Industrial Robot Collision Handling in Harsh Environments

The focus in this thesis is on robot collision handling systems, mainly collision detection and collision avoidance for industrial robots operating in harsh environments (e.g. potentially explosive atmospheres found in the oil and gas sector). Collision detection should prevent the robot from colliding and therefore avoid a potential accident. Collision avoidance builds on the concept of collision detection and aims at enabling the robot to find a collision free path circumventing the obstacle and leading to the goal position. The work has been done in collaboration with ABB Process Automation Division with focus on applications in oil and gas. One of the challenges in this work has been to contribute to safer use of industrial robots in potentially explosive environments. One of the main ideas is that a robot should be able to work together with a human as a robotic co-worker on for instance an oil rig. The robot should then perform heavy lifting and precision tasks, while the operator controls the steps of the operation through typically a hand-held interface. In such situations, when the human works alongside with the robot in potentially explosive environments, it is important that the robot has a way of handling collisions. The work in this thesis presents solutions for collision detection in paper A, B and C, thereafter solutions for collision avoidance are presented in paper D and E. Paper A approaches the problem of collision avoidance comparing an expert system and a hidden markov model (HMM) approach. An industrial robot equipped with a laser scanner is used to gather environment data on arbitrary set of points in the work cell. The two methods are used to detect obstacles within the work cell and shows a different set of strengths. The expert system shows an advantage in algorithm performance and the HMM method shows its strength in its ease of learning models of the environment. Paper B builds upon Paper A by incorporating a CAD model of the environment. The CAD model allows for a very fast setup of the expert system where no manual map creation is needed. The HMM can be trained based on the CAD model, which addresses the previous dependency on real sensor data for training purposes. Paper C compares two different world-model representation techniques, namely octrees and point clouds using both a graphics processing unit (GPU) and a central processing unit (CPU). The GPU showed its strength for uncompressed point clouds and high resolution point cloud models. However, if the resolution gets low enough, the CPU starts to outperform the GPU. This shows that parallel problems containing large data sets are suitable for GPU processing, but smaller parallel problems are still handled better by the CPU. In paper D, real-time collision avoidance is studied for a lightweight industrial robot using a development platform controller. A Microsoft Kinect sensor is used for capturing 3D depth data of the environment. The environment data is used together with an artificial potential fields method for generating virtual forces used for obstacle avoidance. The forces are projected onto the end-effector, preventing collision with the environment while moving towards the goal. Forces are also projected on to the elbow of the 7-Degree of freedom robot, which allows for nullspace movement. The algorithms for manipulating the sensor data and calculating virtual forces were developed for the GPU, this resulted in fast algorithms and is the enabling factor for real-time collision avoidance. Finally, paper E builds on the work in paper D by providing a framework for using the algorithms on a standard industrial controller and robot with minimal modifications. Further, algorithms were specifically developed for the robot controller to handle reactive movement. In addition, a full collision avoidance system for an end-user application which is very simple to implement is presented. The work described in this thesis presents solutions for collision detection and collision avoidance for safer use of robots. The work is also a step towards making businesses more competitive by enabling easy integration of collision handling for industrial robots

Behavioural strategy for indoor mobile robot navigation in dynamic environments

PhD ThesisDevelopment of behavioural strategies for indoor mobile navigation has become a challenging and practical issue in a cluttered indoor environment, such as a hospital or factory, where there are many static and moving objects, including humans and other robots, all of which trying to complete their own specific tasks; some objects may be moving in a similar direction to the robot, whereas others may be moving in the opposite direction. The key requirement for any mobile robot is to avoid colliding with any object which may prevent it from reaching its goal, or as a consequence bring harm to any individual within its workspace. This challenge is further complicated by unobserved objects suddenly appearing in the robots path, particularly when the robot crosses a corridor or an open doorway. Therefore the mobile robot must be able to anticipate such scenarios and manoeuvre quickly to avoid collisions. In this project, a hybrid control architecture has been designed to navigate within dynamic environments. The control system includes three levels namely: deliberative, intermediate and reactive, which work together to achieve short, fast and safe navigation. The deliberative level creates a short and safe path from the current position of the mobile robot to its goal using the wavefront algorithm, estimates the current location of the mobile robot, and extracts the region from which unobserved objects may appear. The intermediate level links the deliberative level and the reactive level, that includes several behaviours for implementing the global path in such a way to avoid any collision. In avoiding dynamic obstacles, the controller has to identify and extract obstacles from the sensor data, estimate their speeds, and then regular its speed and direction to minimize the collision risk and maximize the speed to the goal. The velocity obstacle approach (VO) is considered an easy and simple method for avoiding dynamic obstacles, whilst the collision cone principle is used to detect the collision situation between two circular-shaped objects. However the VO approach has two challenges when applied in indoor environments. The first challenge is extraction of collision cones of non-circular objects from sensor data, in which applying fitting circle methods generally produces large and inaccurate collision cones especially for line-shaped obstacle such as walls. The second challenge is that the mobile robot cannot sometimes move to its goal because all its velocities to the goal are located within collision cones. In this project, a method has been demonstrated to extract the colliii sion cones of circular and non-circular objects using a laser sensor, where the obstacle size and the collision time are considered to weigh the robot velocities. In addition the principle of the virtual obstacle was proposed to minimize the collision risk with unobserved moving obstacles. The simulation and experiments using the proposed control system on a Pioneer mobile robot showed that the mobile robot can successfully avoid static and dynamic obstacles. Furthermore the mobile robot was able to reach its target within an indoor environment without causing any collision or missing the target