Kinematic calibration of Orthoglide-type mechanisms from observation of parallel leg motions

The paper proposes a new calibration method for parallel manipulators that allows efficient identification of the joint offsets using observations of the manipulator leg parallelism with respect to the base surface. The method employs a simple and low-cost measuring system, which evaluates deviation of the leg location during motions that are assumed to preserve the leg parallelism for the nominal values of the manipulator parameters. Using the measured deviations, the developed algorithm estimates the joint offsets that are treated as the most essential parameters to be identified. The validity of the proposed calibration method and efficiency of the developed numerical algorithms are confirmed by experimental results. The sensitivity of the measurement methods and the calibration accuracy are also studied

MScMS-II: an innovative IR-based indoor coordinate measuring system for large-scale metrology applications

According to the current great interest concerning large-scale metrology applications in many different fields of manufacturing industry, technologies and techniques for dimensional measurement have recently shown a substantial improvement. Ease-of-use, logistic and economic issues, as well as metrological performance are assuming a more and more important role among system requirements. This paper describes the architecture and the working principles of a novel infrared (IR) optical-based system, designed to perform low-cost and easy indoor coordinate measurements of large-size objects. The system consists of a distributed network-based layout, whose modularity allows fitting differently sized and shaped working volumes by adequately increasing the number of sensing units. Differently from existing spatially distributed metrological instruments, the remote sensor devices are intended to provide embedded data elaboration capabilities, in order to share the overall computational load. The overall system functionalities, including distributed layout configuration, network self-calibration, 3D point localization, and measurement data elaboration, are discussed. A preliminary metrological characterization of system performance, based on experimental testing, is also presente

Automated freeform assembly of threaded fasteners

Over the past two decades, a major part of the manufacturing and assembly market has been driven by its customer requirements. Increasing customer demand for personalised products create the demand for smaller batch sizes, shorter production times, lower costs, and the flexibility to produce families of products - or different parts - with the same sets of equipment. Consequently, manufacturing companies have deployed various automation systems and production strategies to improve their resource efficiency and move towards right-first-time production. However, many of these automated systems, which are involved with robot-based, repeatable assembly automation, require component- specific fixtures for accurate positioning and extensive robot programming, to achieve flexibility in their production. Threaded fastening operations are widely used in assembly. In high-volume production, the fastening processes are commonly automated using jigs, fixtures, and semi-automated tools. This form of automation delivers reliable assembly results at the expense of flexibility and requires component variability to be adequately controlled. On the other hand, in low- volume, high- value manufacturing, fastening processes are typically carried out manually by skilled workers. This research is aimed at addressing the aforementioned issues by developing a freeform automated threaded fastener assembly system that uses 3D visual guidance. The proof-of-concept system developed focuses on picking up fasteners from clutter, identifying a hole feature in an imprecisely positioned target component and carry out torque-controlled fastening. This approach has achieved flexibility and adaptability without the use of dedicated fixtures and robot programming. This research also investigates and evaluates different 3D imaging technology to identify the suitable technology required for fastener assembly in a non-structured industrial environment. The proposed solution utilises the commercially available technologies to enhance the precision and speed of identification of components for assembly processes, thereby improving and validating the possibility of reliably implementing this solution for industrial applications. As a part of this research, a number of novel algorithms are developed to robustly identify assembly components located in a random environment by enhancing the existing methods and technologies within the domain of the fastening processes. A bolt identification algorithm was developed to identify bolts located in a random clutter by enhancing the existing surface-based matching algorithm. A novel hole feature identification algorithm was developed to detect threaded holes and identify its size and location in 3D. The developed bolt and feature identification algorithms are robust and has sub-millimetre accuracy required to perform successful fastener assembly in industrial conditions. In addition, the processing time required for these identification algorithms - to identify and localise bolts and hole features - is less than a second, thereby increasing the speed of fastener assembly

Navigace mobilních robotů v neznámém prostředí s využitím měření vzdáleností

The ability of a robot to navigate itself in the environment is a crucial step towards its autonomy. Navigation as a subtask of the development of autonomous robots is the subject of this thesis, focusing on the development of a method for simultaneous localization an mapping (SLAM) of mobile robots in six degrees of freedom (DOF). As a part of this research, a platform for 3D range data acquisition based on a continuously inclined laser rangefinder was developed. This platform is presented, evaluating the measurements and also presenting the robotic equipment on which the platform can be fitted. The localization and mapping task is equal to the registration of multiple 3D images into a common frame of reference. For this purpose, a method based on the Iterative Closest Point (ICP) algorithm was developed. First, the originally implemented SLAM method is presented, focusing on the time-wise performance and the registration quality issues introduced by the implemented algorithms. In order to accelerate and improve the quality of the time-demanding 6DOF image registration, an extended method was developed. The major extension is the introduction of a factorized registration, extracting 2D representations of vertical objects called leveled maps from the 3D point sets, ensuring these representations are 3DOF invariant. The extracted representations are registered in 3DOF using ICP algorithm, allowing pre-alignment of the 3D data for the subsequent robust 6DOF ICP based registration. The extended method is presented, showing all important modifications to the original method. The developed registration method was evaluated using real 3D data acquired in different indoor environments, examining the benefits of the factorization and other extensions as well as the performance of the original ICP based method. The factorization gives promising results compared to a single phase 6DOF registration in vertically structured environments. Also, the disadvantages of the method are discussed, proposing possible solutions. Finally, the future prospects of the research are presented.Schopnost lokalizace a navigace je podmínkou autonomního provozu mobilních robotů. Předmětem této disertační práce jsou navigační metody se zaměřením na metodu pro simultánní lokalizaci a mapování (SLAM) mobilních robotů v šesti stupních volnosti (6DOF). Nedílnou součástí tohoto výzkumu byl vývoj platformy pro sběr 3D vzdálenostních dat s využitím kontinuálně naklápěného laserového řádkového scanneru. Tato platforma byla vyvinuta jako samostatný modul, aby mohla být umístěna na různé šasi mobilních robotů. Úkol lokalizace a mapování je ekvivalentní registraci více 3D obrazů do společného souřadného systému. Pro tyto účely byla vyvinuta metoda založená na algoritmu Iterative Closest Point Algorithm (ICP). Původně implementovaná verze navigační metody využívá ICP s akcelerací pomocí kd-stromů přičemž jsou zhodnoceny její kvalitativní a výkonnostní aspekty. Na základě této analýzy byly vyvinuty rozšíření původní metody založené na ICP. Jednou z hlavních modifikací je faktorizace registračního procesu, kdy tato faktorizace je založena na redukci dat: vytvoření 2D „leveled“ map (ve smyslu jednoúrovňových map) ze 3D vzdálenostních obrazů. Pro tuto redukci je technologicky i algoritmicky zajištěna invariantnost těchto map vůči třem stupňům volnosti. Tyto redukované mapy jsou registrovány pomocí ICP ve zbylých třech stupních volnosti, přičemž získaná transformace je aplikována na 3D data za účelem před-registrace 3D obrazů. Následně je provedena robustní 6DOF registrace. Rozšířená metoda je v disertační práci v popsána spolu se všemi podstatnými modifikacemi. Vyvinutá metoda byla otestována a zhodnocena s využitím skutečných 3D vzdálenostních dat naměřených v různých vnitřních prostředích. Jsou zhodnoceny přínosy faktorizace a jiných modifikací ve srovnání s původní jednofázovou 6DOF registrací, také jsou zmíněny nevýhody implementované metody a navrženy způsoby jejich řešení. Nakonec následuje návrh budoucího výzkumu a diskuse o možnostech dalšího rozvoje.

Modeling, optimizing and simulating robot calibration with accuracy improvement

This work describes techniques for modeling, optimizing and simulating calibration processes ofrobots using off-line programming. The identification of geometric parameters of the nominalkinematic model is optimized using techniques of numerical optimization of the mathematicalmodel. The simulation of the actual robot and the measurement system is achieved by introducingrandom errors representing their physical behavior and its statistical repeatability. An evaluationof the corrected nominal kinematic model brings about a clear perception of the influence ofdistinct variables involved in the process for a suitable planning, and indicates a considerableaccuracy improvement when the optimized model is compared to the non-optimized one

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

Robust Intrinsic and Extrinsic Calibration of RGB-D Cameras

Color-depth cameras (RGB-D cameras) have become the primary sensors in most robotics systems, from service robotics to industrial robotics applications. Typical consumer-grade RGB-D cameras are provided with a coarse intrinsic and extrinsic calibration that generally does not meet the accuracy requirements needed by many robotics applications (e.g., highly accurate 3D environment reconstruction and mapping, high precision object recognition and localization, ...). In this paper, we propose a human-friendly, reliable and accurate calibration framework that enables to easily estimate both the intrinsic and extrinsic parameters of a general color-depth sensor couple. Our approach is based on a novel two components error model. This model unifies the error sources of RGB-D pairs based on different technologies, such as structured-light 3D cameras and time-of-flight cameras. Our method provides some important advantages compared to other state-of-the-art systems: it is general (i.e., well suited for different types of sensors), based on an easy and stable calibration protocol, provides a greater calibration accuracy, and has been implemented within the ROS robotics framework. We report detailed experimental validations and performance comparisons to support our statements