Professional Documents
Culture Documents
REGULAR PAPER
Abstract
This paper proposes a novel multi-wound differential pulley winch (MWDPW) component for assisting the ascending/
descending operations of a wall climbing robot. The robotic platform enabling rope access in dangerous environments (ROPE
RIDE) climbs vertical walls using a rope and embedded winch. The original winch installed on the ROPE RIDE was a single
wound winch, which had problems such as rope slip, velocity ripple during descending motion, resulting the bad cleaning
performance and unstable motion on the wall. These problems are mainly due to the concentration of traction force on the
rope because a small portion of the winch pulley holds the entire weight of the robot. Therefore, we have developed a new
winch, MWDPW, by using multi-wound differential traction pulley and pressure rollers to solve the traction force concentra-
tion problem by distributing the traction force along the entire wrapping angle. Compared to other multi-wound winches, the
MWDPW has the special feature of a differential gear and pressure roller to distribute the traction force and minimize the
rope slip. The tension of the MWDPW is analyzed using the basic capstan equation, and empirical results to minimize the
rope slip are presented by varying design parameters such as the winding method and presence of the pressure rollers. We
expect the proposed mechanism to improve the safety of a wall-climbing robot for wall-cleaning operations.
13
Vol.:(0123456789)
International Journal of Precision Engineering and Manufacturing
Fig. 2 Mechanism of rope slip in SWW. The rope of Tfree enters the pulley and the error generates rope slip at Ttension
0.6 0.15
(a) 0.5 (b) 0.1
(c)
0.4 0.05
0.3 0
Veloity (m/s)
Height (m)
0.2 -0.05
0.1 -0.1
0 -0.15
-0.1
Reference Rope-slip -0.2
Measured
-0.2 -0.25
-10 0 10 20 30 40 50 60 0 10 20 30 40 50 60
Time (s) Time(s)
High ripple
in descending
Fig. 3 a Experimental setup to measure the rope slip and velocity ripple, b the position of two repeated ascending and descending operations,
and c the velocity data of the experiment
13
International Journal of Precision Engineering and Manufacturing
capstan winch product specifically used for sailboats [7]. guide mechanism divides the drum surface into the trac-
This kind of traditional capstan winch always has side- tion zone and transition zone, unlike the traditional winch,
ways slip along the drum-axis direction. The slip direction which has a single mixed zone in which traction and transi-
changes according to the direction of drum rotation. The tion occur simultaneously. The special drum called the “ani-
rope coils push each other to one side of the rotating drum sotropic friction drum” is proposed to increase the friction in
so that the rope inlet or outlet is pushed away from the drum. the tangential direction and decrease the friction in the axial
Therefore, there are flanges at either side to prevent the rope direction because the rope should slip in the axial direction
from slipping out. in the transition zone.
There is a famous capstan type MWW called the “power The double-drum winch is another popular MWW type.
ascender” [5]. The distinct component of the winch is the Each drum has multiple grooved surfaces and the rope is
rope guide mechanism, which has small rollers between the wound around two drums. The rope can move from one
rope to change direction of rope on the drum surface. The groove to the other between the two drums. There is no
13
International Journal of Precision Engineering and Manufacturing
sideways slip because the grooved surface prevents the rope the paper is organized as follows. Section 2 describes the
from moving in the axial direction and one drum functions proposed MWDPW design in detail. Section 3 presents the
as a guide mechanism for the other drum [9]. Tension is theoretical foundation for the MWDPW design. Section 4
gradually accumulated along the rope and the relative veloc- provides the design of experiment on rope-slip and velocity
ity between the rope and drum increases because the elonga- ripple minimization by varying several design parameters,
tion of the rope is proportional to the tension. This causes such as the winding method and presence of pressure rollers,
heat on the surface of the drum and rope abrasion. This is the and the rope-slip optimization results are presented.
common phenomenon of all the MWW. There are improved
double-drum winches to reduce the relative velocity with the
grooved ring, which have the same elongation rate as the 2 Mechanical Design of MWDPW
rope [10] and torque control between the two drums [11].
The cable traction control unit (CTCU) is an advanced Figure 4 shows the mechanical design of the proposed
type of MWW that is used to deploy fiber rope for deep- MWDPW. In Fig. 4a, the ROPE RIDE design with two
water installation in the offshore industry. There are two embedded MWDPWs is shown and the MWDPW design
main features of this mechanism. One is the active load dis- is shown in detail in Fig. 4b. The MWDPW is composed of
tribution, as this mechanism can distribute the load between three traction pulleys, three pressure rollers, a geared motor,
the pulleys so as not to exceed the physical limitations of and a rope. The traction pulley is located in series and has
each pulley. The other is slip control. The rotational speed a V-groove to increase the traction force. Three pressure
of each pulley can be controlled to reduce the accumulated rollers are located at each traction pulley and can indepen-
slip due to rope elongation [12]. However, there must be dently press the ropes to the traction pulleys. The pressure
the same number of motors as there are pulleys to be driven rollers can be easily assembled and disassembled by a pin
individually. This CTCU mechanism cannot be directly connection, which makes winding and unwinding the rope
applied to the platform robot because of its complexity. and adjusting the pressure force easy.
The developed MWDPW has three special features to One important component of the MWDPW is the differ-
distribute the traction force well and minimize the rope-slip ential gear between the traction pulleys. Figure 5 shows the
compared to the aforementioned SWW and MWW. The internal design of the traction pulleys. As shown in Fig. 5,
first is the rope-guided mechanism. Although the function the three traction pulleys are connected by the differential
of this mechanism is the same as that of a power ascender, gear mechanism. The differential gear modulates the rota-
the detailed structure is quite different. The MWDPW can tion of each traction pulley such that the rotation of the three
have three traction pulleys because of the guide mechanism traction pulleys is mechanically controlled to have little dif-
that detaches the rope from the traction pulleys so that the ference in the rotational angle. This differential gear mecha-
traction pulleys are not exposed to sideways slip. The power nism has an important role to distribute the traction force
ascender requires a specially designed drum to produce trac- equally and minimize the rope slip.
tion and sideways slip simultaneously. The second feature So far, the mechanical design of the proposed MWDPW
is the differential pulley mechanism for traction distribu- is introduced. It is very difficult to model the MWDPW
tion just like the CTCU. There is a differential gear assem- because it has many mechanical components and a compli-
bly inside each of the three pulleys. The differential pulley cated structure. In this paper, we introduce the theoretical
mechanism can distribute proper traction to the respective interpretation of the effect of the MWDPW design on the
pulley using only one driving motor. As mentioned before, traction force and slip angle briefly and attempt to determine
the CTCU requires several controlled driving motors to dis- the sensitivity of the design parameters through experimen-
tribute the load. The third feature is the multiple-pressure- tal validation.
roller mechanism. The pressure roller is an essential com-
ponent to produce the initial traction force so that the entire
traction force of one traction pulley can be accumulated 3 Theoretical Interpretation of the MWDPW
from the initial traction. Without the differential mechanism, Design
multiple pressure rollers increase the traction differences
between the pulleys, resulting in traction concentration. 3.1 Theoretical Background on Winch Modeling
This paper presents a novel MWDPW mechanism design
to reduce the rope-slip and velocity ripple of the climbing The basic capstan equation, which was derived by Euler in
robot for the safe wall cleaning operation. The effective- 1762, has become a basic tool for understanding both the
ness of three features which are guide, differential pulley, MWW and SWW [13]. There are there important assump-
multiple-pressure-roller is verified through experiment of tions in the equation. The first assumption is that the rope
the six design combination of three mechanism. The rest of radius is negligible compared to the capstan radius. Baser
13
International Journal of Precision Engineering and Manufacturing
Fig. 4 MWDPW design. a
Two MWDPWs with the new (a) (b) Geared motor
ROPE RIDE design and b the
MWDPW design configuration
Three traction
Rope pulleys
(free)
Pressure
Rope
rollers
(tensioned)
13
International Journal of Precision Engineering and Manufacturing
DC geared Pressure
motor rollers
Rope
Traction pulleys
0,
Angle Angle
3 3 2 2 1 1
13
International Journal of Precision Engineering and Manufacturing
13
International Journal of Precision Engineering and Manufacturing
Traction pulley 1
C1 C2 C3 C4
Active all traction pulleys
Triple winding
Winding method
C5 C6
Active 1,3 traction pulleys
Double winding
Fig. 10 Six possible design combinations for pressure rollers and traction pulleys with the winding method
0.500
0.500
0.446
0.427 0.0150
Standard deviation[m/s]
Average slip length [m]
Objective function
0.400 0.369
0.300 0.0100
0.0086 0.198
0.200 0.0073
0.0075
0.0064 0.0062 0.0050
0.0058 0.0060
0.100 0.0056
0.0042 0.0056 0.0045
0.0031
0.000 0.0000
C1 C2 C3 C4 C5 C6
Objective function Standard deviation Average slip length
13
International Journal of Precision Engineering and Manufacturing
Standard 0
C1 (Reference combination)
deviation [m/s] -0.02
Velocity [m/s]
-0.04
0.0086 -0.06
Average slip -0.08
-0.1
length [m] -0.12
0.0031 -0.14
Standard 0
C2
deviation [m/s] -0.02
Velocity [m/s]
-0.04
0.0075 -0.06
Average slip -0.08
-0.1
Triple Winding
C3 Velocity ripple
Standard 0
deviation [m/s] Velocity [m/s] -0.02
-0.04
0.0064 -0.06
Average slip -0.08
-0.1
length [m] -0.12
0.0056 -0.14
Standard 0
C4
-0.02
Velocity [m/s]
Standard 0
C5 (Best combination)
-0.02
Velocity [m/s]
Standard 0
C6
-0.02
Velocity [m/s]
established based on the experimental data presented in After building the prototype, experiments to determine the
this paper. The optimal design configuration and param- optimal combination of the traction and pressure rollers were
eters, such as the pressure force, are required to improve conducted. The proposed winch is expected to increase both
the performance. Finally, the MWPDW should be imple- the performance, in terms of velocity and position accuracy,
mented in the ROPE RIDE system and the climbing and and the safety during operation after this system is embed-
cleaning performance should be analyzed. ded in a wall-cleaning robot.
13
International Journal of Precision Engineering and Manufacturing
2. Liu, Y., & Seo, T. (2018). AnyClimb-II: Dry-adhesive linkage- Inho Joo received his B.S. degree
type climbing robot for uneven vertical surfaces. Mechanism and in Robotics from Kwang woon
Machine Theory, 124, 197–210. University in 2017, and M. S.
3. Lee, G., Kim, H., Seo, K., Kim, J., Sitti, M., & Seo, T. (2016). degree in Mechanical Engineer-
Series of multilinked caterpillar track-type climbing robots. Jour- ing at Seoul National University
nal of Field Robotics, 33(6), 737–750. in 2019. His research interests lie
4. Lee, C., & Chu, B. (2019). Three-modular obstacle-climbing robot in the areas of robot mechanism
for cleaning windows on building exterior walls. International design.
Journal of Precision Engineering and Manufacturing, 20(8),
1371–1380.
5. Seo, K., Cho, S., Kim, T., Kim, H. S., & Kim, J. (2013). Design
and stability analysis of a novel wall-climbing robotic platform
(ROPE RIDE). Mechanism and Machine Theory, 70, 189–208.
6. Kim, T., Jeon, Y., Yoo, S., Kim, K., Kim, H. S., & Kim, J. (2017).
Development of a wall-climbing platform with modularized wall-
cleaning units. Automation in Construction, 83, 1–18.
7. Anderson, F. (1986). U.S. Patent No. 4,595,173. Washington, DC: Jooyoung Hong received his B.S.
U.S. Patent and Trademark Office. degree in Mechanical Engineer-
8. Ball, N., Fofonoff, T., Schmid, B., & Walker, D. (2007). U.S. Pat- ing from Yonsei University in
ent No. 7,261,278. Washington, DC: U.S. Patent and Trademark 2018. He is currently working
Office. toward his M.S. degree in
9. Shafi, M. S., Lu, J., Song, Z., & Fu, Y. (2015). Design and tension Mechanical Engineering at Seoul
control of double drum Winch system for deep-sea exploration National University. His research
equipment. In Proceedings of the 5th International Conference interests lie in the areas of robot
on Information Engineering for Mechanics and Materials. mechanism design.
10. Blanc, M. R. (2007). U.S. Patent No. 7,175,163. Washington, DC:
U.S. Patent and Trademark Office.
11. McKenna, H. A. (1976). U.S. Patent No. 3,966,170. Washington,
DC: U.S. Patent and Trademark Office.
12. Torben, S. R., Ingeberg, P., Bunes, Ø., Bull, S., Paterson, J., &
Davidson, D. (2007). Fiber rope deployment system for ultradeep-
water installations. In Offshore Technology Conference.
13. Capstone equation. Retrieved July 9, 2018, from https://en.wikip
edia.org/wiki/Capstan_equation.
14. Baser, O., & Konukseven, E. I. (2010). Theoretical and experi- Jongwon Kim received the B.S.
mental determination of capstan drive slip error. Mechanism and degree in mechanical engineer-
Machine Theory, 45(6), 815–827. ing from Seoul National Univer-
15. Jung, J. H., Kang, T. J., & Youn, J. R. (2004). Effect of bending sity, Korea, in 1978, the M.S.
rigidity on the capstan equation. Textile Research Journal, 74(12), degree in mechanical and aero-
1085–1096. space engineering from the
16. Leamy, M. J., & Wasfy, T. M. (2002). Analysis of belt-driven Korea Advanced Institute of Sci-
mechanics using a creep-rate-dependent friction law. Journal of ence and Technology (KAIST),
Applied Mechanics, Transactions of ASME, 69(6), 763–771. Korea, in 1980, and the Ph.D.
degree in mechanical engineer-
Publisher’s Note Springer Nature remains neutral with regard to ing from the University of Wis-
jurisdictional claims in published maps and institutional affiliations. consin-Madison, USA, in 1987.
He is currently a Professor in the
School of Mechanical and Aero-
space Engineer ing, Seoul
Sungkeun Yoo received his B.S. National University, Korea. His
degree in Mechanical and Aero- current research interests include parallel mechanisms, Taguchi meth-
space Engineering from Seoul odology, and field robots.
National University in 2014. He
is currently working toward his
Ph.D. degree in Mechanical
Engineering at Seoul National
University. His research interests
lie in the areas of robot mecha-
nism design.
13
International Journal of Precision Engineering and Manufacturing
Hwa Soo Kim received the B.S. Mechanical Engineering, Yeungnam Univ., Korea. His research inter-
and Ph.D. degrees in Mechanical ests include robot design, analysis, control, optimization, and planning.
Engineering from Seoul National Dr. Seo received the Best Mechatronics Paper Award of the IEEE/
University, Korea, in 2000 and ASME Transaction on Mechatronics in 2014, and currently working
2006, respectively. He is cur- as a Technical Editor of IEEE/ASME Transaction on Mechatronics,
rently an Associate Professor at Associate Editor of IEEE Robotics and Automation Letters, and Intel-
the Department of Mechanical ligent Service Robots.
System Engineering, Kyonggi
University. From 2007 to 2008,
H e wa s a P o s t d o c t o r a l
Researcher at the Laboratory for
Innovations in Sensing, Estima-
tion and Control, University of
Minnesota, MN, USA. His cur-
rent research interests include
design, modeling and control of
various mobile platforms.
13