How to Deploy a Wire with a Robotic Platform: Learning from Human Visual Demonstrations

In this paper, we address the problem of deploying a wire along a specific path selected by an unskilled user. The robot has to learn the selected path and pass a wire through the peg table by using the same tool. The main contribution regards the hybrid use of Cartesian positions provided by a learning procedure and joint positions obtained by inverse kinematics and motion planning. Some constraints are introduced to deal with non-rigid material without breaks or knots. We took into account a series of metrics to evaluate the robot learning capabilities, all of them over performed the targets

Developing Overall Equipment Effectiveness Metrics for Prototype Precision Manufacturing

Overall Equipment Effectiveness (OEE) is a powerful metric of manufacturing performance incorporating measures of the utilisation, yield and efficiency of a given process, machine or manufacturing line. When associated with the reasons for performance loss, OEE provides the means to compare and prioritise improvement efforts. This research assesses the current systems used in the high-volume production lines of Company-X, a precision manufacturer of computer components. This assessment led to the design of a singular methodology that functions in a high-volume production environment, in the rapid prototyping production, and the program qualification production divisions of Company-X. The methodology defined indicators (Utilisation, Efficiency and Yield), and factors that must be recorded on an individual piece of equipment within a manufacturing line to determine its OEE. These equipment-level records were captured utilising the equipment’s computer-controller, supplemented by minimal user input, to minimise the non-value added activities associated with data-entry. The methodology also determined the means to aggregate the records to prioritize improvement activities (Weighted OEE Pareto) and calculate the manufacturing lines overall performance (Overall Line Effectiveness)

Development of an intelligent self-learning product assembly system using visual identification

Thesis (Master of Engineering in Electrical Engineering) -- Central University of Technology, Free State, 2018Modern automation systems rely on fixed programming to carry out their production routines. These systems are effective for production outputs but do not allow any flexibility within the production routine. Effort is required to change the ongoing production routine through reprogramming, redesign or complete overhaul of the system to cater for new production outputs. These efforts require down time and result in a loss of revenue. If a completely automated flexible system is introduced into such a production line, the complete reprogramming process required to cater for new production needs could be automated without losing production time. Within this study, a real-time KUKA Robotic Control system is introduced. The KUKA Robotic Controller maintains its original programming methods with no reprogramming required when executing a new production assembly. This is achieved through manoeuvring the KUKA Robotic System in real-time to new destinations based on image-processing outputs and feedback. For demonstration purposes and proof of concept, the system learns a design presented to it by an end user and then reproduces this seen design based on the image-processing results in terms of location and orientation. Therefore, instead of reprogramming each new required position, the system takes over real-time control of the KUKA Robotic System and carries out the required steps autonomously. The benefit of such a system would be that the KUKA Robotic System would not require reprogramming to carry out new routines. It is controlled in a real-time environment to carry out new procedures based on external sensors (in this case, image-processing outputs). KUKA Robotic Sensor Interface (RSI) software is used to implement real-time control of the KUKA Robotic System and is explored extensively throughout this study

Automatic programming of simulation models

The concepts of software engineering were used to improve the simulation modeling environment. Emphasis was placed on the application of an element of rapid prototyping, or automatic programming, to assist the modeler define the problem specification. Then, once the problem specification has been defined, an automatic code generator is used to write the simulation code. The following two domains were selected for evaluating the concepts of software engineering for discrete event simulation: manufacturing domain and a spacecraft countdown network sequence. The specific tasks were to: (1) define the software requirements for a graphical user interface to the Automatic Manufacturing Programming System (AMPS) system; (2) develop a graphical user interface for AMPS; and (3) compare the AMPS graphical interface with the AMPS interactive user interface

Development of a Hybrid Control and Monitoring System within a Reconfigurable Assembly System

Published ThesisExpanding global markets are constantly changing and unstable. South African manufacturing companies need to develop similar levels of sophistication and expertise in the automation industry as its international rivals, to compete for these markets and meet rising consumer expectations. To remain competitive, these manufacturing companies must manage their plants extremely efficiently to ensure the quality of assembled products; allow for rapid product introduction and product changes; achieve shortened throughput cycles; ensure more reliable delivery dates; and effectively coordinate product demand while contending with decreased product lifespans. To accomplish this, manufacturing companies in SA are progressively engaging in the current trend in automation known as reconfigurable manufacturing. Due to the extreme flexibility of these reconfigurable systems, the monitor and control systems for these require the same levels of flexibility. The purpose of the study is to develop a hybrid control and monitoring system, to supervise and control reconfigurable assembly systems (RAS), and adapt to the flexibility of these systems. To achieve this, a literature study was done in the research area to reveal the prerequisites for such systems; the physical assembly devices were designed and built; the separate software modules developed and ultimately integrated into the intended system. The tests to validate the system were developed in such a way that each subsection of the system is validated by using a different system software function. This inevitably confirms the functionality of the fundamental components and the system in entirety. The results indicated that devices are easily added to the system; devices are successfully detected and identified; how the system plans production, and how the system automatically configures itself. Further results showed the capability of the system to generate and virtually wire system runtime code; store and retrieve production data; as well as warn and alarm on unwanted conditions. By obtaining these results, companies can configure their systems with ease, in a shorter amount of time, and without any human error. Moreover, their systems will be more flexible, allow easy addition of new products and assembly devices, and with minimal downtime. This will enable SA manufacturing companies to be more competitive, ensure increased productivity, achieve extreme system flexibility, and decrease lead times – thus ensuring them an advantage over their international competitors

Beta: Bioprinting engineering technology for academia

Higher STEM education is a field of growing potential, but too many middle school and high school students are not testing proficiently in STEM subjects. The BETA team worked to improve biology classroom engagement through the development of technologies for high school biology experiments. The BETA project team expanded functionality of an existing product line to allow for better student and teacher user experience and the execution of more interesting experiments. The BETA project’s first goal was to create a modular incubating Box for the high school classroom. This Box, called the BETA Box was designed with a variety of sensors to allow for custom temperature and lighting environments for each experiment. It was completed with a clear interface to control the settings and an automatic image capture system. The team also conducted a feasibility study on auto calibration and dual-extrusion for SE3D’s existing 3D bioprinter. The findings of this study led to the incorporation of a force sensor for auto calibration and the evidence to support the feasibility of dual extrusion, although further work is needed. These additions to the current SE3D educational product line will increase effectiveness in the classroom and allow the target audience, high school students, to better engage in STEM education activities