Implementation of a robotic flexible assembly system

As part of the Intelligent Task Automation program, a team developed enabling technologies for programmable, sensory controlled manipulation in unstructured environments. These technologies include 2-D/3-D vision sensing and understanding, force sensing and high speed force control, 2.5-D vision alignment and control, and multiple processor architectures. The subsequent design of a flexible, programmable, sensor controlled robotic assembly system for small electromechanical devices is described using these technologies and ongoing implementation and integration efforts. Using vision, the system picks parts dumped randomly in a tray. Using vision and force control, it performs high speed part mating, in-process monitoring/verification of expected results and autonomous recovery from some errors. It is programmed off line with semiautomatic action planning

Coordination of several robots based on temporal synchronization

© 2016. This manuscript version is made available under the CC-BY-NC-ND 4.0 license http://creativecommons.org/licenses/by-nc-nd/4.0/This paper proposes an approach to deal with the problem of coordinating multi-robot systems, in which each robot executes individually planned tasks in a shared workspace. The approach is a decoupled method that can coordinate the participating robots in on-line mode. The coordination is achieved through the adjustment of the time evolution of each robot along its original planned geometric path according to the movements of the other robots to assure a collision-free execution of their respective tasks. To assess the proposed approach different tests were performed in graphical simulations and real experiments.Postprint (published version

Contact-less and Programming-less Human-Robot Collaboration

AbstractIn today's manufacturing environment, safe human-robot collaboration is of paramount importance, to improve efficiency and flexibility. Targeting the safety issue, this paper presents an approach for human-robot collaboration in a shared workplace in close proximity, where real data driven 3D model of a robot and multiple depth images of the workplace are used for monitoring and decision-making to perform a task. The strategy for robot control depends on the current task and the information about the operator's presence and position. A case study of assembly is carried out in a robotic assembly cell with human collaboration. The results show that this approach can be applied in real-world applications such as human-robot collaborative assembly with human operators safeguarded at all time

Trust-Based Control of Robotic Manipulators in Collaborative Assembly in Manufacturing

Human-robot interaction (HRI) is vastly addressed in the field of automation and manufacturing. Most of the HRI literature in manufacturing explored physical human-robot interaction (pHRI) and invested in finding means for ensuring safety and optimized effort sharing amongst a team of humans and robots. The recent emergence of safe, lightweight, and human-friendly robots has opened a new realm for human-robot collaboration (HRC) in collaborative manufacturing. For such robots with the new HRI functionalities to interact closely and effectively with a human coworker, new human-centered controllers that integrate both physical and social interaction are demanded. Social human-robot interaction (sHRI) has been demonstrated in robots with affective abilities in education, social services, health care, and entertainment. Nonetheless, sHRI should not be limited only to those areas. In particular, we focus on human trust in robot as a basis of social interaction. Human trust in robot and robot anthropomorphic features have high impacts on sHRI. Trust is one of the key factors in sHRI and a prerequisite for effective HRC. Trust characterizes the reliance and tendency of human in using robots. Factors within a robotic system (e.g. performance, reliability, or attribute), the task, and the surrounding environment can all impact the trust dynamically. Over-reliance or under-reliance might occur due to improper trust, which results in poor team collaboration, and hence higher task load and lower overall task performance. The goal of this dissertation is to develop intelligent control algorithms for the manipulator robots that integrate both physical and social HRI factors in the collaborative manufacturing. First, the evolution of human trust in a collaborative robot model is identified and verified through a series of human-in-the-loop experiments. This model serves as a computational trust model estimating an objective criterion for the evolution of human trust in robot rather than estimating an individual\u27s actual level of trust. Second, an HRI-based framework is developed for controlling the speed of a robot performing pick and place tasks. The impact of the consideration of the different level of interaction in the robot controller on the overall efficiency and HRI criteria such as human perceived workload and trust and robot usability is studied using a series of human-in-the-loop experiments. Third, an HRI-based framework is developed for planning and controlling the robot motion in performing hand-over tasks to the human. Again, series of human-in-the-loop experimental studies are conducted to evaluate the impact of implementation of the frameworks on overall efficiency and HRI criteria such as human workload and trust and robot usability. Finally, another framework is proposed for the cooperative manipulation of a common object by a team of a human and a robot. This framework proposes a trust-based role allocation strategy for adjusting the proactive behavior of the robot performing a cooperative manipulation task in HRC scenarios. For the mentioned frameworks, the results of the experiments show that integrating HRI in the robot controller leads to a lower human workload while it maintains a threshold level of human trust in robot and does not degrade robot usability and efficiency

Engineering Method and Tool for the Complete Virtual Commissioning of Robotic Cells

Intelligent robotic manufacturing cells must adapt to ever-varying operating conditions, developing autonomously optimal manufacturing strategies to achieve the best quality and overall productivity. Intelligent and cognitive behaviors are realized by using distributed controllers, in which complex control logics must interact and process a wide variety of input/output signals. In particular, programmable logic controllers (PLCs) and robot controllers must be coordinated and integrated. Then, there is the need to simulate the robotic cells’ behavior for performance verification and optimization by evaluating the effects of both PLC and robot control codes. In this context, this work proposes a method, and its implementation into an integrated tool, to exploit the potential of ABB RobotStudio software as a virtual prototyping platform for robotic cells, in which real robots control codes are executed on a virtual controller and integrated with Beckhoff PLC environment. For this purpose, a PLC Smart Component was conceived as an extension of RobotStudio functionalities to exchange signals with a TwinCAT instance. The new module allows the virtual commissioning of a complete robotic cell to be performed, assessing the control logics effects on the overall productivity. The solution is demonstrated on a robotic assembly cell, showing its feasibility and effectiveness in optimizing the final performance

Safety Assessment Strategy for Collaborative Robot Installations

Industrial resource efficiency can be improved if the safety barrier between humans and robots is removed, as this enables operators and robots to work side by side or in direct collaboration to solve a task, usually referred to as a collaborative robot installation. Even though technology development makes the barrier removal ever more feasible from a safety perspective, this still produces a possible hazardous working environment, and safety assessment strategies are crucial. A wide area of knowledge is required to assess all fields that can help ensure safe human-machine interaction. Here the focus is primarily on providing a description of the key fields identified, including how operators psychologically accept working with robots, and providing a cursory description of the research front for each individual field. In addition to covering a large number of parameters, the assessment strategy also needs to be cost-effective. A significant part of all parameters that can be considered when attempting to produce optimized and cost-effective collaborative robot installations will also have a direct impact on operator safety. Hence, assessments for safety, and assessments for cost-effectiveness, cannot be separated, and are treated as two objectives that need to be viewed in sync

Motion planning using synergies : application to anthropomorphic dual-arm robots

Motion planning is a traditional field in robotics, but new problems are nevertheless incessantly appearing, due to continuous advances in the robot developments. In order to solve these new problems, as well as to improve the existing solutions to classical problems, new approaches are being proposed. A paradigmatic case is the humanoid robotics, since the advances done in this field require motion planners not only to look efficiently for an optimal solution in the classic way, i.e. optimizing consumed energy or time in the plan execution, but also looking for human-like solutions, i.e. requiring the robot movements to be similar to those of the human beings. This anthropomorphism in the robot motion is desired not only for aesthetical reasons, but it is also needed to allow a better and safer human-robot collaboration: humans can predict more easily anthropomorphic robot motions thus avoiding collisions and enhancing the collaboration with the robot. Nevertheless, obtaining a satisfactory performance of these anthropomorphic robotic systems requires the automatic planning of the movements, which is still an arduous and non-evident task since the complexity of the planning problem increases exponentially with the number of degrees of freedom of the robotic system. This doctoral thesis tackles the problem of planning the motions of dual-arm anthropomorphic robots (optionally with mobile base). The main objective is twofold: obtaining robot motions both in an efficient and in a human-like fashion at the same time. Trying to mimic the human movements while reducing the complexity of the search space for planning purposes leads to the concept of synergies, which could be conceptually defined as correlations (in the joint configuration space as well as in the joint velocity space) between the degrees of freedom of the system. This work proposes new sampling-based motion-planning procedures that exploit the concept of synergies, both in the configuration and velocity space, coordinating the movements of the arms, the hands and the mobile base of mobile anthropomorphic dual-arm robots.La planificación de movimientos es un campo tradicional de la robótica, sin embargo aparecen incesantemente nuevos problemas debido a los continuos avances en el desarrollo de los robots. Para resolver esos nuevos problemas, así como para mejorar las soluciones existentes a los problemas clásicos, se están proponiendo nuevos enfoques. Un caso paradigmático es la robótica humanoide, ya que los avances realizados en este campo requieren que los algoritmos planificadores de movimientos no sólo encuentren eficientemente una solución óptima en el sentido clásico, es decir, optimizar el consumo de energía o el tiempo de ejecución de la trayectoria; sino que también busquen soluciones con apariencia humana, es decir, que el movimiento del robot sea similar al del ser humano. Este antropomorfismo en el movimiento del robot se busca no sólo por razones estéticas, sino porque también es necesario para permitir una colaboración mejor y más segura entre el robot y el operario: el ser humano puede predecir con mayor facilidad los movimientos del robot si éstos son antropomórficos, evitando así las colisiones y mejorando la colaboración humano robot. Sin embargo, para obtener un desempeño satisfactorio de estos sistemas robóticos antropomórficos se requiere una planificación automática de sus movimientos, lo que sigue siendo una tarea ardua y poco evidente, ya que la complejidad del problema aumenta exponencialmente con el número de grados de libertad del sistema robótico. Esta tesis doctoral aborda el problema de la planificación de movimientos en robots antropomorfos bibrazo (opcionalmente con base móvil). El objetivo aquí es doble: obtener movimientos robóticos de forma eficiente y, a la vez, que tengan apariencia humana. Intentar imitar los movimientos humanos mientras a la vez se reduce la complejidad del espacio de búsqueda conduce al concepto de sinergias, que podrían definirse conceptualmente como correlaciones (tanto en el espacio de configuraciones como en el espacio de velocidades de las articulaciones) entre los distintos grados de libertad del sistema. Este trabajo propone nuevos procedimientos de planificación de movimientos que explotan el concepto de sinergias, tanto en el espacio de configuraciones como en el espacio de velocidades, coordinando así los movimientos de los brazos, las manos y la base móvil de robots móviles, bibrazo y antropomórficos.Postprint (published version