Modeling, simulation and control of microrobots for the microfactory.

Future assembly technologies will involve higher levels of automation in order to satisfy increased microscale or nanoscale precision requirements. Traditionally, assembly using a top-down robotic approach has been well-studied and applied to the microelectronics and MEMS industries, but less so in nanotechnology. With the boom of nanotechnology since the 1990s, newly designed products with new materials, coatings, and nanoparticles are gradually entering everyone’s lives, while the industry has grown into a billion-dollar volume worldwide. Traditionally, nanotechnology products are assembled using bottom-up methods, such as self-assembly, rather than top-down robotic assembly. This is due to considerations of volume handling of large quantities of components, and the high cost associated with top-down manipulation requiring precision. However, bottom-up manufacturing methods have certain limitations, such as components needing to have predefined shapes and surface coatings, and the number of assembly components being limited to very few. For example, in the case of self-assembly of nano-cubes with an origami design, post-assembly manipulation of cubes in large quantities and cost-efficiency is still challenging. In this thesis, we envision a new paradigm for nanoscale assembly, realized with the help of a wafer-scale microfactory containing large numbers of MEMS microrobots. These robots will work together to enhance the throughput of the factory, while their cost will be reduced when compared to conventional nanopositioners. To fulfill the microfactory vision, numerous challenges related to design, power, control, and nanoscale task completion by these microrobots must be overcome. In this work, we study two classes of microrobots for the microfactory: stationary microrobots and mobile microrobots. For the stationary microrobots in our microfactory application, we have designed and modeled two different types of microrobots, the AFAM (Articulated Four Axes Microrobot) and the SolarPede. The AFAM is a millimeter-size robotic arm working as a nanomanipulator for nanoparticles with four degrees of freedom, while the SolarPede is a light-powered centimeter-size robotic conveyor in the microfactory. For mobile microrobots, we have introduced the world’s first laser-driven micrometer-size locomotor in dry environments, called ChevBot to prove the concept of the motion mechanism. The ChevBot is fabricated using MEMS technology in the cleanroom, following a microassembly step. We showed that it can perform locomotion with pulsed laser energy on a dry surface. Based on the knowledge gained with the ChevBot, we refined tits fabrication process to remove the assembly step and increase its reliability. We designed and fabricated a steerable microrobot, the SerpenBot, in order to achieve controllable behavior with the guidance of a laser beam. Through modeling and experimental study of the characteristics of this type of microrobot, we proposed and validated a new type of deep learning controller, the PID-Bayes neural network controller. The experiments showed that the SerpenBot can achieve closed-loop autonomous operation on a dry substrate

Micro-manufacturing : research, technology outcomes and development issues

Besides continuing effort in developing MEMS-based manufacturing techniques, latest effort in Micro-manufacturing is also in Non-MEMS-based manufacturing. Research and technological development (RTD) in this field is encouraged by the increased demand on micro-components as well as promised development in the scaling down of the traditional macro-manufacturing processes for micro-length-scale manufacturing. This paper highlights some EU funded research activities in micro/nano-manufacturing, and gives examples of the latest development in micro-manufacturing methods/techniques, process chains, hybrid-processes, manufacturing equipment and supporting technologies/device, etc., which is followed by a summary of the achievements of the EU MASMICRO project. Finally, concluding remarks are given, which raise several issues concerning further development in micro-manufacturing

Robotic micromanipulation for microassembly : modelling by sequencial function chart and achievement by multiple scale visual servoings.

International audienceThe paper investigates robotic assembly by focusing on the manipulation of microparts. This task is formalized through the notion of basic tasks which are organized in a logical sequence represented by a function chart and interpreted as the model of the behavior of the experimental setup. The latter includes a robotic system, a gripping system, an imaging system, and a clean environment. The imaging system is a photon videomicroscope able to work at multiple scales. It is modelled by a linear projective model where the relation between the scale factor and the magnification or zoom is explicitly established. So, the usual visual control law is modified in order to take into account this relation. The manipulation of some silicon microparts (400 μm×400 μm×100 μm) by means of a distributed robotic system (xyθ system, ϕz system), a two-finger gripping system and a controllable zoom and focus videomicroscope shows the relevance of the concepts. The 30 % of failure rate comes mainly from the physical phenomena (electrostatic and capillary forces) instead of the accuracy of control or the occultations of microparts

International Workshop on MicroFactories (IWMF 2012): 17th-20th June 2012 Tampere Hall Tampere, Finland

This Workshop provides a forum for researchers and practitioners in industry working on the diverse issues of micro and desktop factories, as well as technologies and processes applicable for micro and desktop factories. Micro and desktop factories decrease the need of factory floor space, and reduce energy consumption and improve material and resource utilization thus strongly supporting the new sustainable manufacturing paradigm. They can be seen also as a proper solution to point-of-need manufacturing of customized and personalized products near the point of need

Towards an integrated framework for the configuration of modular micro assembly systems

The future of manufacturing in high-cost economies is to maximise responsiveness to change whilst simultaneously minimising the financial implications. The concept of Reconfigurable Assembly Systems (RAS) has been proposed as a potential route to achieving this ideal. RASs offer the potential to rapidly change the configuration of a system in response to predicted or unforeseen events through standardised mechanical, electrical and software interfaces within a modular environment. This greatly reduces the design and integration effort for a single configuration, which, in combination with the concept of equipment leasing, enables the potential for reduction in system cost, reconfiguration cost, lead time and down time. This work was motivated by the slow implementation of the RAS concept in industry due, in part, to the limited research into the planning of multiple system reconfigurations. The challenge is to enable consideration of, and planning for, the production of numerous different products within a single modular, reconfigurable assembly environment. The developed methodology is to be structured and traceable, but also adaptable to specific and varying circumstances. This thesis presents an approach that aims towards providing a framework for the configuration of modular assembly systems. The approach consists of a capability model, a reconfiguration methodology and auxiliary functions. As a result, the approach facilitates the complete process of requirement elicitation, capability identification, definition and comparison, configuration analysis and optimisation and the generation of a system configuration lifecycle. The developed framework is demonstrated through a number of test case applications, which were used during the research, as well as the development of some specific technological applications needed to support the approach and application

Towards an integrated framework for the configuration of modular micro assembly systems

The future of manufacturing in high-cost economies is to maximise responsiveness to change whilst simultaneously minimising the financial implications. The concept of Reconfigurable Assembly Systems (RAS) has been proposed as a potential route to achieving this ideal. RASs offer the potential to rapidly change the configuration of a system in response to predicted or unforeseen events through standardised mechanical, electrical and software interfaces within a modular environment. This greatly reduces the design and integration effort for a single configuration, which, in combination with the concept of equipment leasing, enables the potential for reduction in system cost, reconfiguration cost, lead time and down time. This work was motivated by the slow implementation of the RAS concept in industry due, in part, to the limited research into the planning of multiple system reconfigurations. The challenge is to enable consideration of, and planning for, the production of numerous different products within a single modular, reconfigurable assembly environment. The developed methodology is to be structured and traceable, but also adaptable to specific and varying circumstances. This thesis presents an approach that aims towards providing a framework for the configuration of modular assembly systems. The approach consists of a capability model, a reconfiguration methodology and auxiliary functions. As a result, the approach facilitates the complete process of requirement elicitation, capability identification, definition and comparison, configuration analysis and optimisation and the generation of a system configuration lifecycle. The developed framework is demonstrated through a number of test case applications, which were used during the research, as well as the development of some specific technological applications needed to support the approach and application

Factors of Micromanipulation Accuracy and Learning

Micromanipulation refers to the manipulation under a microscope in order to perform delicate procedures. It is difficult for humans to manipulate objects accurately under a microscope due to tremor and imperfect perception, limiting performance. This project seeks to understand factors affecting accuracy in micromanipulation, and to propose strategies for learning improving accuracy. Psychomotor experiments were conducted using computer-controlled setups to determine how various feedback modalities and learning methods can influence micromanipulation performance. In a first experiment, static and motion accuracy of surgeons, medical students and non-medical students under different magniification levels and grip force settings were compared. A second experiment investigated whether the non-dominant hand placed close to the target can contribute to accurate pointing of the dominant hand. A third experiment tested a training strategy for micromanipulation using unstable dynamics to magnify motion error, a strategy shown to be decreasing deviation in large arm movements. Two virtual reality (VR) modules were then developed to train needle grasping and needle insertion tasks, two primitive tasks in a microsurgery suturing procedure. The modules provided the trainee with a visual display in stereoscopic view and information on their grip, tool position and angles. Using the VR module, a study examining effects of visual cues was conducted to train tool orientation. Results from these studies suggested that it is possible to learn and improve accuracy in micromanipulation using appropriate sensorimotor feedback and training

Proceedings of the 2018 Canadian Society for Mechanical Engineering (CSME) International Congress

Published proceedings of the 2018 Canadian Society for Mechanical Engineering (CSME) International Congress, hosted by York University, 27-30 May 2018