradually losses these properties as the machining process advances. Similarly, at the beginning of the machining process, amplitude of tool vibrations is considerably low and it increases gradually and peaks at the end of service period of cutting tool while machining. Application of MR damper along with the working methodology in metal cutting is presented, challenges met are analyzed and a scope for development is reviewed.

This study provides corresponding real-time varying damping to control tool vibration which directly influences accuracy and quality of productivity. Using an MR damper popularly known for its semi-active damping characteristics is very adaptable and flexible in controlling chatter by providing damping to real-time amplitudes of tool vibration.

This study attempts to implement smart damper in metal cutting to control vibrations.

It is significant to provide corresponding real-time varying damping to control tool vibration which directly influences accuracy and quality of productivity.

Industrial robots are extensively deployed to perform repetitive and simple tasks at high speed to reduce production time and improve productivity. In most cases, a compliant gripper is used for assembly tasks such as peg-in-hole assembly. A compliant mechanism in the gripper introduces flexibility that may cause oscillation in the grasped object. Such a flexible gripper–object system can be considered as an under-actuated object held by the gripper and the oscillations can be attributed to transient disturbance of the robot itself. The commercially available robots do not have a control mechanism to reduce such induced vibration. Thus, this paper aims to propose a contactless vision-based approach for vibration suppression which uses a predictive vibrational amplitude error-based second-stage controller.

The proposed predictive vibrational amplitude error-based second-stage controller is a real-time vibration control strategy that uses predicted error to estimate the second-stage controller output. Based on controller output, input trajectories were estimated for the internal controller of the robot. The control strategy efficiently handles the system delay to execute the control input trajectories when the oscillating object is at an extreme position.

The present controller works along with the internal controller of the robot without any interruption to suppress the residual vibration of the object. To demonstrate the robustness of the proposed controller, experimental implementation on Asea Brown Boveri make industrial robot (IRB) 1410 robot with a low frame rate camera has been carried out. In this experiment, two objects have been considered that have a low (<2.38 Hz) and high (>2.38 Hz) natural frequency. The proposed controller can suppress 95% of vibration amplitude in less than 3 s and reduce the stability time by 90% for a peg-in-hole assembly task.

The present vibration control strategy uses a camera with a low frame rate (25 fps) and the delays are handled intelligently to favour suppression of high-frequency vibration. The mathematical model and the second-stage controller implemented suppress vibration without modifying the robot dynamical model and the internal controller.

This paper presents an optimal design method of number and placements of piezoelectric patch actuators in active vibration control of a plate. Eigenvalue distribution of energy correlative matrix of control input force is applied to determine optimal number of the required actuators. Genetic algorithms (GAs) using active vibration control effects, which are taken as the objective function, are adopted to search optimal placements of actuators. The results show that disturbance exerted on a plate is a key factor of determining optimal number and placements of actuators in active structural vibration control, and a global and efficient optimization solution of multiple actuator placements can be obtained using GAs.

To provide an approach to vibration reduction of flexible spacecraft which operates in the presence of various disturbances, model uncertainty and control input non‐linearities during attitude control for spacecraft designers, which can help them analyze and design the attitude control system.

The new approach integrates the technique of active vibration suppression and the method of variable structure control. The design process is twofold: first design of the active vibration controller by using piezoelectric materials to add damping to the structures in certain critical modes in the inner feedback loop, and then a second feedback loop designed using the variable structure output feedback control (VSOFC) to slew the spacecraft and satisfy the pointing requirements.

Numerical simulations for the flexible spacecraft show that the precise attitude control and vibration suppression can be accomplished using the derived vibration attenuator and attitude control controller.

Studies on how to control the flywheel (motor) under the action of the friction are left for future work.

An effective method is proposed for the spacecraft engineers planning to design attitude control system for actively suppressing the vibration and at the same time quickly and precisely responding to the attitude control command.

This paper fulfills a useful source of theoretical analysis for the attitude control system design and offers practical help for the spacecraft designers.

To provide an approach to active vibration reduction of flexible spacecraft actuated by on‐off thrusters during attitude control for spacecraft designers, which can help them analysis and design the attitude control system.

The new approach includes attitude controller acting on the rigid hub, designed by using pulse‐width pulse‐frequency modulation integrated with component command technique, and the piezoelectric material elements as sensors/actuators bonded on the surface of the beam appendages for active vibration suppression of flexible appendages, designed by optimal positive position feedback (OPPF) control technique. The OPPF compensator is devised by setting up a cost function to be minimized by feedback gains, which are subject to the stability criterion at the same time, and an extension to the conventional positive position feedback control design approach is investigated.

Numerical simulations for the flexible spacecraft show that the precise attitude control and vibration suppression can be accomplished using the derived vibration attenuator and attitude control controller.

Studies on how to control the on‐off actuated system under impulse disturbances are left for future work.

An effective method is proposed for the spacecraft engineers planning to design attitude control system for actively suppressing the vibration and at the same time quickly and precisely responding to the attitude control command.

The advantage in this scheme is that the controllers are designed separately, allowing the two objectives to be satisfied independently of one another. It fulfils a useful source of theoretical analysis for the attitude control system design and offers practical help for the spacecraft designers.

This paper aims to present a multi-axis actuating approach to attenuate the bending and torsional vibration of the solar array through the reaction wheel (RW) actuators.

The motion equation of the solar array with the RW actuators is derived in modal coordinates for controller design. The reaction torques, induced by the speed change of the RW actuators, are controlled for vibration attenuation through the constraints on the actuators’ rotating speed. The proposed control approach is firstly verified with numerical simulation on the finite element model of a full-scale solar array. Experimental study of a simplified elastic plate model is subsequently performed for feasibility and validity investigation.

Both the numerical and experimental studies demonstrated the success of adopting RW as the actuator. Results from numerical simulation reveal that the vibration response peak can be reduced by 80% with 2% of mass increase by using the RW actuators.

It is demonstrated that the multi-axis actuating method using RW actuators has a great potential in vibration attenuation of the multi-panel deployable solar array.

An approach to reduce bending and torsional vibration of solar array based on RW actuators is investigated. Theoretical analysis, numerical simulation and experimental study are conducted to demonstrate the validity of the proposed vibration attenuation approach and its potential application in the spacecraft design.

The purpose of this paper is to design a component synthesis method to suppress the vibration of the flexible spacecraft, which has the constant amplitude force/moment actuator.

The authors proposed a method to construct constant amplitude of time delay and composite coefficient sequences based on the principles of the component synthesis vibration suppression (CSVS). The associated design strategy of the CSVS torque control is also developed. The dynamic model consisting of a single axis rotating rigid central body and a fixed flexibility panel is used to validate the proposed method. Constraint modal and free modal method are both tested to analyse the natural frequencies of the panel and dynamic properties of rigid–flexible decoupling system, under the conditions of known and unknown frequencies. The feasibility of constructing CSVS control force based on the constraint modal frequency is also analysed.

The proposed method can suppress multistage vibration and has arbitrary order robustness for each order frequencies simultaneously. Simulation results show that only the duration time of the actuator has to be set for the proposed method, reasonable vibration suppression effect can be achieved.

The method can be used in spacecraft, especially flexible spacecraft to suppress the vibration; the approach is convenient for engineering application and can be easily designed.

The authors proposed a method to construct constant amplitude of time delay and composite coefficient sequences based on the principles of the CSVS.

This paper aims to develop a robust controller to control vibration of a thin plate attached with two piezoelectric patches in the presence of uncertainties in the mass of the plate. The main goal of this study is to tackle dynamic perturbation that could lead to modelling error in flexible structures. The controller is designed to suppress first and second modal vibrations.

Out of various robust control strategies, μ-synthesis controller design algorithm has been used for active vibration control of a simply supported thin place excited and actuated using two piezoelectric patches. Parametric uncertainty in the system is taken into account so that the robust system will be achieved by maximizing the complex stability radius of the closed-loop system. Effectiveness of the designed controller is validated through robust stability and performance analysis.

Results obtained from numerical simulation indicate that implementation of the designed controller can effectively suppress the vibration of the system at the first and second modal frequencies by 98.5 and 88.4 per cent, respectively, despite the presence of structural uncertainties. The designed controller has also shown satisfactory results in terms of robustness and performance.

Although vibration control in designing any structural system has been an active topic for decades, Ordinary fixed controllers designed based on nominal parameters do not take into account the uncertainties present in and around the system and hence lose their effectiveness when subjected to uncertainties. This paper fulfills an identified need to design a robust control system that accommodates uncertainties.

The purpose of this paper is to examine a new idea of vibration control which minimizes joint‐torques and suppresses vibration of the flexible redundant manipulator.

Using the kinematics redundancy feature of the flexible redundant manipulator, the self‐motion in the joint space can be properly chosen to both suppress vibration and minimize joint‐torques.

The study shows that the flexible redundant manipulator still has the second optimization feature on the premise of vibration suppression. The second optimization feature can be used to minimize joint‐torques on the premise of vibration suppression.

To a flexible redundant manipulator, its joint‐torques and vibration can be reduced simultaneously via its kinematics redundancy feature.

The method and algorithm discussed in the paper can be used to minimize joint‐torques and suppress vibration for the flexible redundant manipulator.

The paper contributes to the study on improving dynamic performance of the flexible redundant manipulator via its kinematics redundancy feature. The second optimization capability of the flexible redundant manipulator is discovered and used to both minimize joint‐torques and suppress vibration.