Linear accelerometers and rate gyros for rotary joint angle estimation of heavy-duty mobile manipulators using forward kinematic modeling

A gravity-referenced joint angle estimation approach is proposed for multiple-degree-of-freedom hydraulic manipulators. The approach is built solely upon easy-to-install linear accelerometers and angular rate gyroscopes to avoid physical contact to rotary joint mechanisms and the use of in-axis sensors. As a significant novelty, a comprehensive kinematics model for linear accelerations acting on the accelerometers during motion is associated with the well-known principles of complementary sensor fusion for the first time, which provides a practical solution for using the force of gravity as an angular reference while in fast motion. In experiments with a serial-link manipulator of a multiton off-road forestry vehicle, gyro-aided sensor fusion employing the kinematics model achieved a joint angle sensing error of less than ±1°, which translated to a centimeter end-effector positioning accuracy. This can be considered a significant result in view of the vibrations oscillating through the manipulator structure, coupled linear accelerations of linkage motion, and nonstatic interaction between the vehicle base and the terrain.