In this paper, a new robust fault detection technique for robotic manipulators is developed. The new approach, called robust nonlinear analytic redundancy (RNLAR) technique, detects both sensor and actuator faults in a robotic manipulator The proposed RNLAR technique can compensate for the effects of model-plan-mismatch (MPM) and process disturbance. A nonlinear primary residual vectors (PRV) design method to detect faults is proposed where the PRVs are highly sensitive to faults and less sensitive to MPM and process disturbance. Experimental results on a PUMA 560 are presented to justify the effectiveness of the RNLAR scheme.
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