Evaluation of automated decisionmaking methodologies and development of an integrated robotic system simulation

A generic computer simulation for manipulator systems (ROBSIM) was implemented and the specific technologies necessary to increase the role of automation in various missions were developed. The specific items developed are: (1) capability for definition of a manipulator system consisting of multiple arms, load objects, and an environment; (2) capability for kinematic analysis, requirements analysis, and response simulation of manipulator motion; (3) postprocessing options such as graphic replay of simulated motion and manipulator parameter plotting; (4) investigation and simulation of various control methods including manual force/torque and active compliances control; (5) evaluation and implementation of three obstacle avoidance methods; (6) video simulation and edge detection; and (7) software simulation validation

On Robotic Work-Space Sensing and Control

Industrial robots are fast and accurate when working with known objects at precise locations in well-structured manufacturing environments, as done in the classical automation setting. In one sense, limited use of sensors leaves robots blind and numb, unaware of what is happening in their surroundings. Whereas equipping a system with sensors has the potential to add new functionality and increase the set of uncertainties a robot can handle, it is not as simple as that. Often it is difficult to interpret the measurements and use them to draw necessary conclusions about the state of the work space. For effective sensor-based control, it is necessary to both understand the sensor data and to know how to act on it, giving the robot perception-action capabilities. This thesis presents research on how sensors and estimation techniques can be used in robot control. The suggested methods are theoretically analyzed and evaluated with a large focus on experimental verification in real-time settings. One application class treated is the ability to react fast and accurately to events detected by vision, which is demonstrated by the realization of a ball-catching robot. A new approach is proposed for performing high-speed color-based image analysis that is robust to varying illumination conditions and motion blur. Furthermore, a method for object tracking is presented along with a novel way of Kalman-filter initialization that can handle initial-state estimates with infinite variance. A second application class treated is robotic assembly using force control. A study of two assembly scenarios is presented, investigating the possibility of using force-controlled assembly in industrial robotics. Two new approaches for robotic contact-force estimation without any force sensor are presented and validated in assembly operations. The treated topics represent some of the challenges in sensor-based robot control, and it is demonstrated how they can be used to extend the functionality of industrial robots

Velocity dependence of joint friction in robotic manipulators with gear transmissions

This paper analyses the problem of modelling joint friction in robotic manipulators with gear transmissions at joint velocities varying from close to zero until their maximum appearing values. It is shown that commonly used friction models that incorporate Coulomb, (linear) viscous and Stribeck components are inadequate to describe the friction behaviour for the full velocity range. A new friction model is proposed that relies on insights from tribological models. The basic friction model of two lubricated discs in rolling-sliding contact is used to analyse viscous friction and friction caused by asperity contacts inside gears and roller bearings of robot joint transmissions. The analysis shows different viscous friction behaviour for gears and pre-stressed bearings. The sub-models describing the viscous friction and the friction due to the asperity contacts are combined into two friction models; one for gears and one for the pre-stressed roller bearings. In this way, a new friction model [1] is developed that accurately describes the friction behaviour in the sliding regime with a minimal and physically sound parametrisation. The model is linear in the parameters that are temperature dependent, which allows to estimate these parameters during the inertia parameter identification experiments. The model, in which the Coulomb friction effect has disappeared, has the same number of parameters as the commonly used Stribeck model [2]. The model parameters are identified experimentally on a St ¨aubli RX90 industrial robot

Design of an Anthropomorphic, Compliant, and Lightweight Dual Arm for Aerial Manipulation

This paper presents an anthropomorphic, compliant and lightweight dual arm manipulator designed and developed for aerial manipulation applications with multi-rotor platforms. Each arm provides four degrees of freedom in a human-like kinematic configuration for end effector positioning: shoulder pitch, roll and yaw, and elbow pitch. The dual arm, weighting 1.3 kg in total, employs smart servo actuators and a customized and carefully designed aluminum frame structure manufactured by laser cut. The proposed design reduces the manufacturing cost as no computer numerical control machined part is used. Mechanical joint compliance is provided in all the joints, introducing a compact spring-lever transmission mechanism between the servo shaft and the links, integrating a potentiometer for measuring the deflection of the joints. The servo actuators are partially or fully isolated against impacts and overloads thanks to the ange bearings attached to the frame structure that support the rotation of the links and the deflection of the joints. This simple mechanism increases the robustness of the arms and safety in the physical interactions between the aerial robot and the environment. The developed manipulator has been validated through different experiments in fixed base test-bench and in outdoor flight tests.Unión Europea H2020-ICT-2014- 644271Ministerio de Economía y Competitividad DPI2015-71524-RMinisterio de Economía y Competitividad DPI2017-89790-

Semi-autonomous scheme for pushing micro-objects

-In many microassembly applications, it is often desirable to position and orient polygonal micro-objects lying on a planar surface. Pushing micro-objects using point contact provides more flexibility and less complexity compared to pick and place operation. Due to the fact that in micro-world surface forces are much more dominant than inertial forces and these forces are distributed unevenly, pushing through the center of mass of the micro-object will not yield a pure translational motion. In order to translate a micro-object, the line of pushing should pass through the center of friction. In this paper, a semi-autonomous scheme based on hybrid vision/force feedback is proposed to push microobjects with human assistance using a custom built telemicromanipulation setup to achieve pure translational motion. The pushing operation is divided into two concurrent processes: In one process human operator who acts as an impedance controller alters the velocity of the pusher while in contact with the micro-object through scaled bilateral teleoperation with force feedback. In the other process, the desired line of pushing for the micro-object is determined continuously using visual feedback procedures so that it always passes through the varying center of friction. Experimental results are demonstrated to prove nanoNewton range force sensing, scaled bilateral teleoperation with force feedback and pushing microobjects

An Omnidirectional Aerial Platform for Multi-Robot Manipulation

The objectives of this work were the modeling, control and prototyping of a new fully-actuated aerial platform. Commonly, the multirotor aerial platforms are under-actuated vehicles, since the total propellers thrust can not be directed in every direction without inferring a vehicle body rotation. The most common fully-actuated aerial platforms have tilted or tilting rotors that amplify the aerodynamic perturbations between the propellers, reducing the efficiency and the provided thrust. In order to overcome this limitation a novel platform, the ODQuad (OmniDirectional Quadrotor), has been proposed, which is composed by three main parts, the platform, the mobile and rotor frames, that are linked by means of two rotational joints, namely the roll and pitch joints. The ODQuad is able to orient the total thrust by moving only the propellers frame by means of the roll and pitch joints. Kinematic and dynamic models of the proposed multirotor have been derived using the Euler- Lagrange approach and a model-based controller has been designed. The latter is based on two control loops: an outer loop for vehicle position control and an inner one for vehicle orientation and roll-pitch joint control. The effectiveness of the controller has been tested by means of numerical simulations in the MATLAB c SimMechanics environment. In particular, tests in free motion and in object transportation tasks have been carried out. In the transportation task simulation, a momentum based observer is used to estimate the wrenches exchanged between the vehicle and the transported object. The ODQuad concept has been tested also in cooperative manipulation tasks. To this aim, a simulation model was considered, in which multiple ODQuads perform the manipulation of a bulky object with unknown inertial parameters which are identified in the first phase of the simulation. In order to reduce the mechanical stresses due to the manipulation and enhance the system robustness to the environment interactions, two admittance filters have been implemented: an external filter on the object motion and an internal one local for each multirotor. Finally, the prototyping process has been illustrated step by step. In particular, three CAD models have been designed. The ODQuad.01 has been used in the simulations and in a preliminary static analysis that investigated the torque values for a rough sizing of the roll-pitch joint actuators. Since in the ODQuad.01 the components specifications and the related manufacturing techniques have not been taken into account, a successive model, the ODQuad.02, has been designed. The ODQuad.02 design can be developed with aluminum or carbon fiber profiles and 3D printed parts, but each component must be custom manufactured. Finally, in order to shorten the prototype development time, the ODQuad.03 has been created, which includes some components of the off-the-shelf quadrotor Holybro X500 into a novel custom-built mechanical frame

Compliant aerial manipulation.

The aerial manipulation is a research field which proposes the integration of robotic manipulators in aerial platforms, typically multirotors – widely known as “drones” – or autonomous helicopters. The development of this technology is motivated by the convenience to reduce the time, cost and risk associated to the execution of certain operations or tasks in high altitude areas or difficult access workspaces. Some illustrative application examples are the detection and insulation of leaks in pipe structures in chemical plants, repairing the corrosion in the blades of wind turbines, the maintenance of power lines, or the installation and retrieval of sensor devices in polluted areas. Although nowadays it is possible to find a wide variety of commercial multirotor platforms with payloads from a few gramps up to several kilograms, and flight times around thirty minutes, the development of an aerial manipulator is still a technological challenge due to the strong requirements relative to the design of the manipulator in terms of very low weight, low inertia, dexterity, mechanical robustness and control. The main contribution of this thesis is the design, development and experimental validation of several prototypes of lightweight (<2 kg) and compliant manipulators to be integrated in multirotor platforms, including human-size dual arm systems, compliant joint arms equipped with human-like finger modules for grasping, and long reach aerial manipulators. Since it is expected that the aerial manipulator is capable to execute inspection and maintenance tasks in a similar way a human operator would do, this thesis proposes a bioinspired design approach, trying to replicate the human arm in terms of size, kinematics, mass distribution, and compliance. This last feature is actually one of the key concepts developed and exploited in this work. Introducing a flexible element such as springs or elastomers between the servos and the links extends the capabilities of the manipulator, allowing the estimation and control of the torque/force, the detection of impacts and overloads, or the localization of obstacles by contact. It also improves safety and efficiency of the manipulator, especially during the operation on flight or in grabbing situations, where the impacts and contact forces may damage the manipulator or destabilize the aerial platform. Unlike most industrial manipulators, where force-torque control is possible at control rates above 1 kHz, the servo actuators typically employed in the development of aerial manipulators present important technological limitations: no torque feedback nor control, only position (and in some models, speed) references, low update rates (<100 Hz), and communication delays. However, these devices are still the best solution due to their high torque to weight ratio, low cost, compact design, and easy assembly and integration. In order to cope with these limitations, the compliant joint arms presented here estimate and control the wrenches from the deflection of the spring-lever transmission mechanism introduced in the joints, measured at joint level with encoders or potentiometers, or in the Cartesian space employing vision sensors. Note that in the developed prototypes, the maximum joint deflection is around 25 degrees, which corresponds to a deviation in the position of the end effector around 20 cm for a human-size arm. The capabilities and functionalities of the manipulators have been evaluated in fixed base test-bench firstly, and then in outdoor flight tests, integrating the arms in different commercial hexarotor platforms. Frequency characterization, position/force/impedance control, bimanual grasping, arm teleoperation, payload mass estimation, or contact-based obstacle localization are some of the experiments presented in this thesis that validate the developed prototypes.La manipulación aérea es un campo de investigación que propone la integración de manipuladores robóticos in plataformas aéreas, típicamente multirotores – comúnmente conocidos como “drones” – o helicópteros autónomos. El desarrollo de esta tecnología está motivada por la conveniencia de reducir el tiempo, coste y riesgo asociado a la ejecución de ciertas operaciones o tareas en áreas de gran altura o espacios de trabajo de difícil acceso. Algunos ejemplos ilustrativos de aplicaciones son la detección y aislamiento de fugas en estructura de tuberías en plantas químicas, la reparación de la corrosión en las palas de aerogeneradores, el mantenimiento de líneas eléctricas, o la instalación y recuperación de sensores en zonas contaminadas. Aunque hoy en día es posible encontrar una amplia variedad de plataformas multirotor comerciales con cargas de pago desde unos pocos gramos hasta varios kilogramos, y tiempo de vuelo entorno a treinta minutos, el desarrollo de los manipuladores aéreos es todavía un desafío tecnológico debido a los exigentes requisitos relativos al diseño del manipulador en términos de muy bajo peso, baja inercia, destreza, robustez mecánica y control. La contribución principal de esta tesis es el diseño, desarrollo y validación experimental de varios prototipos de manipuladores de bajo peso (<2 kg) con capacidad de acomodación (“compliant”) para su integración en plataformas aéreas multirotor, incluyendo sistemas bi-brazo de tamaño humano, brazos robóticos de articulaciones flexibles con dedos antropomórficos para agarre, y manipuladores aéreos de largo alcance. Puesto que se prevé que el manipulador aéreo sea capaz de ejecutar tareas de inspección y mantenimiento de forma similar a como lo haría un operador humano, esta tesis propone un enfoque de diseño bio-inspirado, tratando de replicar el brazo humano en cuanto a tamaño, cinemática, distribución de masas y flexibilidad. Esta característica es de hecho uno de los conceptos clave desarrollados y utilizados en este trabajo. Al introducir un elemento elástico como los muelles o elastómeros entre el los actuadores y los enlaces se aumenta las capacidades del manipulador, permitiendo la estimación y control de las fuerzas y pares, la detección de impactos y sobrecargas, o la localización de obstáculos por contacto. Además mejora la seguridad y eficiencia del manipulador, especialmente durante las operaciones en vuelo, donde los impactos y fuerzas de contacto pueden dañar el manipulador o desestabilizar la plataforma aérea. A diferencia de la mayoría de manipuladores industriales, donde el control de fuerzas y pares es posible a tasas por encima de 1 kHz, los servo motores típicamente utilizados en el desarrollo de manipuladores aéreos presentan importantes limitaciones tecnológicas: no hay realimentación ni control de torque, sólo admiten referencias de posición (o bien de velocidad), y presentan retrasos de comunicación. Sin embargo, estos dispositivos son todavía la mejor solución debido al alto ratio de torque a peso, por su bajo peso, diseño compacto y facilidad de ensamblado e integración. Para suplir estas limitaciones, los brazos robóticos flexibles presentados aquí permiten estimar y controlar las fuerzas a partir de la deflexión del mecanismo de muelle-palanca introducido en las articulaciones, medida a nivel articular mediante potenciómetros o codificadores, o en espacio Cartesiano mediante sensores de visión. Tómese como referencia que en los prototipos desarrollados la máxima deflexión articular es de unos 25 grados, lo que corresponde a una desviación de posición en torno a 20 cm en el efector final para un brazo de tamaño humano. Las capacidades y funcionalidades de estos manipuladores se han evaluado en base fija primero, y luego en vuelos en exteriores, integrando los brazos en diferentes plataformas hexartor comerciales. Caracterización frecuencial, control de posición/fuerza/impedancia, agarre bimanual, teleoperación de brazos, estimación de carga, o la localización de obstáculos mediante contacto son algunos de los experimentos presentados en esta tesis para validar los prototipos desarrollados por el auto