Transfer Learning Approach for Estimating Modal Parameters of Robot Manipulators Using Minimal Experimental Data

Robots are used more and more in manufacturing, especially in tasks like robotic machining, where understanding their vibration behavior is very important. However, robot vibrations vary with posture, and evaluating all representative postures requires significant time and cost. This study proposes a deep learning (DL) based transfer learning (TL) approach to predict robot vibration behavior using fewer experiments. A large dataset was collected from a KUKA KR300 robot (Robot A) by testing nearly 250 postures. This dataset was then used to train a model to predict modal parameters such as natural frequencies (ω_n), damping ratios (ξ), and modal stiffness (k) within the workspace. TL was then used to apply the knowledge from Robot A to two other robots: a Comau NJ 650-2.7 (Robot B, high-payload) and an ABB IRB 4400 (Robot C, low-payload). Only a small number of postures were tested for Robots B and C. They were chosen carefully to cover different workspace areas and avoid collisions. Hammer tests were performed, and a four-step process was used to identify the real vibration modes. Stabilization diagrams were applied to confirm valid modes and remove noise. The results show that TL can accurately predict modal parameters for both Robot B and Robot C, even with limited data. These predictions were also used to estimate frequency response functions (FRFs), which matched well with experimental results. The main novelties of this work are: achieving accurate prediction of posture-dependent dynamics using minimal experimental data, demonstrating generalization across robots with different payload capacities, and revealing that data coverage across the workspace is more critical than dataset size.