Collision-free path coordination and cycle time optimization of industrial robot cells

In industry, short ramp-up times, product quality, product customization and high production rates are among the main drivers of technological progress. This is especially true for automotive manufacturers whose market is very competitive, constantly pushing for new solutions. In this industry, many of the processes are carried out by robots: for example, operations such as stud/spot welding, sealing, painting and inspection. Besides higher production rates, the improvement of these processes is important from a sustainability perspective, since an optimized equipment utilization may be achieved, in terms of resources used, including such things as robots, energy, and physical prototyping. The achievements of such goals may, nowadays, be reached also thanks to virtual methods, which make modeling, simulation and optimization of industrial processes possible. The work in this thesis may be positioned in this area and focuses on virtual product and production development for throughput improvement of robotics processes in the automotive industry. Specifically, the thesis presents methods, algorithms and tools to avoid collisions and minimize cycle time in multi-robot stations. It starts with an overview of the problem, providing insights into the relationship between the volumes shared by the robots\u27 workspaces and more abstract modeling spaces. It then describes a computational method for minimizing cycle time when robot paths are geometrically fixed and only velocity tuning is allowed to avoid collisions. Additional requirements are considered for running these solutions in industrial setups, specifically the time delays introduced when stopping robots to exchange information with a programmable logic controller (PLC). A post-processing step is suggested, with algorithms taking into account these practical constraints. When no communication at all with the PLC is highly desirable, a method of providing such programs is described to give completely separated robot workspaces. Finally, when this is not possible (in very cluttered environments and with densely distributed tasks, for example), robot routes are modified by changing the order of operations to avoid collisions between robots.In summary, by requiring fewer iterations between different planning stages, using automatic tools to optimize the process and by reducing physical prototyping, the research presented in this thesis (and the corresponding implementation in software platforms) will improve virtual product and production realization for robotic applications

Coordination control of robot manipulators using flat outputs

Published ArticleThis paper focuses on the synchronizing control of multiple interconnected flexible robotic manipulators using differential flatness theory. The flatness theory has the advantage of simplifying trajectory tracking tasks of complex mechanical systems. Using this theory, we propose a new synchronization scheme whereby a formation of flatness based systems can be stabilized using their respective flat outputs. Using the flat outputs, we eliminate the need for cross coupling laws and communication protocols associated with such formations. The problem of robot coordination is reduced to synchronizing the flat outputs between the respective robot manipulators. Furthermore, the selection of the flat output used for the synchronizing control is not restricted as any system variable can be used. The problem of unmeasured states used in the control is also solved by reconstructing the missing states using flatness based interpolation. The proposed control law is less computationally intensive when compared to earlier reported work as integration of the differential equations is not required. Simulations using a formation of single link flexible joint robots are used to validate the proposed synchronizing control

Coordination control of robot manipulators using flat outputs

Published ArticleThis paper focuses on the synchronizing control of multiple interconnected flexible robotic manipulators using differential flatness theory. The flatness theory has the advantage of simplifying trajectory tracking tasks of complex mechanical systems. Using this theory, we propose a new synchronization scheme whereby a formation of flatness based systems can be stabilized using their respective flat outputs. Using the flat outputs, we eliminate the need for cross coupling laws and communication protocols associated with such formations. The problem of robot coordination is reduced to synchronizing the flat outputs between the respective robot manipulators. Furthermore, the selection of the flat output used for the synchronizing control is not restricted as any system variable can be used. The problem of unmeasured states used in the control is also solved by reconstructing the missing states using flatness based interpolation. The proposed control law is less computationally intensive when compared to earlier reported work as integration of the differential equations is not required. Simulations using a formation of single link flexible joint robots are used to validate the proposed synchronizing control

Engineering evolutionary control for real-world robotic systems

Evolutionary Robotics (ER) is the field of study concerned with the application of evolutionary computation to the design of robotic systems. Two main issues have prevented ER from being applied to real-world tasks, namely scaling to complex tasks and the transfer of control to real-robot systems. Finding solutions to complex tasks is challenging for evolutionary approaches due to the bootstrap problem and deception. When the task goal is too difficult, the evolutionary process will drift in regions of the search space with equally low levels of performance and therefore fail to bootstrap. Furthermore, the search space tends to get rugged (deceptive) as task complexity increases, which can lead to premature convergence. Another prominent issue in ER is the reality gap. Behavioral control is typically evolved in simulation and then only transferred to the real robotic hardware when a good solution has been found. Since simulation is an abstraction of the real world, the accuracy of the robot model and its interactions with the environment is limited. As a result, control evolved in a simulator tends to display a lower performance in reality than in simulation. In this thesis, we present a hierarchical control synthesis approach that enables the use of ER techniques for complex tasks in real robotic hardware by mitigating the bootstrap problem, deception, and the reality gap. We recursively decompose a task into sub-tasks, and synthesize control for each sub-task. The individual behaviors are then composed hierarchically. The possibility of incrementally transferring control as the controller is composed allows transferability issues to be addressed locally in the controller hierarchy. Our approach features hybridity, allowing different control synthesis techniques to be combined. We demonstrate our approach in a series of tasks that go beyond the complexity of tasks where ER has been successfully applied. We further show that hierarchical control can be applied in single-robot systems and in multirobot systems. Given our long-term goal of enabling the application of ER techniques to real-world tasks, we systematically validate our approach in real robotic hardware. For one of the demonstrations in this thesis, we have designed and built a swarm robotic platform, and we show the first successful transfer of evolved and hierarchical control to a swarm of robots outside of controlled laboratory conditions.A Robótica Evolutiva (RE) é a área de investigação que estuda a aplicação de computação evolutiva na conceção de sistemas robóticos. Dois principais desafios têm impedido a aplicação da RE em tarefas do mundo real: a dificuldade em solucionar tarefas complexas e a transferência de controladores evoluídos para sistemas robóticos reais. Encontrar soluções para tarefas complexas é desafiante para as técnicas evolutivas devido ao bootstrap problem e à deception. Quando o objetivo é demasiado difícil, o processo evolutivo tende a permanecer em regiões do espaço de procura com níveis de desempenho igualmente baixos, e consequentemente não consegue inicializar. Por outro lado, o espaço de procura tende a enrugar à medida que a complexidade da tarefa aumenta, o que pode resultar numa convergência prematura. Outro desafio na RE é a reality gap. O controlo robótico é tipicamente evoluído em simulação, e só é transferido para o sistema robótico real quando uma boa solução tiver sido encontrada. Como a simulação é uma abstração da realidade, a precisão do modelo do robô e das suas interações com o ambiente é limitada, podendo resultar em controladores com um menor desempenho no mundo real. Nesta tese, apresentamos uma abordagem de síntese de controlo hierárquica que permite o uso de técnicas de RE em tarefas complexas com hardware robótico real, mitigando o bootstrap problem, a deception e a reality gap. Decompomos recursivamente uma tarefa em sub-tarefas, e sintetizamos controlo para cada subtarefa. Os comportamentos individuais são então compostos hierarquicamente. A possibilidade de transferir o controlo incrementalmente à medida que o controlador é composto permite que problemas de transferibilidade possam ser endereçados localmente na hierarquia do controlador. A nossa abordagem permite o uso de diferentes técnicas de síntese de controlo, resultando em controladores híbridos. Demonstramos a nossa abordagem em várias tarefas que vão para além da complexidade das tarefas onde a RE foi aplicada. Também mostramos que o controlo hierárquico pode ser aplicado em sistemas de um robô ou sistemas multirobô. Dado o nosso objetivo de longo prazo de permitir o uso de técnicas de RE em tarefas no mundo real, concebemos e desenvolvemos uma plataforma de robótica de enxame, e mostramos a primeira transferência de controlo evoluído e hierárquico para um exame de robôs fora de condições controladas de laboratório.This work has been supported by the Portuguese Foundation for Science and Technology (Fundação para a Ciência e Tecnologia) under the grants SFRH/BD/76438/2011, EXPL/EEI-AUT/0329/2013, and by Instituto de Telecomunicações under the grant UID/EEA/50008/2013

Task Allocation Strategies in Multi-Robot Environment

Multirobot systems (MRS) hold the promise of improved performance and increased fault tolerance for large-scale problems. A robot team can accomplish a given task more quickly than a single agent by executing them concurrently. A team can also make effective use of specialists designed for a single purpose rather than requiring that a single robot be a generalist. Multirobot coordination, however, is a complex problem. An empirical study is described in the thesis that sought general guidelines for task allocation strategies. Different strategies are identified, and demonstrated in the multi-robot environment.Robot selection is one of the critical issues in the design of robotic workcells. Robot selection for an application is generally done based on experience, intuition and at most using the kinematic considerations like workspace, manipulability, etc. This problem has become more difficult in recent years due to increasing complexity, available features, and facilities offered by different robotic products. A systematic procedure is developed for selection of robot manipulators based on their different pertinent attributes. The robot selection procedure allows rapid convergence from a very large number of candidate robots to a manageable shortlist of potentially suitable robots. Subsequently, the selection procedure proceeds to rank the alternatives in the shortlist by employing different attributes based specification methods. This is an attempt to create exhaustive procedure by identifying maximum possible number of attributes for robot manipulators.Availability of large number of robot configurations has made the robot workcell designers think over the issue of selecting the most suitable one for a given set of operations. The process of selection of the appropriate kind of robot must consider the various attributes of the robot manipulator in conjunction with the requirement of the various operations for accomplishing the task. The present work is an attempt to develop a systematic procedure for selection of robot based on an integrated model encompassing the manipulator attributes and manipulator requirements

Design of an UAV swarm

This master thesis tries to give an overview on the general aspects involved in the design of an UAV swarm. UAV swarms are continuoulsy gaining popularity amongst researchers and UAV manufacturers, since they allow greater success rates in task accomplishing with reduced times. Appart from this, multiple UAVs cooperating between them opens a new field of missions that can only be carried in this way. All the topics explained within this master thesis will explain all the agents involved in the design of an UAV swarm, from the communication protocols between them, navigation and trajectory analysis and task allocation