Intelligent systems for welding process automation

This paper presents and evaluates the concept and implementation of two distinct multi-sensor systems for the automated manufacturing based on parallel hardware. In the most sophisticated implementation, 12 processors had been integrated in a parallel multi-sensor system. Some specialized nodes implement an Artificial Neural Network, used to improve photogrammetry-based computer vision, and Fuzzy Logic supervision of the sensor fusion. Trough the implementation of distributed and intelligent processing units, it was shown that parallel architectures can provide significant advantages compared to conventional bus-based systems. The paper concludes with the comparison of the main aspects of the transputer and the DSP-based implementation of sensor guided robots

Aspects of an open architecture robot controller and its integration with a stereo vision sensor.

The work presented in this thesis attempts to improve the performance of industrial robot systems in a flexible manufacturing environment by addressing a number of issues related to external sensory feedback and sensor integration, robot kinematic positioning accuracy, and robot dynamic control performance. To provide a powerful control algorithm environment and the support for external sensor integration, a transputer based open architecture robot controller is developed. It features high computational power, user accessibility at various robot control levels and external sensor integration capability. Additionally, an on-line trajectory adaptation scheme is devised and implemented in the open architecture robot controller, enabling a real-time trajectory alteration of robot motion to be achieved in response to external sensory feedback. An in depth discussion is presented on integrating a stereo vision sensor with the robot controller to perform external sensor guided robot operations. Key issues for such a vision based robot system are precise synchronisation between the vision system and the robot controller, and correct target position prediction to counteract the inherent time delay in image processing. These were successfully addressed in a demonstrator system based on a Puma robot. Efforts have also been made to improve the Puma robot kinematic and dynamic performance. A simple, effective, on-line algorithm is developed for solving the inverse kinematics problem of a calibrated industrial robot to improve robot positioning accuracy. On the dynamic control aspect, a robust adaptive robot tracking control algorithm is derived that has an improved performance compared to a conventional PID controller as well as exhibiting relatively modest computational complexity. Experiments have been carried out to validate the open architecture robot controller and demonstrate the performance of the inverse kinematics algorithm, the adaptive servo control algorithm, and the on-line trajectory generation. By integrating the open architecture robot controller with a stereo vision sensor system, robot visual guidance has been achieved with experimental results showing that the integrated system is capable of detecting, tracking and intercepting random objects moving in 3D trajectory at a velocity up to 40mm/s

Mechatronics of systems with undetermined configurations

This work is submitted for the award of a PhD by published works. It deals with some of the efforts of the author over the last ten years in the field of Mechatronics. Mechatronics is a new area invented by the Japanese in the late 1970's, it consists of a synthesis of computers and electronics to improve mechanical systems. To control any mechanical event three fundamental features must be brought together: the sensors used to observe the process, the control software, including the control algorithm used and thirdly the actuator that provides the stimulus to achieve the end result. Simulation, which plays such an important part in the Mechatronics process, is used in both in continuous and discrete forms. The author has spent some considerable time developing skills in all these areas. The author was certainly the first at Middlesex to appreciate the new developments in Mechatronics and their significance for manufacturing. The author was one of the first mechanical engineers to recognise the significance of the new transputer chip. This was applied to the LQG optimal control of a cinefilm copying process. A 300% improvement in operating speed was achieved, together with tension control. To make more efficient use of robots they have to be made both faster and cheaper. The author found extremely low natural frequencies of vibration, ranging from 3 to 25 Hz. This limits the speed of response of existing robots. The vibration data was some of the earliest available in this field, certainly in the UK. Several schemes have been devised to control the flexible robot and maintain the required precision. Actuator technology is one area where mechatronic systems have been the subject of intense development. At Middlesex we have improved on the Aexator pneumatic muscle actuator, enabling it to be used with a precision of about 2 mm. New control challenges have been undertaken now in the field of machine tool chatter and the prevention of slip. A variety of novel and traditional control algorithms have been investigated in order to find out the best approach to solve this problem

Model-Based Robot Control and Multiprocessor Implementation

Model-based control of robot manipulators has been gaining momentum in recent years. Unfortunately there are very few experimental validations to accompany simulation results and as such majority of conclusions drawn lack the credibility associated with the real control implementation

Autonomy in the real real-world: A behaviour based view of autonomous systems control in an industrial product inspection system

The thesis presented in this dissertation appears in two sequential parts that arose from an exploration of the use of Behaviour Based Artificial Intelligence (BBAI) techniques in a domain outside that of robotics, where BBAI is most frequently used. The work details a real-world physical implementation of the control and interactions of an industrial product inspection system from a BBAI perspective. It concentrates particularly on the control of a number of active laser scanning sensor systems (each a subsystem of a larger main inspection system), using a subsumption architecture. This industrial implementation is in itself a new direction for BBAI control and an important aspect of this thesis. However, the work has also led on to the development of a number of key ideas which contribute to the field of BBAI in general. The second part of the thesis concerns the nature of physical and temporal constraints on a distributed control system and the desirability of utilising mechanisms to provide continuous, low-level learning and adaptation of domain knowledge on a sub-behavioural basis. Techniques used include artificial neural networks and hill-climbing state-space search algorithms. Discussion is supported with examples from experiments with the laser scanning inspection system. Encouraging results suggest that concerted design effort at this low level of activity will benefit the whole system in terms of behavioural robustness and reliability. Relevant aspects of the design process that should be of value in similar real-world projects are identified and emphasised. These issues are particularly important in providing a firm foundation for artificial intelligence based control systems

Technology for an intelligent, free-flying robot for crew and equipment retrieval in space

Crew rescue and equipment retrieval is a Space Station Freedom requirement. During Freedom's lifetime, there is a high probability that a number of objects will accidently become separated. Members of the crew, replacement units, and key tools are examples. Retrieval of these objects within a short time is essential. Systems engineering studies were conducted to identify system requirements and candidate approaches. One such approach, based on a voice-supervised, intelligent, free-flying robot was selected for further analysis. A ground-based technology demonstration, now in its second phase, was designed to provide an integrated robotic hardware and software testbed supporting design of a space-borne system. The ground system, known as the EVA Retriever, is examining the problem of autonomously planning and executing a target rendezvous, grapple, and return to base while avoiding stationary and moving obstacles. The current prototype is an anthropomorphic manipulator unit with dexterous arms and hands attached to a robot body and latched in a manned maneuvering unit. A precision air-bearing floor is used to simulate space. Sensor data include two vision systems and force/proximity/tactile sensors on the hands and arms. Planning for a shuttle file experiment is underway. A set of scenarios and strawman requirements were defined to support conceptual development. Initial design activities are expected to begin in late 1989 with the flight occurring in 1994. The flight hardware and software will be based on lessons learned from both the ground prototype and computer simulations

Visual servoing with hand-eye manipulator-optimal control approach

This paper proposes a control theoretic formulation and a controller design method for the feature-based visual servoing with redundant features. The linear time-invariant (LTI) formulation copes with the redundant features and provides a simple framework for controller design. The proposed linear quadratic (LQ) method can deal with the redundant features, which is important because the previous LQ methods are not applicable to redundant systems. Moreover, this LQ method gives flexibility for performance improvement instead of the very limited design parameters provided by the generalized inverse and task function controllers. Validity of the LTI model and effectiveness and flexibility of the LQ optimal controller are evaluated by real-time experiments on a PUMA 560 manipulator</p