Design and Prototype of Variable Gravity Compensation Mechanism

Paper:

Design and Prototype of Variable Gravity Compensation

Mechanism (VGCM)
Naoyuki Takesue∗ , Takashi Ikematsu∗ , Hideyuki Murayama∗∗ , and Hideo Fujimoto∗∗∗
∗ Tokyo Metropolitan University
6-6 Asahigaoka, Hino-shi, Tokyo 191-0065, Japan
E-mail: [email protected]
∗∗ Toyota Motor Corporation, Japan
∗∗∗ Nagoya Institute of Technology, Japan

[Received October 1, 2010; accepted January 27, 2011]

A machine moving vertically requires strong grav- has been proposed [9]. Even with this, however, spring
itational resistance. Gravity compensation mecha- mass is transferred too far to be negligible if springs are
nisms devised to reduce actuator force mostly com- large and heavy.
pensate for constant weight, but practical use requires Another way of improving robustness without using
that the mechanism compensate for weight variations. wires and without changing the Center Of Gravity (COG)
This paper presents a Variable Gravity Compensa- of spring by positioning is a gravity compensation mech-
tion Mechanism (VGCM) that uses two types of linear anism using cams and springs [10–12]. Cams appro-
springs and changes the equilibrium position of one. priately predesigned ensure a certain degree of gravita-
The mechanism principle is described and the proto- tional compensation regardless of positioning, but differ-
type is designed. Performance is experimentally con- ent cams are required for differing gravity.
firmed. A constant repulsive force spring model using two
types of springs has been proposed for the pantograph
mechanism [13, 14], applying spring force to cope with
Keywords: gravity compensation, mechanism, spring, horizontal and vertical displacement. It is adapted to
balance, weight nearly constant gravity by adjusting parameters. A sim-
ilar method is a gravitational balancer using two types of
springs fixed at one end to the robot arm at a 90◦ phase
1. Introduction difference in rotation axis [15]. It is identical in principle
to the pantograph mechanism and balancing is achieved
Machines involved in vertical component movement for nearly constant weight.
against gravitation require actuators large enough to sus- Most of these proposed gravitational compensation
tain their own gravity. Therefore, mechanisms capable of mechanisms are not designed, however, to handle grav-
compensating for gravitation have been devised to reduce ity variations, and fail to balance gravity, causing exces-
actuator size. sive loads on motors if gravity changes from that in design
Simply constructed counterweights invariably increase specifications or if work mass varies widely. Gravity com-
in size and construction in handling heavy loads, and are pensation methods able to cope with gravity variation by
poorly suited to acceleration and deceleration due to large shifting bearing points [16] based on the principle in [1–
inertia around bearings. 3], however, use wires compromising robustness.
Simple spring balancers require springs selected appro- We propose a Variable Gravity Compensation Mech-
priately for stiffness, length, expansion, contraction, etc. anism (VGCM) that copes with variable gravity without
If heavy gravity must be compensated for, spring mass be- using wires or being adversely affected by positioning.
comes too large to be negligible, potentially causing too Section 2 describes the principle that enables compen-
much variation in compensation, depending on machine sation for constant gravity regardless of positioning, at
positioning – when springs are selected appropriately [1– which point variable gravity can be handled without a
3], the moment of inertia does not increase much, ensur- problem. Our proposed VGCM uses two types of springs
ing good equilibrium for any machine positioning. One with a 90◦ phase difference in the same way as [13–15],
approach to compensation not depending on machine po- but it is adaptable to variable gravity by deriving complete
sitioning uses a pantograph mechanism with springs at balancing conditions. Section 3 describes configurations
the bottom [4]. A certain degree of gravity compensa- and prototype design actually implemented based on this
tion does not depend on machine positioning if pulleys basic principle. Unique features of our proposed proto-
are appropriate [5–8], but heavy gravity somewhat de- type are that joint angles respond to multiple rotations
creases stiffness and robustness, perhaps due to wires. up to 360◦ . Section 4 confirms features through experi-
To improve machine reliability in response to these con- ments. Section 5 summarizes the VGCM and its projected
cerns, using an oscillating block slider crank mechanism prospects.

Journal of Robotics and Mechatronics Vol.23 No.2, 2011 249

Takesue, N. et al.

Original position Original position

l
θ l’B = lB(β —1)
θ
lB kB
mg mg
lA fB
O: Rotation axis kA O: Rotation axis
y B
fA B
x A
A

Fig. 1. Gravity compensation mechanism concept.

Fig. 2. VGCM concept.

2. VGCM
A comparison with gravity torque expressed by Eq. (1)
2.1. Principle Compensating for Constant Gravity shows that total spring torque and gravity torque are bal-
In this section, we explain a principle in which the anced if C = mgl.
gravity compensation mechanism using two types of In this principle, two types of springs are arranged on a
springs with a 90◦ phase difference is completely bal- 90◦ phase the same as [13, 14], while two types of springs
anced against constant gravity. Fig. 1 shows the con- are arranged almost parallel and fitted to the arm in a 90◦
cept, in which mass m is concentrated at the forward link phase in [15]. No specific conditions are provided to bal-
length l away from the rotation axis. A and B denote ance gravity torque completely in [13–15]. We establish
points lA and lB away from the rotation axis on the straight conditions under which gravity torque is completely bal-
link line. θ denotes the angle at which the link is rotated. anced.
Torque produced by gravity is expressed as follows:
τg = mgl sin θ . . . . . . . . . . . . . (1) 2.2. Variable Gravity Compensation Principle
Gravity torque is compensated for if torque generated by Having explained methods for balancing constant grav-
spring balances the gravity-induced torque above. ity, we propose compensating for variable gravity as fol-
To return the link to initial positioning (θ = 0), force fA lows.
is applied horizontally and fB vertically to the link at To add initial tension to spring force at Point B, the
Points A and B, then horizontal displacement x of Point A equilibrium point is shifted by lB = lB (β − 1), as shown
and vertical displacement y of Point B are expressed as in Fig. 2, and Spring B tension is expressed by Eq. (11)
follows: and total torque by Eq. (12):

x = lA sin θ . . . . . . . . . . . . . . (2) fy = kB lB (β − cos θ ) . . . . . . . . . . (11)

y = lB (1 − cos θ ). . . . . . . . . . . (3) τk = Cβ sin θ . . . . . . . . . . . . . (12)
Derived spring force is as follows: where β = 1 denotes lB = 0 corresponding to original
gravity m. When for example β = 2, initial displacement
fA = kA x = kA lA sin θ . . . . . . . . . . (4) becomes lB = lB , enabling the gravity to be handled to be
fB = kB y = kB lB (1 − cos θ ). . . . . . . . (5) twice as large as m. This gravity is adjusted by chang-
Torque produced by spring force around rotation axis is ing initial displacement (equilibrium point), as shown in
obtained as follows: Fig. 2.
It is also possible to vary the gravity to be handled
τA = kA lA2 sin θ cos θ . . . . . . . . . . . (6) by shifting spring bearing positions [16], but using wires
τB = kB lB2 (1 − cos θ ) sin θ . . . . . . . . (7) raises concerns, requiring that we account for a COG shift
due to spring deformation. To compensate for gravity us-
Total torque thus produced is obtained as follows: ing counterweights, large (heavy) weights must be moved,
τk = kA lA2 sin θ cos θ + kB lB2 (1 − cos θ ) sin θ . (8) making machine large and complex. Our proposal, in con-
trast, achieves the variable gravity compensation mecha-
Total torque is expressed as following Eq. (10), assuming nism simply by shifting spring end points.
that Eq. (9) conditions are met:
kA lA2 = kB lB2 = C . . . . . . . . . . . . (9)
τk = C sin θ . . . . . . . . . . . . . . (10)

250 Journal of Robotics and Mechatronics Vol.23 No.2, 2011

 Design and Prototype of Variable Gravity Compensation Mechanism

5
Table 1. Prototype specification.

Torque [Nm]
τA
m 0.952 kg
0
β 1∼3.2
l 0.3 m
lA , lB 0.01 m τg
τB
kA , kB 2.8 × 104 N/m −5
0 1 2
Angle θ [π rad]
3. Prototype Design
Fig. 3. Torque simulation.
3.1. Prototype Specifications
We design our prototype under the conditions: weight
mass m = 1–3 kg and link length l = 0.3 m. With base 20
β : 1 −> 1.5
wB
wg
mass m = 1 kg and link length lA = lB = 0.01 m, spring

Load [N]
stiffness meeting conditions in Eq. (9) is calculated as fol- 10
lows:
0
mgl
kA = kB = 2 = 29400 [N/m]. wA
lA −10

Then, at 0 ≤ θ ≤ π , maximum spring displacement be- 0 1 2

comes sA = lA = 0.01 m and sB = 2lB = 0.02 m. To adapt Angle θ [π rad]
the prototype up to m = 3 kg, the equilibrium point of
Spring B must be shifted by lB = 2lB , requiring the pro- Fig. 4. Load force simulation.
totype to have total allowable displacement sB = 4lB =
0.04 m.
We decided to use two springs (MISUMI Corp.,
SWU26-35), 0.035 m in natural length, 0.021 m in al- Force wB borne by Spring B is expressed as follows:
lowable displacement and k̄A = 1.4 × 104 N/m in elastic
coefficient, for Spring A, and two springs (MISUMI Corp, kB lB2
wB = (β − cos θ ). . . . . . . . . (15)
SWU43-70), 0.07 m in natural length, 0.042 m in allow- l
able displacement and k̄B = 1.4 × 104 N/m in elastic co- The relationship among these elements is shown in
efficient, for Spring B because of spring conformity with Fig. 4, in which wA is denoted by a dotted line, wB , by
the above requirements. a broken line, and wg , by a heavy broken line. When
With these springs, actual base mass is: Spring B equilibrium point is shifted from β = 1 to β =
kA lA2 1.5, for example, wg changes from the heavy broken line
m=  0.952 [kg]. to the dot-dash line.
gl
For an allowable displacement of 0.042 m, maximum
gravity compensated for is 3.05 kg. Table 1 gives pro- 3.3. Prototype
totype specifications.
The principle scheme (Fig. 5(a)) shows spring force ap-
plied directly to Points A and B on the link. In actual
3.2. Sharing of Compensation by Positioning implementation, however, force is applied by springs con-
strained to a single Degree Of Freedom (DOF) to the table
Our proposed gravity compensation mechanism has contacting followers at Points A and B. Even using these
two types of springs to share required compensation. We followers, no displacement difference occurs at Points A
checked through simulation how such sharing is changed and B or on the table contacting followers (Fig. 5(b)), en-
by positioning θ . suring that the gravity compensation principle is applica-
Based on design values (specifications) above, Eqs. (1), ble as is.
(6), and (7) are denoted by graphs in Fig. 3. Figure 5(b) shows implementation with relatively
Torque is converted to vertical force at the forward end small followers. When θ is small, no problems arise,
of the arm, so the gravity to be compensated for is ex- but when the range of movement is large, interference oc-
pressed as follows: curs between the table for Spring B and the rotation axis.
wg = mg = C/l = wA + wB . . . . . . . . (13) Alternative use of a larger follower containing the rota-
tion axis invariably positions the table for Spring B above
Force wA borne by Spring A is expressed as follows: the rotation axis, so no interference arises with the rota-
kA lA2 tion axis, ensuring the large movement range shown in
wA = cos θ . . . . . . . . . . . . (14) Fig. 5(c).
l

Journal of Robotics and Mechatronics Vol.23 No.2, 2011 251

Takesue, N. et al.

Original position

lB(β —1) θ

kB mg
kA O: Rotation axis
y
A, B
x

(a) Principle scheme

Original position

θ
Fig. 6. VGCM configuration.
mg
y
y O
A, B
x
x

(b) Implementation scheme with small follower

Original position

y mg

y O
A,B
Fig. 7. VGCM prototype.
x x

(c) Implementation scheme with large follower

Fig. 5. VGCM implementation.

Figure 6 shows the VGCM prototyped under the above θ = 0 [rad] θ = π/4 [rad] θ = π/2 [rad]
specifications, together with major dimensions. The main
material is stainless steel, weighs 7.5 kg. Fig. 7 shows the
prototype VGCM and its CAD assembly plan.
The prototype uses an eccentric follower with the ro-
tation axis inside. Since rotation speed of followers on
tables differ between Springs A and B, two followers are
concentrically arranged side by side. Tables contacting
followers are constrained to single-DOF motion by the θ = 3π/4 [rad] θ = π [rad] θ = 5π/4 [rad]
linear guide, and spring force is applied to the opposite
side of the table contacting followers. Springs are retained Fig. 8. VGCM schematic.
by the holder so that they are not dislocated. Spring B’s
table motions are constrained to single DOF by the linear
guide at the top of Spring B. Spring B’s equilibrium point Fig. 8 schematically diagrams the device during rotation.
is shifted by rotating the knob at the top of the device and Geared actuator (Harmonic Drive Systems Inc., RH-
moving the table. Arranging Spring A on each side of 11-6001) and encoder (Canon Marketing Japan Inc.,
the rotation axis enables rotating the device 360◦ (Fig. 6). TR-1) are connected to the rotation axis on the opposite

252 Journal of Robotics and Mechatronics Vol.23 No.2, 2011

 Design and Prototype of Variable Gravity Compensation Mechanism

5
Spring A

Torque [Nm]
0

−5
0 1 2
Angle θ [π rad]

Fig. 11. Spring torque with Spring A.

5
Fig. 9. Side view of VGCM.
Spring B

Torque [Nm]
2
0
Torque [Nm]

0
−5
0 1 2
Angle θ [π rad]
−2 Fig. 12. Spring torque with Spring B.
0 1 2
Angle θ [π rad]

Fig. 10. Motor torque with followers and arm.

5
Total (A+B)
Torque [Nm]

side of the arm as shown in Fig. 9. Design specifications 0

allow for compensation of gravity up to 3 kg, but evalua-
tion experiments, which follow, are limited to gravity up
to 2.5 kg due to maximum motor torque.
−5
0 1 2
Angle θ [π rad]
4. Experiments
Fig. 13. Spring torque with Springs A and B.
Inexperiments, the axis is rotated 360◦from 0 rad (ver-
tically upright) clockwise in 12 s at a constant speed of
30◦ /s = π /6 rad/s by angular motor control. It is rotated
anticlockwise back to the original position at the same 0.01 m to the opposite side of the arm, mass m f of follow-
constant speed as clockwise rotation. Angles and motor ers produces a gravitational torque of τ f = −m f glA sin θ .
torque are measured during link rotation. Combined torques acts on the rotation axis as gravity
(basic features), so motor torque in Fig. 10 denotes a grav-
itational torque of −0.2 sin θ [N·m] as opposite sinusoidal
4.1. Basics torque. In experiments, a weight of 1–2.5 kg is fitted at the
Figure 10 shows angles and motor torque when the axis forward end of the arm (l = 0.3 m) to cause gravitational
is rotated using only with followers and an arm is installed torque of 3–7.5 N·m.
(or in a spring-less state). Filled circles denote data for Any clockwise and anticlockwise rotation difference
clockwise rotation and open circles data for anticlockwise in torque is attributed to friction. Frictional torque of
rotation. 0.5 N·m is observed in clockwise rotation and of 0.4 N·m
Sinusoidal waveforms denote gravitational torque due in anticlockwise rotation. Torque produced by springs is
to arm and follower eccentricity. With an arm length of estimated from motor torque from which frictional torque
l = 0.3 m and the COG at 0.15 m or half the length of was deducted.
the arm, arm mass ma produces a gravitational torque of Experimental results using one or more springs are
ma gl shown in Figs. 11–13. Fig. 11 shows results for Spring A
τa = sin θ . only, Fig. 12 for Spring B only, and Fig. 13 for both
2
With the center of followers displaced by lA = lB = springs. Filled circles denote clockwise and open circles

Journal of Robotics and Mechatronics Vol.23 No.2, 2011 253

Takesue, N. et al.

5 5
Weight: 1 [kg] Weight: 1 [kg] β = 1.0
Torque [Nm]

Torque [Nm]
With compensation (β = 1)

0 0

Without compensation

−5 −5
0 1 2 0 1 2
Angle θ [π rad] Angle θ [π rad]
5
Fig. 14. Motor torque while 1 kg is rotating. Weight: 1.5 [kg] β = 1.5

Torque [Nm]
5 0
Weight: 2 [kg]
Torque [Nm]

With compensation (β = 2)

0 −5
0 1 2
Angle θ [π rad]
5
With compensation (β = 1)
Weight: 2 [kg] β = 2.0
−5

Torque [Nm]
0 1 2
Angle θ [π rad]
0
Fig. 15. Motor torque while 2 kg is rotating.

−5
0 1 2
anticlockwise rotation. Data corresponds to gravitational Angle θ [π rad]
compensation torque τA , τB, , and τk by springs. 5
Although some difference in results exists between ro- Weight: 2.5 [kg] β = 2.5
Torque [Nm]

tational directions, features similar to simulation results

denoted by a gray broken line in Fig. 3 are realized.
0

4.2. Reduction in Motor Load due to Gravitational

Compensation
−5
Having confirmed that gravitational compensation by 0 1 2
springs is possible when equilibrium point β = 1.0, we Angle θ [π rad]
rotate a device weighing 1 kg fitted at the forward end
of the arm 0.3 m away from the rotation axis. Fig. 14 Fig. 16. Motor torque with differing equilibrium with equiv-
shows motor torque by circles without springs fitted – no alent weight.
gravitational compensation – and that by squares when
springs are fitted to compensate for gravity.
With gravitational torque produced by weight of 3 N·m
and frictional torque of the actuator 0.5 N·m, peak motor Figure 16 shows motor torque required to rotate de-
torque is 3.5 N·m without compensation. vices weighting 1, 1.5, 2.0, and 2.5 kg corresponding to
When springs compensate somewhat for gravitation, β = 1, 1.5, 2.0, and 2.5. Results confirm that the device is
torque falls within 1 N·m or less regardless of position- rotated with almost constant torque of 1–2 N/m. A weight
ing (angles), indicating that motor load is reduced. of 2.5 kg generally requires a peak torque of 7.5 N·m
We rotate a device weighing 2 kg fitted at the forward to manage gravitational torque, but our proposed device
end of the arm. Rotating the device with equilibrium point demonstrates that it can be driven by torque one-fifth of
β = 1.0 produced the results shown by circles in Fig. 15. that.
1 kg of the 2 kg weight has been compensated for with the
remaining 1 kg managed by compensatory motor torque.
Rotating the device with the equilibrium point shifted to 4.3. Variations in Compensation Torque due to
β = 2 corresponding to 2 kg produced results shown by Equilibrium Shift
squares in Fig. 15, confirming that the device is driven Having confirmed gravitational compensation effects,
by motor torque of 1–1.5 N·m as in using a 1 kg weight we show compensation torque of springs in Fig. 17 when
(Fig. 14). the device is rotated at different equilibria of springs at

254 Journal of Robotics and Mechatronics Vol.23 No.2, 2011

 Design and Prototype of Variable Gravity Compensation Mechanism

10 5
β = 1.0 β = 1.0
Torque [Nm]

Torque [Nm]
0 0
30 [deg/s]
60 [deg/s]
120 [deg/s]
180 [deg/s]
−10 −5
0 1 2 0 1 2
Angle θ [π rad] Angle θ [π rad]
10
β = 1.5
Fig. 18. Motor torque with differing velocity.
Torque [Nm]

(thin broken line), and 180◦ /s (heavy solid line). The gray
broken line denotes design values.
−10 Figure 18 demonstrates that motor load torque in gen-
0 1 2
Angle θ [π rad] eral increases with rotation speed. Incremental load
10 torque in line with speed suggests that the load torque in-
β = 2.0 crease is due to viscous friction. The lack of substantial
change in sinusoidal waveforms suggests that increase in
Torque [Nm]

load torque only negligibly affects gravitational compen-

0 sation for springs.
Experimental results thus show some increase in load
torque due to viscous resistance, limited to within 1 N·m
−10 at maximum at any rotation speed up to 180◦ /s, in turn
0 1 2 demonstrating that our proposed device reduces gravita-
Angle θ [π rad] tional torque considerably for the motor.
10
β = 2.5
Torque [Nm]

5. Conclusions
0
Our research outcome is summarized as follows:

(1) We have devised and explained the principle of a

−10 gravity compensation mechanism that handles vari-
0 1 2
able gravity using Springs A and B with differing
Angle θ [π rad]
equilibrium points for Spring B.
Fig. 17. Spring torque with differing equilibrium. (2) We have designed and prototyped a gravity com-
pensation mechanism making multiple rotations and
easily altering gravity.
β = 1, 1.5, 2.0, and 2.5. Filled circles denote data for (3) We have confirmed through evaluation experiments
clockwise and open circles data for anticlockwise rota- on the prototype that gravity compensation was real-
tion. The gray broken line denotes design values. Fig. 17 ized as designed.
confirms that compensation torque varies with the equi-
librium shift as designed. (4) We have confirmed through experiments that motor
load torque is considerably reduced even under sig-
4.4. Variations in Motor Torque due to Rotation nificant gravity.
Speed The device we have introduced here requires further
Having conducted experiments relatively slowly, i.e., study for miniaturization and lighter weight. This mech-
one round rotation in 12 seconds (30◦ /s), we examine pos- anism is expected to be applied to multi-DOF robots.
sible effects of differing rotation speed. Fig. 18 shows In such serial applications, miniaturization and lighter
motor torque when the device is rotated without load with weight must be addressed. Other possible applications
equilibrium β = 1.0 at 30◦ /s, 60◦ /s, 120◦ /s, and 180◦ /s. include: multiaxial robot arms with horizontal and lift-
Fig. 18 shows data corresponding to rotation speed of ing axes with our proposed VGCM built in, multi-DOF
30◦ /s (heavy dotted line), 60◦ /s (thin solid line), 120◦ /s parallel-link robots, and energy-saving lifts.

Journal of Robotics and Mechatronics Vol.23 No.2, 2011 255

Takesue, N. et al.

Acknowledgements
We thank Mr. Fujiwara of Toyota Motor Corporation and Messrs. Name:
Ochiai, Komiya, and Nakano of Ochiai Nexus Corporation for Naoyuki Takesue
inspiring and motivating our research.
Affiliation:
Associate Professor, Faculty of System Design,
Tokyo Metropolitan University
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Brief Biographical History:
2009- Master Student, Graduate School of System Design, Tokyo
Metropolitan University

256 Journal of Robotics and Mechatronics Vol.23 No.2, 2011

 Design and Prototype of Variable Gravity Compensation Mechanism

Name:
Hideyuki Murayama

Affiliation:
Toyota Motor Corporation

Address:
1 Toyota-cho, Toyota, Aichi 471-8571, Japan
Brief Biographical History:
1997- Joined Production Engineering Center, Mitsubishi Electric
Corporation
2003- Joined Production Engineering Development Div., Toyota Motor
Corporation
2005- Partner Robot Div., Toyota Motor Corporation
2011- Production Engineering Development Div., Toyota Motor
Corporation
Main Works:
• K. Kosuge and H. Murayama, “Teleoperation via Computer Network,”
Electrical Engineering in Japan, Vol.124, No.3, pp. 49-56, 1998.
• “Human-robot collaboration in precise positioning of a
three-dimensional object,” Automatica (Journal of IFAC), Vol.45, Issue 2
February 2009.
• “Kinesthetic Assistance for Improving Task Performance – The Case of
Window Installation Assist –,” Int. J. of Automation Technology, Vol.3,
No.6, pp. 663-670, 2009.
Membership in Academic Societies:
• Robotics Society of Japan (RSJ)

Name:
Hideo Fujimoto

Affiliation:
Professor, Graduate School of Engineering,
Nagoya Institute of Technology

Address:
Gokiso-cho, Showa-ku, Nagoya-shi, Aichi 466-8555, Japan
Brief Biographical History:
1972- Research Associate, Nagoya Institute of Technology
1977- Assistant Professor, Nagoya Institute of Technology
1982- Associate Professor, Nagoya Institute of Technology
1993- Professor, Nagoya Institute of Technology
Main Works:
• “Development of Multi-Fingered Hand for Telepresence Based on
Tactile Information,” Trans. of the Society of Instrument and Control
Engineers, Vol.40, No.2, pp. 164-171, 2004. (Excellent Paper Award)
• “Network-based Micro Teleoperation,” Proc. of 2000 Japan-USA
Symposium on Flexible Automation, Vol.13044, No.1-6, 2000. (Best
Paper Award)
Membership in Academic Societies:
• Japan Society of Mechanical Engineers (JSME)
• Scheduling Society of Japan (SSJ)
• Society of Instrument of Control Engineers (SICE)
• Robotics Society of Japan (RSJ)

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