Traceability of on-machine tool measurement: a review

Nowadays, errors during the manufacturing process of high value components are not acceptable in driving industries such as energy and transportation. Sectors such as aerospace, automotive, shipbuilding, nuclear power, large science facilities or wind power need complex and accurate components that demand close measurements and fast feedback into their manufacturing processes. New measuring technologies are already available in machine tools, including integrated touch probes and fast interface capabilities. They provide the possibility to measure the workpiece in-machine during or after its manufacture, maintaining the original setup of the workpiece and avoiding the manufacturing process from being interrupted to transport the workpiece to a measuring position. However, the traceability of the measurement process on a machine tool is not ensured yet and measurement data is still not fully reliable enough for process control or product validation. The scientific objective is to determine the uncertainty on a machine tool measurement and, therefore, convert it into a machine integrated traceable measuring process. For that purpose, an error budget should consider error sources such as the machine tools, components under measurement and the interactions between both of them. This paper reviews all those uncertainty sources, being mainly focused on those related to the machine tool, either on the process of geometric error assessment of the machine or on the technology employed to probe the measurand

Design and Control of Robotic Systems for Lower Limb Stroke Rehabilitation

Lower extremity stroke rehabilitation exhausts considerable health care resources, is labor intensive, and provides mostly qualitative metrics of patient recovery. To overcome these issues, robots can assist patients in physically manipulating their affected limb and measure the output motion. The robots that have been currently designed, however, provide assistance over a limited set of training motions, are not portable for in-home and in-clinic use, have high cost and may not provide sufficient safety or performance. This thesis proposes the idea of incorporating a mobile drive base into lower extremity rehabilitation robots to create a portable, inherently safe system that provides assistance over a wide range of training motions. A set of rehabilitative motion tasks were established and a six-degree-of-freedom (DOF) motion and force-sensing system was designed to meet high-power, large workspace, and affordability requirements. An admittance controller was implemented, and the feasibility of using this portable, low-cost system for movement assistance was shown through tests on a healthy individual. An improved version of the robot was then developed that added torque sensing and known joint elasticity for use in future clinical testing with a flexible-joint impedance controller

Concept development for lightweight binary-actuated robotic devices, with application to space systems

Thesis (S.M.)--Massachusetts Institute of Technology, Dept. of Mechanical Engineering, 2001."June 2001."Includes bibliographical references (leaves 66-71).Exploratory space missions of the future will require robotic systems to lead the way by negotiating and mapping very rough terrain, collecting samples, performing science tasks, and constructing facilities. These robots will need to be adaptable and reconfigurable in order to achieve a wide variety of objectives. Conventional designs using gears, motors, bearings, encoders, and many discrete components will be too complex, heavy, and failure-prone to allow highly-reconfigurable systems to be feasible. This thesis develops new concepts that may potentially enable the design of self-transforming space explorers. The vision of this research is to integrate compliant bistable mechanisms with large numbers of binary-actuated embedded smart materials. Compliant mechanisms are lightweight and robust. Binary actuation is the idea of using an actuator in a discrete on/off manner rather than in a continuous manner. A binary actuator is easy to control and robust, and by using tens or hundreds of binary actuators, one can approximate a continuous system, much like a digital computer can approximate an analog system. The first part of this thesis examines the fundamental planning issues involved with systems having large numbers of binary actuators. The notion of a workspace is described and applied to the optimization of a manipulator design. Methods for solving the forward and inverse kinematics are discussed in the context of this application. These methods are extended to the trajectory and locomotion planning problems. Methods for planning systems of substantial complexity are developed in the context of exploratory space robotics. The second part of this thesis presents experimental demonstrations that examine elements of the concept. The results of several design prototypes are discussed.by Matthew D. Lichter.S.M

Human Motion Analysis with Wearable Inertial Sensors

High-resolution, quantitative data obtained by a human motion capture system can be used to better understand the cause of many diseases for effective treatments. Talking about the daily care of the aging population, two issues are critical. One is to continuously track motions and position of aging people when they are at home, inside a building or in the unknown environment; the other is to monitor their health status in real time when they are in the free-living environment. Continuous monitoring of human movement in their natural living environment potentially provide more valuable feedback than these in laboratory settings. However, it has been extremely challenging to go beyond laboratory and obtain accurate measurements of human physical activity in free-living environments. Commercial motion capture systems produce excellent in-studio capture and reconstructions, but offer no comparable solution for acquisition in everyday environments. Therefore in this dissertation, a wearable human motion analysis system is developed for continuously tracking human motions, monitoring health status, positioning human location and recording the itinerary. In this dissertation, two systems are developed for seeking aforementioned two goals: tracking human body motions and positioning a human. Firstly, an inertial-based human body motion tracking system with our developed inertial measurement unit (IMU) is introduced. By arbitrarily attaching a wearable IMU to each segment, segment motions can be measured and translated into inertial data by IMUs. A human model can be reconstructed in real time based on the inertial data by applying high efficient twists and exponential maps techniques. Secondly, for validating the feasibility of developed tracking system in the practical application, model-based quantification approaches for resting tremor and lower extremity bradykinesia in Parkinson’s disease are proposed. By estimating all involved joint angles in PD symptoms based on reconstructed human model, angle characteristics with corresponding medical ratings are employed for training a HMM classifier for quantification. Besides, a pedestrian positioning system is developed for tracking user’s itinerary and positioning in the global frame. Corresponding tests have been carried out to assess the performance of each system

Real-time 3D hand reconstruction in challenging scenes from a single color or depth camera

Hands are one of the main enabling factors for performing complex tasks and humans naturally use them for interactions with their environment. Reconstruction and digitization of 3D hand motion opens up many possibilities for important applications. Hands gestures can be directly used for human–computer interaction, which is especially relevant for controlling augmented or virtual reality (AR/VR) devices where immersion is of utmost importance. In addition, 3D hand motion capture is a precondition for automatic sign-language translation, activity recognition, or teaching robots. Different approaches for 3D hand motion capture have been actively researched in the past. While being accurate, gloves and markers are intrusive and uncomfortable to wear. Hence, markerless hand reconstruction based on cameras is desirable. Multi-camera setups provide rich input, however, they are hard to calibrate and lack the flexibility for mobile use cases. Thus, the majority of more recent methods uses a single color or depth camera which, however, makes the problem harder due to more ambiguities in the input. For interaction purposes, users need continuous control and immediate feedback. This means the algorithms have to run in real time and be robust in uncontrolled scenes. These requirements, achieving 3D hand reconstruction in real time from a single camera in general scenes, make the problem significantly more challenging. While recent research has shown promising results, current state-of-the-art methods still have strong limitations. Most approaches only track the motion of a single hand in isolation and do not take background-clutter or interactions with arbitrary objects or the other hand into account. The few methods that can handle more general and natural scenarios run far from real time or use complex multi-camera setups. Such requirements make existing methods unusable for many aforementioned applications. This thesis pushes the state of the art for real-time 3D hand tracking and reconstruction in general scenes from a single RGB or depth camera. The presented approaches explore novel combinations of generative hand models, which have been used successfully in the computer vision and graphics community for decades, and powerful cutting-edge machine learning techniques, which have recently emerged with the advent of deep learning. In particular, this thesis proposes a novel method for hand tracking in the presence of strong occlusions and clutter, the first method for full global 3D hand tracking from in-the-wild RGB video, and a method for simultaneous pose and dense shape reconstruction of two interacting hands that, for the first time, combines a set of desirable properties previously unseen in the literature.Hände sind einer der Hauptfaktoren für die Ausführung komplexer Aufgaben, und Menschen verwenden sie auf natürliche Weise für Interaktionen mit ihrer Umgebung. Die Rekonstruktion und Digitalisierung der 3D-Handbewegung eröffnet viele Möglichkeiten für wichtige Anwendungen. Handgesten können direkt als Eingabe für die Mensch-Computer-Interaktion verwendet werden. Dies ist insbesondere für Geräte der erweiterten oder virtuellen Realität (AR / VR) relevant, bei denen die Immersion von größter Bedeutung ist. Darüber hinaus ist die Rekonstruktion der 3D Handbewegung eine Voraussetzung zur automatischen Übersetzung von Gebärdensprache, zur Aktivitätserkennung oder zum Unterrichten von Robotern. In der Vergangenheit wurden verschiedene Ansätze zur 3D-Handbewegungsrekonstruktion aktiv erforscht. Handschuhe und physische Markierungen sind zwar präzise, aber aufdringlich und unangenehm zu tragen. Daher ist eine markierungslose Handrekonstruktion auf der Basis von Kameras wünschenswert. Multi-Kamera-Setups bieten umfangreiche Eingabedaten, sind jedoch schwer zu kalibrieren und haben keine Flexibilität für mobile Anwendungsfälle. Daher verwenden die meisten neueren Methoden eine einzelne Farb- oder Tiefenkamera, was die Aufgabe jedoch schwerer macht, da mehr Ambiguitäten in den Eingabedaten vorhanden sind. Für Interaktionszwecke benötigen Benutzer kontinuierliche Kontrolle und sofortiges Feedback. Dies bedeutet, dass die Algorithmen in Echtzeit ausgeführt werden müssen und robust in unkontrollierten Szenen sein müssen. Diese Anforderungen, 3D-Handrekonstruktion in Echtzeit mit einer einzigen Kamera in allgemeinen Szenen, machen das Problem erheblich schwieriger. Während neuere Forschungsarbeiten vielversprechende Ergebnisse gezeigt haben, weisen aktuelle Methoden immer noch Einschränkungen auf. Die meisten Ansätze verfolgen die Bewegung einer einzelnen Hand nur isoliert und berücksichtigen keine alltäglichen Umgebungen oder Interaktionen mit beliebigen Objekten oder der anderen Hand. Die wenigen Methoden, die allgemeinere und natürlichere Szenarien verarbeiten können, laufen nicht in Echtzeit oder verwenden komplexe Multi-Kamera-Setups. Solche Anforderungen machen bestehende Verfahren für viele der oben genannten Anwendungen unbrauchbar. Diese Dissertation erweitert den Stand der Technik für die Echtzeit-3D-Handverfolgung und -Rekonstruktion in allgemeinen Szenen mit einer einzelnen RGB- oder Tiefenkamera. Die vorgestellten Algorithmen erforschen neue Kombinationen aus generativen Handmodellen, die seit Jahrzehnten erfolgreich in den Bereichen Computer Vision und Grafik eingesetzt werden, und leistungsfähigen innovativen Techniken des maschinellen Lernens, die vor kurzem mit dem Aufkommen neuronaler Netzwerke entstanden sind. In dieser Arbeit werden insbesondere vorgeschlagen: eine neuartige Methode zur Handbewegungsrekonstruktion bei starken Verdeckungen und in unkontrollierten Szenen, die erste Methode zur Rekonstruktion der globalen 3D Handbewegung aus RGB-Videos in freier Wildbahn und die erste Methode zur gleichzeitigen Rekonstruktion von Handpose und -form zweier interagierender Hände, die eine Reihe wünschenwerter Eigenschaften komibiniert

Teleoperation of MRI-Compatible Robots with Hybrid Actuation and Haptic Feedback

Image guided surgery (IGS), which has been developing fast recently, benefits significantly from the superior accuracy of robots and magnetic resonance imaging (MRI) which is a great soft tissue imaging modality. Teleoperation is especially desired in the MRI because of the highly constrained space inside the closed-bore MRI and the lack of haptic feedback with the fully autonomous robotic systems. It also very well maintains the human in the loop that significantly enhances safety. This dissertation describes the development of teleoperation approaches and implementation on an example system for MRI with details of different key components. The dissertation firstly describes the general teleoperation architecture with modular software and hardware components. The MRI-compatible robot controller, driving technology as well as the robot navigation and control software are introduced. As a crucial step to determine the robot location inside the MRI, two methods of registration and tracking are discussed. The first method utilizes the existing Z shaped fiducial frame design but with a newly developed multi-image registration method which has higher accuracy with a smaller fiducial frame. The second method is a new fiducial design with a cylindrical shaped frame which is especially suitable for registration and tracking for needles. Alongside, a single-image based algorithm is developed to not only reach higher accuracy but also run faster. In addition, performance enhanced fiducial frame is also studied by integrating self-resonant coils. A surgical master-slave teleoperation system for the application of percutaneous interventional procedures under continuous MRI guidance is presented. The slave robot is a piezoelectric-actuated needle insertion robot with fiber optic force sensor integrated. The master robot is a pneumatic-driven haptic device which not only controls the position of the slave robot, but also renders the force associated with needle placement interventions to the surgeon. Both of master and slave robots mechanical design, kinematics, force sensing and feedback technologies are discussed. Force and position tracking results of the master-slave robot are demonstrated to validate the tracking performance of the integrated system. MRI compatibility is evaluated extensively. Teleoperated needle steering is also demonstrated under live MR imaging. A control system of a clinical grade MRI-compatible parallel 4-DOF surgical manipulator for minimally invasive in-bore prostate percutaneous interventions through the patient’s perineum is discussed in the end. The proposed manipulator takes advantage of four sliders actuated by piezoelectric motors and incremental rotary encoders, which are compatible with the MRI environment. Two generations of optical limit switches are designed to provide better safety features for real clinical use. The performance of both generations of the limit switch is tested. MRI guided accuracy and MRI-compatibility of whole robotic system is also evaluated. Two clinical prostate biopsy cases have been conducted with this assistive robot

Traceable onboard metrology for machine tools and large-scale systems

Esta tesis doctoral persigue la mejora de las funcionalidades de las máquinas herramienta para la fabricación de componentes de alto valor añadido. En concreto, la tesis se centra en mejorar la precisión de las máquinas herramienta en todo su volumen de trabajo y en desarrollar el conocimiento para realizar la medición por coordenadas trazable con este medio productivo. En realidad, la tecnología para realizar mediciones en máquina herramienta ya está disponible, como son los palpadores de contacto y los softwares de medición, sin embargo, hay varios factores que limitan la trazabilidad de la medición realizada en condiciones de taller, que no permiten emplear estas medidas para controlar el proceso de fabricación o validar la pieza en la propia máquina-herramienta, asegurando un proceso de fabricación de cero-defectos. Aquí, se propone el empleo del documento técnico ISO 15530-3 para piezas de tamaño medio. Para las piezas de gran tamaño se presenta una nueva metodología basada en la guía VDI 2617-11, que no está limitada por el empleo de una pieza patrón para caracterizar el error sistemático de la medición por coordenadas en la máquina-herramienta. De esta forma, se propone una calibración previa de la máquina-herramienta mediante una solución de multilateración integrada en máquina, que se traduce en la automatización del proceso de verificación y permite reducir el tiempo y la incertidumbre de medida. En paralelo, con el conocimiento generado en la integración de esta solución en la máquina-herramienta, se propone un nuevo procedimiento para la caracterización de la precisión de apunte del telescopio LSST en todo su rango de trabajo. Este nuevo procedimiento presenta una solución automática e integrada con tecnología láser tracker para aplicaciones de gran tamaño donde la precisión del sistema es un requerimiento clave para su buen funcionamiento.<br /