Robotic path planning for non-destructive testing - a custom MATLAB toolbox approach

The requirement to increase inspection speeds for non-destructive testing (NDT) of composite aerospace parts is common to many manufacturers. The prevalence of complex curved surfaces in the industry provides motivation for the use of 6 axis robots in these inspections. The purpose of this paper is to present work undertaken for the development of a KUKA robot manipulator based automated NDT system. A new software solution is presented that enables flexible trajectory planning to be accomplished for the inspection of complex curved surfaces often encountered in engineering production. The techniques and issues associated with conventional manual inspection techniques and automated systems for the inspection of large complex surfaces were reviewed. This approach has directly influenced the development of a MATLAB toolbox targeted to NDT automation, capable of complex path planning, obstacle avoidance, and external synchronization between robots and associated external NDT systems. This paper highlights the advantages of this software over conventional off-line-programming approaches when applied to NDT measurements. An experimental validation of path trajectory generation, on a large and curved composite aerofoil component, is presented. Comparative metrology experiments were undertaken to evaluate the real path accuracy of the toolbox when inspecting a curved 0.5 m2 and a 1.6 m2 surface using a KUKA KR16 L6-2 robot. The results have shown that the deviation of the distance between the commanded TCPs and the feedback positions were within 2.7 mm. The variance of the standoff between the probe and the scanned surfaces was smaller than the variance obtainable via commercial path-planning software. Tool paths were generated directly on the triangular mesh imported from the CAD models of the inspected components without need for an approximating analytical surface. By implementing full external control of the robotic hardware, it has been possible to synchronise the NDT data collection with positions at all points along the path, and our approach allows for the future development of additional functionality that is specific to NDT inspection problems. For the current NDT application, the deviations from CAD design and the requirements for both coarse and fine inspections, dependent on measured NDT data, demand flexibility in path planning beyond what is currently available from existing off-line robot programming software

A Nonlinear Model Predictive Control Scheme for Cooperative Manipulation with Singularity and Collision Avoidance

This paper addresses the problem of cooperative transportation of an object rigidly grasped by $N$ robotic agents. In particular, we propose a Nonlinear Model Predictive Control (NMPC) scheme that guarantees the navigation of the object to a desired pose in a bounded workspace with obstacles, while complying with certain input saturations of the agents. Moreover, the proposed methodology ensures that the agents do not collide with each other or with the workspace obstacles as well as that they do not pass through singular configurations. The feasibility and convergence analysis of the NMPC are explicitly provided. Finally, simulation results illustrate the validity and efficiency of the proposed method.Comment: Simulation results with 3 agents adde

KCT: a MATLAB toolbox for motion control of KUKA robot manipulators

Abstract—The Kuka Control Toolbox (KCT) is a collection of MATLAB functions for motion control of KUKA robot manipulators, developed to offer an intuitive and high-level programming interface to the user. The toolbox, which is compatible with all 6 DOF small and low payload KUKA robots that use the Eth.RSIXML, runs on a remote computer connected with the KUKA controller via TCP/IP. KCT includes more than 30 functions, spanning operations such as forward and inverse kinematics computation, point-to-point joint and Cartesian control, trajectory generation, graphical display and diagnostics. The flexibility, ease of use and reliability of the toolbox is demonstrated through two applicative examples. I

Robotic path planning for non-destructive testing of complex shaped surfaces

The requirement to increase inspection speeds for non-destructive testing (NDT) of composite aerospace parts is common to many manufacturers. The prevalence of complex curved surfaces in the industry provides significant motivation for the use of 6 axis robots for deployment of NDT probes in these inspections. A new system for robot deployed ultrasonic inspection of composite aerospace components is presented. The key novelty of the approach is through the accommodation of flexible robotic trajectory planning, coordinated with the NDT data acquisition. Using a flexible approach in MATLAB, the authors have developed a high level custom toolbox that utilizes external control of an industrial 6 axis manipulator to achieve complex path planning and provide synchronization of the employed ultrasonic phase array inspection system. The developed software maintains a high level approach to the robot programming, in order to ease the programming complexity for an NDT inspection operator. Crucially the approach provides a pathway for a conditional programming approach and the capability for multiple robot control (a significant limitation in many current off-line programming applications). Ultrasonic and experimental data has been collected for the validation of the inspection technique. The path trajectory generation for a large, curved carbon-fiber-reinforced polymer (CFRP) aerofoil component has been proven and is presented. The path error relative to a raster-scan tool-path, suitable for ultrasonic phased array inspection, has been measured to be within ± 2mm over the 1.6 m2 area of the component surface

Kinematics modeling of six degrees of freedom humanoid robot arm using improved damped least squares for visual grasping

The robotic arm has functioned as an arm in the humanoid robot and is generally used to perform grasping tasks. Accordingly, kinematics modeling both forward and inverse kinematics is required to calculate the end-effector position in the cartesian space before performing grasping activities. This research presents the kinematics modeling of six degrees of freedom (6-DOF) robotic arm of the T-FLoW humanoid robot for the grasping mechanism of visual grasping systems on the robot operating system (ROS) platform and CoppeliaSim. Kinematic singularity is a common problem in the inverse kinematics model of robots, but. However, other problems are mechanical limitations and computational time. The work uses the homogeneous transformation matrix (HTM) based on the Euler system of the robot for the forward kinematics and demonstrates the capability of an improved damped least squares (I-DLS) method for the inverse kinematics. The I-DLS method was obtained by improving the original DLS method with the joint limits and clamping techniques. The I-DLS performs better than the original DLS during the experiments yet increases the calculation iteration by 10.95%, with a maximum error position between the end-effector and target positions in path planning of 0.1 cm

On the Issue of Camera Calibration with Narrow Angular Field of View

This paper considers the issue of calibrating a camera with narrow angular field of view using standard, perspective methods in computer vision. In doing so, the significance of perspective distortion both for camera calibration and for pose estimation is revealed. Since narrow angular field of view cameras make it difficult to obtain rich images in terms of perspectivity, the accuracy of the calibration results is expectedly low. From this, we propose an alternative method that compensates for this loss by utilizing the pose readings of a robotic manipulator. It facilitates accurate pose estimation by nonlinear optimization, minimizing reprojection errors and errors in the manipulator transformations at the same time. Accurate pose estimation in turn enables accurate parametrization of a perspective camera

Cooperative Object Manipulation with Force Tracking on the da Vinci Research Kit

The da Vinci Surgical System is one of the most established robot-assisted surgery device commended for its dexterity and ergonomics in minimally invasive surgery. Conversely, it inherits disadvantages which are lack of autonomy and haptic feedback. In order to address these issues, this work proposes an industry-inspired solution to the field of force control in medical robotics. This approach contributes to shared autonomy by developing a controller for cooperative object manipulation with force tracking utilizing available manipulators and force feedback. To achieve simultaneous position and force tracking of the object, master and slave manipulators were assigned then controlled with Cartesian position control and impedance control respectively. Because impedance control requires a model-based feedforward compensation, we identified the lumped base parameters of mass, inertias, and frictions of a three degree-of-freedom double four-bar linkage mechanism with least squares and weighted least squares regression methods. Additionally, semidefinite programming was used to constrain the parameters to a feasible physical solution in standard parameter space. Robust stick-slip static friction compensation was applied where linear Viscous and Coulomb friction was inadequate in modeling the prismatic third joint. The Robot Operating System based controller was tested in RViz to check the cooperative kinematics of up to three manipulators. Additionally, simulation with the dynamic engine Gazebo verified the cooperative controller applying a constant tension force on a massless spring-damper virtual object. With adequate model feedback linearization, the cooperative impedance controller tested on the da Vinci Research Kit yielded stable tension force tracking while simultaneously moving in Cartesian space. The maximum force tracking error was +/- 0.5 N for both a compliant and stiff manipulated object

Flexible-Link Robot Control Using a Linear Parameter Varying Systems Methodology

This paper addresses the issues of the Linear Parameter Varying (LPV) modelling and control of flexible-link robot manipulators. The LPV formalism allows the synthesis of nonlinear control laws and the assessment of their closed-loop stability and performances in a simple and effective manner, based on the use of Linear Matrix Inequalities (LMI). Following the quasi-LPV modelling approach, an LPV model of a flexible manipulator is obtained, starting from the nonlinear dynamic model stemming from Euler-Lagrange equations. Based on this LPV model, which has a rational dependence in terms of the varying parameters, two different methods for the synthesis of LPV controllers are explored. They guarantee the asymptotic stability and some level of closed-loop ℒ 2 -gain performance on a bounded parametric set. The first method exploits a descriptor representation that simplifies the rational dependence of the LPV model, whereas the second one manages the troublesome rational dependence by using dilated LMI conditions and taking the particular structure of the model into account. The resulting controllers involve the measured state variables only, namely the joint positions and velocities. Simulation results are presented that illustrate the validity of the proposed control methodology. Comparisons with an inversion-based nonlinear control method are performed in the presence of velocity measurement noise, model uncertainties and high-frequency inputs