Enhanced online programming for industrial robots

The use of robots and automation levels in the industrial sector is expected to grow, and is driven by the on-going need for lower costs and enhanced productivity. The manufacturing industry continues to seek ways of realizing enhanced production, and the programming of articulated production robots has been identified as a major area for improvement. However, realizing this automation level increase requires capable programming and control technologies. Many industries employ offline-programming which operates within a manually controlled and specific work environment. This is especially true within the high-volume automotive industry, particularly in high-speed assembly and component handling. For small-batch manufacturing and small to medium-sized enterprises, online programming continues to play an important role, but the complexity of programming remains a major obstacle for automation using industrial robots. Scenarios that rely on manual data input based on real world obstructions require that entire production systems cease for significant time periods while data is being manipulated, leading to financial losses. The application of simulation tools generate discrete portions of the total robot trajectories, while requiring manual inputs to link paths associated with different activities. Human input is also required to correct inaccuracies and errors resulting from unknowns and falsehoods in the environment. This study developed a new supported online robot programming approach, which is implemented as a robot control program. By applying online and offline programming in addition to appropriate manual robot control techniques, disadvantages such as manual pre-processing times and production downtimes have been either reduced or completely eliminated. The industrial requirements were evaluated considering modern manufacturing aspects. A cell-based Voronoi generation algorithm within a probabilistic world model has been introduced, together with a trajectory planner and an appropriate human machine interface. The robot programs so achieved are comparable to manually programmed robot programs and the results for a Mitsubishi RV-2AJ five-axis industrial robot are presented. Automated workspace analysis techniques and trajectory smoothing are used to accomplish this. The new robot control program considers the working production environment as a single and complete workspace. Non-productive time is required, but unlike previously reported approaches, this is achieved automatically and in a timely manner. As such, the actual cell-learning time is minimal

Three-dimensional localization and mapping of static environments by means of mobile perception

Model-based task planning is one of the main capabilities of autonomous mobile robots. Especially for model-based localization and path planning, a large-scale description of the operation environment is required. Cognitive communication between man and his machine could be based on a common, three-dimensional understanding of the environment. In the case of a personal service robot, the operation environment may comprise both indoor and outdoor spaces. In this thesis, a method for the generation of a three-dimensional geometric model for large scale, structured and natural environments is presented. The environment mapping method, which uses range images as measurement data, consists of three main phases: first, geometric features are extracted from each of the range images. Secondly, the relative coordinate transformations (i.e. registrations) between the sensor viewpoint locations, where the range data was measured, are computed. And, finally, an integrated map is formed by transforming the sub-map data into a common frame of reference. Two types of geometric features are extracted from the range images: cylinder segments (or more generally truncated cone segments) and straight-line segments. With cylinder segments tree trunks and other elongated cylindrical objects can be modeled, whereas the straight line segments correspond to the upper corners of vertical walls. The features are utilized as natural landmarks for registration computation. The presented method is tested by mapping three test sites representing structured, semi-structured and natural environments. The structured environment corresponds to a part of the premises of an office building, the semi-structured environment corresponds to the surroundings of a parking lot and the natural environment is a small forest area. The dimensions of the test sites are about 50 meters, 120 meters and 40 meters square, respectively. A simple incremental approach is used to build an integrated model for the parking lot and office corridor environments. For the principal mapping experiment, concerning the small forest area, a statistically more sound, optimal approach is applied. With respect to the feature extraction methods and the computation of the relative coordinate transformations between the viewpoints, robustness to outlier data and failure modes of the methods are discussed in more detail.reviewe