Artificial cognitive architecture with self-learning and self-optimization capabilities. Case studies in micromachining processes

Tesis doctoral inédita leída en la Universidad Autónoma de Madrid, Escuela Politécnica Superior, Departamento de Ingeniería Informática. Fecha de lectura : 22-09-201

Optimized state feedback regulation of 3DOF helicopter system via extremum seeking

In this paper, an optimized state feedback regulation of a 3 degree of freedom (DOF) helicopter is designed via extremum seeking (ES) technique. Multi-parameter ES is applied to optimize the tracking performance via tuning State Vector Feedback with Integration of the Control Error (SVFBICE). Discrete multivariable version of ES is developed to minimize a cost function that measures the performance of the controller. The cost function is a function of the error between the actual and desired axis positions. The controller parameters are updated online as the optimization takes place. This method significantly decreases the time in obtaining optimal controller parameters. Simulations were conducted for the online optimization under both fixed and varying operating conditions. The results demonstrate the usefulness of using ES for preserving the maximum attainable performance

System of Terrain Analysis, Energy Estimation and Path Planning for Planetary Exploration by Robot Teams

NASA’s long term plans involve a return to manned moon missions, and eventually sending humans to mars. The focus of this project is the use of autonomous mobile robotics to enhance these endeavors. This research details the creation of a system of terrain classification, energy of traversal estimation and low cost path planning for teams of inexpensive and potentially expendable robots. The first stage of this project was the creation of a model which estimates the energy requirements of the traversal of varying terrain types for a six wheel rocker-bogie rover. The wheel/soil interaction model uses Shibly’s modified Bekker equations and incorporates a new simplified rocker-bogie model for estimating wheel loads. In all but a single trial the relative energy requirements for each soil type were correctly predicted by the model. A path planner for complete coverage intended to minimize energy consumption was designed and tested. It accepts as input terrain maps detailing the energy consumption required to move to each adjacent location. Exploration is performed via a cost function which determines the robot’s next move. This system was successfully tested for multiple robots by means of a shared exploration map. At peak efficiency, the energy consumed by our path planner was only 56% that used by the best case back and forth coverage pattern. After performing a sensitivity analysis of Shibly’s equations to determine which soil parameters most affected energy consumption, a neural network terrain classifier was designed and tested. The terrain classifier defines all traversable terrain as one of three soil types and then assigns an assumed set of soil parameters. The classifier performed well over all, but had some difficulty distinguishing large rocks from sand. This work presents a system which successfully classifies terrain imagery into one of three soil types, assesses the energy requirements of terrain traversal for these soil types and plans efficient paths of complete coverage for the imaged area. While there are further efforts that can be made in all areas, the work achieves its stated goals

Control of deviations and prediction of surface roughness from micro machining of THz waveguides using acoustic emission signals

By using acoustic emission (AE) it is possible to control deviations and surface quality during micro milling operations. The method of micro milling is used to manufacture a submillimetre waveguide where micro machining is employed to achieve the required superior finish and geometrical tolerances. Submillimetre waveguide technology is used in deep space signal retrieval where highest detection efficiencies are needed and therefore every possible signal loss in the receiver has to be avoided and stringent tolerances achieved. With a sub-standard surface finish the signals travelling along the waveguides dissipate away faster than with perfect surfaces where the residual roughness becomes comparable with the electromagnetic skin depth. Therefore, the higher the radio frequency the more critical this becomes. The method of time-frequency analysis (STFT) is used to transfer raw AE into more meaningful salient signal features (SF). This information was then correlated against the measured geometrical deviations and, the onset of catastrophic tool wear. Such deviations can be offset from different AE signals (different deviations from subsequent tests) and feedback for a final spring cut ensuring the geometrical accuracies are met. Geometrical differences can impact on the required transfer of AE signals (change in cut off frequencies and diminished SNR at the interface) and therefore errors have to be minimised to within 1 µm. Rules based on both Classification and Regression Trees (CART) and Neural Networks (NN) were used to implement a simulation displaying how such a control regime could be used as a real time controller, be it corrective measures (via spring cuts) over several initial machining passes or, with a micron cut introducing a level plain measure for allowing setup corrective measures (similar to a spirit level)

Design of an intelligent embedded system for condition monitoring of an industrial robot

PhD ThesisIndustrial robots have long been used in production systems in order to improve productivity, quality and safety in automated manufacturing processes. There are significant implications for operator safety in the event of a robot malfunction or failure, and an unforeseen robot stoppage, due to different reasons, has the potential to cause an interruption in the entire production line, resulting in economic and production losses. Condition monitoring (CM) is a type of maintenance inspection technique by which an operational asset is monitored and the data obtained is analysed to detect signs of degradation, diagnose the causes of faults and thus reduce maintenance costs. So, the main focus of this research is to design and develop an online, intelligent CM system based on wireless embedded technology to detect and diagnose the most common faults in the transmission systems (gears and bearings) of the industrial robot joints using vibration signal analysis. To this end an old, but operational, PUMA 560 robot was utilized to synthesize a number of different transmission faults in one of the joints (3 - elbow), such as backlash between the gear pair, gear tooth and bearing faults. A two-stage condition monitoring algorithm is proposed for robot health assessment, incorporating fault detection and fault diagnosis. Signal processing techniques play a significant role in building any condition monitoring system, in order to determine fault-symptom relationships, and detect abnormalities in robot health. Fault detection stage is based on time-domain signal analysis and a statistical control chart (SCC) technique. For accurate fault diagnosis in the second stage, a novel implementation of a time-frequency signal analysis technique based on the discrete wavelet transform (DWT) is adopted. In this technique, vibration signals are decomposed into eight levels of wavelet coefficients and statistical features, such as standard deviation, kurtosis and skewness, are obtained at each level and analysed to extract the most salient feature related to faults; the artificial neural network (ANN) is then used for fault classification. A data acquisition system based on National Instruments (NI) software and hardware was initially developed for preliminary robot vibration analysis and feature extraction. The transmission faults induced in the robot can change the captured vibration spectra, and the robot’s natural frequencies were established using experimental modal analysis, and also the fundamental fault frequencies for the gear transmission and bearings were obtained and utilized for preliminary robot condition monitoring. In addition to simulation of different levels of backlash fault, gear tooth and bearing faults which have not been previously investigated in industrial robots, with several levels of ii severity, were successfully simulated and detected in the robot’s joint transmission. The vibration features extracted, which are related to the robot healthy state and different fault types, using the data acquisition system were subsequently used in building the SCC and ANN, which were trained using part of the measured data set that represents the robot operating range. Another set of data, not used within the training stage, was then utilized for validation. The results indicate the successful detection and diagnosis of faults using the key extracted parameters. A wireless embedded system based on the ZigBee communication protocol was designed for the application of the proposed CM algorithm in real-time, using an Arduino DUE as the core of the wireless sensor unit attached on the robot arm. A Texas Instruments digital signal processor (TMS320C6713 DSK board) was used as the base station of the wireless system on which the robot’s fault diagnosis algorithm is run. To implement the two stages of the proposed CM algorithm on the designed embedded system, software based on the C programming language has been developed. To demonstrate the reliability of the designed wireless CM system, experimental validations were performed, and high reliability was shown in the detection and diagnosis of several seeded faults in the robot. Optimistically, the established wireless embedded system could be envisaged for fault detection and diagnostics on any type of rotating machine, with the monitoring system realized using vibration signal analysis. Furthermore, with some modifications to the system’s hardware and software, different CM techniques such as acoustic emission (AE) analysis or motor current signature analysis (MCSA), can be applied.Iraqi government, represented by the Ministry of Higher Education and Scientific Research, the Iraqi Cultural Attaché in London, and the University of Technology in Baghda

Adaptive Sampling with Mobile Sensor Networks

Mobile sensor networks have unique advantages compared with wireless sensor networks. The mobility enables mobile sensors to flexibly reconfigure themselves to meet sensing requirements. In this dissertation, an adaptive sampling method for mobile sensor networks is presented. Based on the consideration of sensing resource constraints, computing abilities, and onboard energy limitations, the adaptive sampling method follows a down sampling scheme, which could reduce the total number of measurements, and lower sampling cost. Compressive sensing is a recently developed down sampling method, using a small number of randomly distributed measurements for signal reconstruction. However, original signals cannot be reconstructed using condensed measurements, as addressed by Shannon Sampling Theory. Measurements have to be processed under a sparse domain, and convex optimization methods should be applied to reconstruct original signals. Restricted isometry property would guarantee signals can be recovered with little information loss. While compressive sensing could effectively lower sampling cost, signal reconstruction is still a great research challenge. Compressive sensing always collects random measurements, whose information amount cannot be determined in prior. If each measurement is optimized as the most informative measurement, the reconstruction performance can perform much better. Based on the above consideration, this dissertation is focusing on an adaptive sampling approach, which could find the most informative measurements in unknown environments and reconstruct original signals. With mobile sensors, measurements are collect sequentially, giving the chance to uniquely optimize each of them. When mobile sensors are about to collect a new measurement from the surrounding environments, existing information is shared among networked sensors so that each sensor would have a global view of the entire environment. Shared information is analyzed under Haar Wavelet domain, under which most nature signals appear sparse, to infer a model of the environments. The most informative measurements can be determined by optimizing model parameters. As a result, all the measurements collected by the mobile sensor network are the most informative measurements given existing information, and a perfect reconstruction would be expected. To present the adaptive sampling method, a series of research issues will be addressed, including measurement evaluation and collection, mobile network establishment, data fusion, sensor motion, signal reconstruction, etc. Two dimensional scalar field will be reconstructed using the method proposed. Both single mobile sensors and mobile sensor networks will be deployed in the environment, and reconstruction performance of both will be compared.In addition, a particular mobile sensor, a quadrotor UAV is developed, so that the adaptive sampling method can be used in three dimensional scenarios

NASA SBIR abstracts of 1991 phase 1 projects

The objectives of 301 projects placed under contract by the Small Business Innovation Research (SBIR) program of the National Aeronautics and Space Administration (NASA) are described. These projects were selected competitively from among proposals submitted to NASA in response to the 1991 SBIR Program Solicitation. The basic document consists of edited, non-proprietary abstracts of the winning proposals submitted by small businesses. The abstracts are presented under the 15 technical topics within which Phase 1 proposals were solicited. Each project was assigned a sequential identifying number from 001 to 301, in order of its appearance in the body of the report. Appendixes to provide additional information about the SBIR program and permit cross-reference of the 1991 Phase 1 projects by company name, location by state, principal investigator, NASA Field Center responsible for management of each project, and NASA contract number are included

Computation Approaches for Continuous Reinforcement Learning Problems

Optimisation theory is at the heart of any control process, where we seek to control the behaviour of a system through a set of actions. Linear control problems have been extensively studied, and optimal control laws have been identified. But the world around us is highly non-linear and unpredictable. For these dynamic systems, which don’t possess the nice mathematical properties of the linear counterpart, the classic control theory breaks and other methods have to be employed. But nature thrives by optimising non-linear and over-complicated systems. Evolutionary Computing (EC) methods exploit nature’s way by imitating the evolution process and avoid to solve the control problem analytically. Reinforcement Learning (RL) from the other side regards the optimal control problem as a sequential one. In every discrete time step an action is applied. The transition of the system to a new state is accompanied by a sole numerical value, the “reward” that designate the quality of the control action. Even though the amount of feedback information is limited into a sole real number, the introduction of the Temporal Difference method made possible to have accurate predictions of the value-functions. This paved the way to optimise complex structures, like the Neural Networks, which are used to approximate the value functions. In this thesis we investigate the solution of continuous Reinforcement Learning control problems by EC methodologies. The accumulated reward of such problems throughout an episode suffices as information to formulate the required measure, fitness, in order to optimise a population of candidate solutions. Especially, we explore the limits of applicability of a specific branch of EC, that of Genetic Programming (GP). The evolving population in the GP case is comprised from individuals, which are immediately translated to mathematical functions, which can serve as a control law. The major contribution of this thesis is the proposed unification of these disparate Artificial Intelligence paradigms. The provided information from the systems are exploited by a step by step basis from the RL part of the proposed scheme and by an episodic basis from GP. This makes possible to augment the function set of the GP scheme with adaptable Neural Networks. In the quest to achieve stable behaviour of the RL part of the system a modification of the Actor-Critic algorithm has been implemented. Finally we successfully apply the GP method in multi-action control problems extending the spectrum of the problems that this method has been proved to solve. Also we investigated the capability of GP in relation to problems from the food industry. These type of problems exhibit also non-linearity and there is no definite model describing its behaviour

Human skill capturing and modelling using wearable devices

Industrial robots are delivering more and more manipulation services in manufacturing. However, when the task is complex, it is difficult to programme a robot to fulfil all the requirements because even a relatively simple task such as a peg-in-hole insertion contains many uncertainties, e.g. clearance, initial grasping position and insertion path. Humans, on the other hand, can deal with these variations using their vision and haptic feedback. Although humans can adapt to uncertainties easily, most of the time, the skilled based performances that relate to their tacit knowledge cannot be easily articulated. Even though the automation solution may not fully imitate human motion since some of them are not necessary, it would be useful if the skill based performance from a human could be firstly interpreted and modelled, which will then allow it to be transferred to the robot. This thesis aims to reduce robot programming efforts significantly by developing a methodology to capture, model and transfer the manual manufacturing skills from a human demonstrator to the robot. Recently, Learning from Demonstration (LfD) is gaining interest as a framework to transfer skills from human teacher to robot using probability encoding approaches to model observations and state transition uncertainties. In close or actual contact manipulation tasks, it is difficult to reliabley record the state-action examples without interfering with the human senses and activities. Therefore, wearable sensors are investigated as a promising device to record the state-action examples without restricting the human experts during the skilled execution of their tasks. Firstly to track human motions accurately and reliably in a defined 3-dimensional workspace, a hybrid system of Vicon and IMUs is proposed to compensate for the known limitations of the individual system. The data fusion method was able to overcome occlusion and frame flipping problems in the two camera Vicon setup and the drifting problem associated with the IMUs. The results indicated that occlusion and frame flipping problems associated with Vicon can be mitigated by using the IMU measurements. Furthermore, the proposed method improves the Mean Square Error (MSE) tracking accuracy range from 0.8˚ to 6.4˚ compared with the IMU only method. Secondly, to record haptic feedback from a teacher without physically obstructing their interactions with the workpiece, wearable surface electromyography (sEMG) armbands were used as an indirect method to indicate contact feedback during manual manipulations. A muscle-force model using a Time Delayed Neural Network (TDNN) was built to map the sEMG signals to the known contact force. The results indicated that the model was capable of estimating the force from the sEMG armbands in the applications of interest, namely in peg-in-hole and beater winding tasks, with MSE of 2.75N and 0.18N respectively. Finally, given the force estimation and the motion trajectories, a Hidden Markov Model (HMM) based approach was utilised as a state recognition method to encode and generalise the spatial and temporal information of the skilled executions. This method would allow a more representative control policy to be derived. A modified Gaussian Mixture Regression (GMR) method was then applied to enable motions reproduction by using the learned state-action policy. To simplify the validation procedure, instead of using the robot, additional demonstrations from the teacher were used to verify the reproduction performance of the policy, by assuming human teacher and robot learner are physical identical systems. The results confirmed the generalisation capability of the HMM model across a number of demonstrations from different subjects; and the reproduced motions from GMR were acceptable in these additional tests. The proposed methodology provides a framework for producing a state-action model from skilled demonstrations that can be translated into robot kinematics and joint states for the robot to execute. The implication to industry is reduced efforts and time in programming the robots for applications where human skilled performances are required to cope robustly with various uncertainties during tasks execution