Accuracy improvement is an important research topic in the field of cable-driven parallel robots (CDPRs). One reason for inaccuracies of CDPRs are deviations in the cable lengths. Such deviations can be caused by the elongation of the cable due to its elasticity or creep behavior. For most common CDPRs, the cable lengths are controlled using motor encoders of the winches, without feedback about the actual elongation of the cables. To address this problem, this paper proposes a direct cable length measurement sensor based on a laser distance sensor. We present the mechanical design, the first prototype and an experimental evaluation. As a result, the measurement principle works well and the accuracy of the measured cable lengths is within −2.32 mm to +1.86 mm compared to a range from −5.19 mm to +6.02 mm of the cable length set with the motor encoders. The standard deviation of the cable length error of the direct cable length measurement sensor is 58% lower compared to the one set with the motor encoders. Equipping all cables of the cable robot with direct cable length measurement sensors results in the possibility to correct cable length deviations and thus increase the accuracy of CDPRs. Furthermore, it enables new possibilities like the automatic recalibration of the home pose.

This paper proposes a hybrid position–force control strategy for overconstrained cable-driven parallel robots (CDPRs). Overconstrained CDPRs have more cables (m) than degrees of freedom (n), and the idea of the proposed controller is to control n cables in length and the other $m-n$ ones in force. Two controller implementations are developed, one using the motor torque and one using the motor following-error in the feedback loop for cable force control. A friction model of the robot kinematic chain is introduced to improve the accuracy of the cable force estimation. Compared to similar approaches available in the literature, the novelty of the proposed control strategy is that it does not rely on force sensors, which reduces the hardware complexity and cost. The developed control scheme is compared to classical methods that exploit force sensors and to a pure inverse kinematic controller. The experimental results show that the new controller provides good tracking of the desired cable forces, maintaining them within the given bounds. The positioning accuracy and repeatability are similar those obtained with the other controllers. The new approach also allows an online switch between position and force control of cables.

Training ship crews for new scenarios at sea in reproducible sea conditions is weather-dependent and dangerous. The Maritime Research Institute Netherlands (MARIN) addresses this issue by offering a variety of different simulators to safely train people onshore. For scenarios involving a swinging hook or a ladder for a pilot boarding a ship in turbulent sea conditions, a safe cable-driven parallel robot, the IPAnema Safe, is developed. Its safety features allow its platform to move above people during training scenarios. Therefore, in addition to standard safety features and a proper mechanical design, the safety functions Safely Limited Position (SLP) and Safely Limited Speed (SLS) for a cable-driven parallel robot are implemented on safety-certified hardware with Performance Level e (PL e). This work presents the design process and implementation of the IPAnema Safe, focusing on its layout, winches, platform optimization and functional safety features.