Learning-based robotic manipulation for dynamic object handling : a thesis presented in partial fulfilment of the requirements for the degree of Doctor of Philosophy in Mechatronic Engineering at the School of Food and Advanced Technology, Massey University, Turitea Campus, Palmerston North, New Zealand

Figures are re-used in this thesis with permission of their respective publishers or under a Creative Commons licence.Recent trends have shown that the lifecycles and production volumes of modern products are shortening. Consequently, many manufacturers subject to frequent change prefer flexible and reconfigurable production systems. Such schemes are often achieved by means of manual assembly, as conventional automated systems are perceived as lacking flexibility. Production lines that incorporate human workers are particularly common within consumer electronics and small appliances. Artificial intelligence (AI) is a possible avenue to achieve smart robotic automation in this context. In this research it is argued that a robust, autonomous object handling process plays a crucial role in future manufacturing systems that incorporate robotics—key to further closing the gap between manual and fully automated production. Novel object grasping is a difficult task, confounded by many factors including object geometry, weight distribution, friction coefficients and deformation characteristics. Sensing and actuation accuracy can also significantly impact manipulation quality. Another challenge is understanding the relationship between these factors, a specific grasping strategy, the robotic arm and the employed end-effector. Manipulation has been a central research topic within robotics for many years. Some works focus on design, i.e. specifying a gripper-object interface such that the effects of imprecise gripper placement and other confounding control-related factors are mitigated. Many universal robotic gripper designs have been considered, including 3-fingered gripper designs, anthropomorphic grippers, granular jamming end-effectors and underactuated mechanisms. While such approaches have maintained some interest, contemporary works predominantly utilise machine learning in conjunction with imaging technologies and generic force-closure end-effectors. Neural networks that utilise supervised and unsupervised learning schemes with an RGB or RGB-D input make up the bulk of publications within this field. Though many solutions have been studied, automatically generating a robust grasp configuration for objects not known a priori, remains an open-ended problem. An element of this issue relates to a lack of objective performance metrics to quantify the effectiveness of a solution—which has traditionally driven the direction of community focus by highlighting gaps in the state-of-the-art. This research employs monocular vision and deep learning to generate—and select from—a set of hypothesis grasps. A significant portion of this research relates to the process by which a final grasp is selected. Grasp synthesis is achieved by sampling the workspace using convolutional neural networks trained to recognise prospective grasp areas. Each potential pose is evaluated by the proposed method in conjunction with other input modalities—such as load-cells and an alternate perspective. To overcome human bias and build upon traditional metrics, scores are established to objectively quantify the quality of an executed grasp trial. Learning frameworks that aim to maximise for these scores are employed in the selection process to improve performance. The proposed methodology and associated metrics are empirically evaluated. A physical prototype system was constructed, employing a Dobot Magician robotic manipulator, vision enclosure, imaging system, conveyor, sensing unit and control system. Over 4,000 trials were conducted utilising 100 objects. Experimentation showed that robotic manipulation quality could be improved by 10.3% when selecting to optimise for the proposed metrics—quantified by a metric related to translational error. Trials further demonstrated a grasp success rate of 99.3% for known objects and 98.9% for objects for which a priori information is unavailable. For unknown objects, this equated to an improvement of approximately 10% relative to other similar methodologies in literature. A 5.3% reduction in grasp rate was observed when removing the metrics as selection criteria for the prototype system. The system operated at approximately 1 Hz when contemporary hardware was employed. Experimentation demonstrated that selecting a grasp pose based on the proposed metrics improved grasp rates by up to 4.6% for known objects and 2.5% for unknown objects—compared to selecting for grasp rate alone. This project was sponsored by the Richard and Mary Earle Technology Trust, the Ken and Elizabeth Powell Bursary and the Massey University Foundation. Without the financial support provided by these entities, it would not have been possible to construct the physical robotic system used for testing and experimentation. This research adds to the field of robotic manipulation, contributing to topics on grasp-induced error analysis, post-grasp error minimisation, grasp synthesis framework design and general grasp synthesis. Three journal publications and one IEEE Xplore paper have been published as a result of this research

Flexible Automation and Intelligent Manufacturing: The Human-Data-Technology Nexus

This is an open access book. It gathers the first volume of the proceedings of the 31st edition of the International Conference on Flexible Automation and Intelligent Manufacturing, FAIM 2022, held on June 19 – 23, 2022, in Detroit, Michigan, USA. Covering four thematic areas including Manufacturing Processes, Machine Tools, Manufacturing Systems, and Enabling Technologies, it reports on advanced manufacturing processes, and innovative materials for 3D printing, applications of machine learning, artificial intelligence and mixed reality in various production sectors, as well as important issues in human-robot collaboration, including methods for improving safety. Contributions also cover strategies to improve quality control, supply chain management and training in the manufacturing industry, and methods supporting circular supply chain and sustainable manufacturing. All in all, this book provides academicians, engineers and professionals with extensive information on both scientific and industrial advances in the converging fields of manufacturing, production, and automation

Flexible Automation and Intelligent Manufacturing: The Human-Data-Technology Nexus

This is an open access book. It gathers the first volume of the proceedings of the 31st edition of the International Conference on Flexible Automation and Intelligent Manufacturing, FAIM 2022, held on June 19 – 23, 2022, in Detroit, Michigan, USA. Covering four thematic areas including Manufacturing Processes, Machine Tools, Manufacturing Systems, and Enabling Technologies, it reports on advanced manufacturing processes, and innovative materials for 3D printing, applications of machine learning, artificial intelligence and mixed reality in various production sectors, as well as important issues in human-robot collaboration, including methods for improving safety. Contributions also cover strategies to improve quality control, supply chain management and training in the manufacturing industry, and methods supporting circular supply chain and sustainable manufacturing. All in all, this book provides academicians, engineers and professionals with extensive information on both scientific and industrial advances in the converging fields of manufacturing, production, and automation

Bin Picking of Reflective Steel Parts Using a Dual-Resolution Convolutional Neural Network Trained in a Simulated Environment

We consider the case of robotic bin picking of reflective steel parts, using a structured light 3D camera as a depth imaging device. In this paper, we present a new method for bin picking, based on a dual-resolution convolutional neural network trained entirely in a simulated environment. The dual-resolution network consists of a high resolution focus network to compute the grasp and a low resolution context network to avoid local collisions. The reflectivity of the steel parts result in depth images that have a lot of missing data. To take this into account, training of the neural net is done by domain randomization on a large set of synthetic depth images that simulate the missing data problems of the real depth images. We demonstrate both in simulation and in a real-world test that our method can perform bin picking of reflective steel parts

A ROS-based software architecture for a versatile collaborative dual-armed autonomous mobile robot for the manufacturing industry

The industrial context is changing rapidly due to advancements in technology fueled by the Internet and Information Technology. The fourth industrial revolution counts integration, flexibility, and optimization as its fundamental pillars, and, in this context, Human-Robot Collaboration has become a crucial factor for manufacturing sustainability in Europe. Collaborative robots are appealing to many companies due to their low installation and running costs and high degree of flexibility, making them ideal for reshoring production facilities with a short return on investment. The ROSSINI European project aims to implement a true Human-Robot Collaboration by designing, developing, and demonstrating a modular and scalable platform for integrating human-centred robotic technologies in industrial production environments. The project focuses on safety concerns related to introducing a cobot in a shared working area and aims to lay the groundwork for a new working paradigm at the industrial level. The need for a software architecture suitable to the robotic platform employed in one of three use cases selected to deploy and test the new technology was the main trigger of this Thesis. The chosen application consists of the automatic loading and unloading of raw-material reels to an automatic packaging machine through an Autonomous Mobile Robot composed of an Autonomous Guided Vehicle, two collaborative manipulators, and an eye-on-hand vision system for performing tasks in a partially unstructured environment. The results obtained during the ROSSINI use case development were later used in the SENECA project, which addresses the need for robot-driven automatic cleaning of pharmaceutical bins in a very specific industrial context. The inherent versatility of mobile collaborative robots is evident from their deployment in the two projects with few hardware and software adjustments. The positive impact of Human-Robot Collaboration on diverse production lines is a motivation for future investments in research on this increasingly popular field by the industry

Robotics Dexterous Grasping: The Methods Based on Point Cloud and Deep Learning

Dexterous manipulation, especially dexterous grasping, is a primitive and crucial ability of robots that allows the implementation of performing human-like behaviors. Deploying the ability on robots enables them to assist and substitute human to accomplish more complex tasks in daily life and industrial production. A comprehensive review of the methods based on point cloud and deep learning for robotics dexterous grasping from three perspectives is given in this paper. As a new category schemes of the mainstream methods, the proposed generation-evaluation framework is the core concept of the classification. The other two classifications based on learning modes and applications are also briefly described afterwards. This review aims to afford a guideline for robotics dexterous grasping researchers and developers

Bin Picking of Reflective Steel Parts using a Dual-Resolution Convolutional Neural Network Trained in a Simulated Environment

We consider the case of robotic bin picking of reflective steel parts, using a structured light 3D camera as a depth imaging device. In this paper, we present a new method for bin picking, based on a dual-resolution convolutional neural network trained entirely in a simulated environment. The dualresolution network consists of a high resolution focus network to compute the grasp and a low resolution context network to avoid local collisions.The reflectivity of the steel parts result in depth images that have a lot of missing data. To take this into account, training of the neural net is done by domain randomization on a large set of synthetic depth images that simulate the missing data problems of the real depth images. We demonstrate both in simulation and in a real-world test that our method can perform bin picking of reflective steel part

Learning Fine-Grained Bimanual Manipulation with Low-Cost Hardware

Fine manipulation tasks, such as threading cable ties or slotting a battery, are notoriously difficult for robots because they require precision, careful coordination of contact forces, and closed-loop visual feedback. Performing these tasks typically requires high-end robots, accurate sensors, or careful calibration, which can be expensive and difficult to set up. Can learning enable low-cost and imprecise hardware to perform these fine manipulation tasks? We present a low-cost system that performs end-to-end imitation learning directly from real demonstrations, collected with a custom teleoperation interface. Imitation learning, however, presents its own challenges, particularly in high-precision domains: errors in the policy can compound over time, and human demonstrations can be non-stationary. To address these challenges, we develop a simple yet novel algorithm, Action Chunking with Transformers (ACT), which learns a generative model over action sequences. ACT allows the robot to learn 6 difficult tasks in the real world, such as opening a translucent condiment cup and slotting a battery with 80-90% success, with only 10 minutes worth of demonstrations. Project website: https://tonyzhaozh.github.io/aloha

Instrumentation, Data, And Algorithms For Visually Understanding Haptic Surface Properties

Autonomous robots need to efficiently walk over varied surfaces and grasp diverse objects. We hypothesize that the association between how such surfaces look and how they physically feel during contact can be learned from a database of matched haptic and visual data recorded from various end-effectors\u27 interactions with hundreds of real-world surfaces. Testing this hypothesis required the creation of a new multimodal sensing apparatus, the collection of a large multimodal dataset, and development of a machine-learning pipeline. This thesis begins by describing the design and construction of the Portable Robotic Optical/Tactile ObservatioN PACKage (PROTONPACK, or Proton for short), an untethered handheld sensing device that emulates the capabilities of the human senses of vision and touch. Its sensory modalities include RGBD vision, egomotion, contact force, and contact vibration. Three interchangeable end-effectors (a steel tooling ball, an OptoForce three-axis force sensor, and a SynTouch BioTac artificial fingertip) allow for different material properties at the contact point and provide additional tactile data. We then detail the calibration process for the motion and force sensing systems, as well as several proof-of-concept surface discrimination experiments that demonstrate the reliability of the device and the utility of the data it collects. This thesis then presents a large-scale dataset of multimodal surface interaction recordings, including 357 unique surfaces such as furniture, fabrics, outdoor fixtures, and items from several private and public material sample collections. Each surface was touched with one, two, or three end-effectors, comprising approximately one minute per end-effector of tapping and dragging at various forces and speeds. We hope that the larger community of robotics researchers will find broad applications for the published dataset. Lastly, we demonstrate an algorithm that learns to estimate haptic surface properties given visual input. Surfaces were rated on hardness, roughness, stickiness, and temperature by the human experimenter and by a pool of purely visual observers. Then we trained an algorithm to perform the same task as well as infer quantitative properties calculated from the haptic data. Overall, the task of predicting haptic properties from vision alone proved difficult for both humans and computers, but a hybrid algorithm using a deep neural network and a support vector machine achieved a correlation between expected and actual regression output between approximately ρ = 0.3 and ρ = 0.5 on previously unseen surfaces

New Methods for ferrous raw materials characterization in electric steelmaking

425 p.In the siderurgical sector, the steel scrap is the most important raw material in electric steelmaking,contributing between 70% of the total production costs. It is well-known how the degree of which thescrap mix can be optimized, and also the degree of which the melting operation can be controlled andautomated, is limited by the knowledge of the properties of the scrap and other raw-materials in thecharge mix.Therefore, it is of strategic importance having accurate information about the scrap composition of thedifferent steel scrap types. In other words, knowing scrap characteristics is a key point in order to managethe steel-shop resources, optimize the scrap charge mix/composition at the electric arc furnace (EAF),increase the plant productivity, minimize the environmental footprint of steelmaking activities and tohave the lowest total cost of ownership of the plant.As a main objective of present doctoral thesis, the doctorate will provide new tools and methods of scrapcharacterization to increase the current recycling ration, through better knowledge of the quality of thescrap, and thus go in the direction of a 100% recycling ratio. In order to achieve it, two main workinglines were developed in present research. Firstly, it was analysed not only the different existingmethodologies for scrap characterization and EAF process optimization, but also to develop new methodsor combination of existing, Secondly, it was defined a general recommendations guide for implementingthese methods based on the specifics of each plant