John Wen

Chen-Lung Lu, John Wen

Robotics Wire Arc Additive Manufacturing (WAAM) is governed by complex and nonlinear process dynamics coupling thermal field to the build geometry. The process may be regarded as a multi-input/multi-output dynamical system with welding torch speed and wire feed rate as inputs and weld bead deposition height and width as outputs. In this paper, we use the input/output data to learn a data-driven model and use it for weld planning and control. We show that a simple recurrent neural network architecture and one-step-ahead predictive control can improve the process performance in terms of height and width consistency. To account for the changing thermal conditions during the printing process, we update the learning model using prediction error from the previous layer. This adaptation step further improves the prediction accuracy and controller performance. Experiments on a robotic WAAM testbed with integrated line-scanner feedback significant improvements in height and width consistency compared to constant input and static model baselines. The proposed learning and adaptation framework provides a practical pathway toward robust, data-driven regulation of additive manufacturing processes.

Shuyang Chen, John Wen

Collaborative robots and space manipulators contain significant joint flexibility. It complicates the control design, compromises the control bandwidth, and limits the tracking accuracy. The imprecise knowledge of the flexible joint dynamics compounds the challenge. In this paper, we present a new control architecture for controlling flexible-joint robots. Our approach uses a multi-layer neural network to approximate unknown dynamics needed for the feedforward control. The network may be viewed as a linear-in-parameter representation of the robot dynamics, with the nonlinear basis of the robot dynamics connected to the linear output layer. The output layer weights are updated based on the tracking error and the nonlinear basis. The internal weights of the nonlinear basis are updated by online backpropagation to further reduce the tracking error. To use time scale separation to reduce the coupling of the two steps - the update of the internal weights is at a lower rate compared to the update of the output layer weights. With the update of the output layer weights, our controller adapts quickly to the unknown dynamics change and disturbances (such as attaching a load). The update of the internal weights would continue to improve the converge of the nonlinear basis functions. We show the stability of the proposed scheme under the "outer loop" control, where the commanded joint position is considered as the control input. Simulation and physical experiments are conducted to demonstrate the performance of the proposed controller on a Baxter robot, which exhibits significant joint flexibility due to the series-elastic joint actuators.