Enabling technologies for precise aerial manufacturing with unmanned aerial vehicles

The construction industry is currently experiencing a revolution with automation techniques such as additive manufacturing and robot-enabled construction. Additive Manufacturing (AM) is a key technology that can o er productivity improvement in the construction industry by means of o -site prefabrication and on-site construction with automated systems. The key bene t is that building elements can be fabricated with less materials and higher design freedom compared to traditional manual methods. O -site prefabrication with AM has been investigated for some time already, but it has limitations in terms of logistical issues of components transportation and due to its lack of design exibility on-site. On-site construction with automated systems, such as static gantry systems and mobile ground robots performing AM tasks, can o er additional bene ts over o -site prefabrication, but it needs further research before it will become practical and economical. Ground-based automated construction systems also have the limitation that they cannot extend the construction envelope beyond their physical size. The solution of using aerial robots to liberate the process from the constrained construction envelope has been suggested, albeit with technological challenges including precision of operation, uncertainty in environmental interaction and energy e ciency. This thesis investigates methods of precise manufacturing with aerial robots. In particular, this work focuses on stabilisation mechanisms and origami-based structural elements that allow aerial robots to operate in challenging environments. An integrated aerial self-aligning delta manipulator has been utilised to increase the positioning accuracy of the aerial robots, and a Material Extrusion (ME) process has been developed for Aerial Additive Manufacturing (AAM). A 28-layer tower has been additively manufactured by aerial robots to demonstrate the feasibility of AAM. Rotorigami and a bioinspired landing mechanism demonstrate their abilities to overcome uncertainty in environmental interaction with impact protection capabilities and improved robustness for UAV. Design principles using tensile anchoring methods have been explored, enabling low-power operation and explores possibility of low-power aerial stabilisation. The results demonstrate that precise aerial manufacturing needs to consider not only just the robotic aspects, such as ight control algorithms and mechatronics, but also material behaviour and environmental interaction as factors for its success.Open Acces

Unmanned Systems Sentinel / 3 June 2016

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COMPUTATIONAL MULTICOPTER MODELING AND DESIGN

This thesis utilizes a modified version of Axial Momentum Theory (AMT) and computational fluid dynamics (CFD) to model multiple propellers with similar, simplified flows for estimates of aerodynamic constant force on small unmanned aerial vehicles (UAVs). Utilizing the modified version of AMT, a comparison of a commercial-off-the-shelf (COTS) vertical take-off and landing (VTOL) platform and a new design optimized for forward flight is conducted.Office of Naval Research, Arlington, VA 22217Lieutenant, United States NavyApproved for public release. Distribution is unlimited

Locomotion system for ground mobile robots in uneven and unstructured environments

One of the technology domains with the greatest growth rates nowadays is service robots. The extensive use of ground mobile robots in environments that are unstructured or structured for humans is a promising challenge for the coming years, even though Automated Guided Vehicles (AGV) moving on flat and compact grounds are already commercially available and widely utilized to move components and products inside indoor industrial buildings. Agriculture, planetary exploration, military operations, demining, intervention in case of terrorist attacks, surveillance, and reconnaissance in hazardous conditions are important application domains. Due to the fact that it integrates the disciplines of locomotion, vision, cognition, and navigation, the design of a ground mobile robot is extremely interdisciplinary. In terms of mechanics, ground mobile robots, with the exception of those designed for particular surroundings and surfaces (such as slithering or sticky robots), can move on wheels (W), legs (L), tracks (T), or hybrids of these concepts (LW, LT, WT, LWT). In terms of maximum speed, obstacle crossing ability, step/stair climbing ability, slope climbing ability, walking capability on soft terrain, walking capability on uneven terrain, energy efficiency, mechanical complexity, control complexity, and technology readiness, a systematic comparison of these locomotion systems is provided in [1]. Based on the above-mentioned classification, in this thesis, we first introduce a small-scale hybrid locomotion robot for surveillance and inspection, WheTLHLoc, with two tracks, two revolving legs, two active wheels, and two passive omni wheels. The robot can move in several different ways, including using wheels on the flat, compact ground,[1] tracks on soft, yielding terrain, and a combination of tracks, legs, and wheels to navigate obstacles. In particular, static stability and non-slipping characteristics are considered while analyzing the process of climbing steps and stairs. The experimental test on the first prototype has proven the planned climbing maneuver’s efficacy and the WheTLHLoc robot's operational flexibility. Later we present another development of WheTLHLoc and introduce WheTLHLoc 2.0 with newly designed legs, enabling the robot to deal with bigger obstacles. Subsequently, a single-track bio-inspired ground mobile robot's conceptual and embodiment designs are presented. This robot is called SnakeTrack. It is designed for surveillance and inspection activities in unstructured environments with constrained areas. The vertebral column has two end modules and a variable number of vertebrae linked by compliant joints, and the surrounding track is its essential component. Four motors drive the robot: two control the track motion and two regulate the lateral flexion of the vertebral column for steering. The compliant joints enable limited passive torsion and retroflection of the vertebral column, which the robot can use to adapt to uneven terrain and increase traction. Eventually, the new version of SnakeTrack, called 'Porcospino', is introduced with the aim of allowing the robot to move in a wider variety of terrains. The novelty of this thesis lies in the development and presentation of three novel designs of small-scale mobile robots for surveillance and inspection in unstructured environments, and they employ hybrid locomotion systems that allow them to traverse a variety of terrains, including soft, yielding terrain and high obstacles. This thesis contributes to the field of mobile robotics by introducing new design concepts for hybrid locomotion systems that enable robots to navigate challenging environments. The robots presented in this thesis employ modular designs that allow their lengths to be adapted to suit specific tasks, and they are capable of restoring their correct position after falling over, making them highly adaptable and versatile. Furthermore, this thesis presents a detailed analysis of the robots' capabilities, including their step-climbing and motion planning abilities. In this thesis we also discuss possible refinements for the robots' designs to improve their performance and reliability. Overall, this thesis's contributions lie in the design and development of innovative mobile robots that address the challenges of surveillance and inspection in unstructured environments, and the analysis and evaluation of these robots' capabilities. The research presented in this thesis provides a foundation for further work in this field, and it may be of interest to researchers and practitioners in the areas of robotics, automation, and inspection. As a general note, the first robot, WheTLHLoc, is a hybrid locomotion robot capable of combining tracked locomotion on soft terrains, wheeled locomotion on flat and compact grounds, and high obstacle crossing capability. The second robot, SnakeTrack, is a small-size mono-track robot with a modular structure composed of a vertebral column and a single peripherical track revolving around it. The third robot, Porcospino, is an evolution of SnakeTrack and includes flexible spines on the track modules for improved traction on uneven but firm terrains, and refinements of the shape of the track guidance system. This thesis provides detailed descriptions of the design and prototyping of these robots and presents analytical and experimental results to verify their capabilities

Low computational SLAM for an autonomous indoor aerial inspection vehicle

The past decade has seen an increase in the capability of small scale Unmanned Aerial Vehicle (UAV) systems, made possible through technological advancements in battery, computing and sensor miniaturisation technology. This has opened a new and rapidly growing branch of robotic research and has sparked the imagination of industry leading to new UAV based services, from the inspection of power-lines to remote police surveillance. Miniaturisation of UAVs have also made them small enough to be practically flown indoors. For example, the inspection of elevated areas in hazardous or damaged structures where the use of conventional ground-based robots are unsuitable. Sellafield Ltd, a nuclear reprocessing facility in the U.K. has many buildings that require frequent safety inspections. UAV inspections eliminate the current risk to personnel of radiation exposure and other hazards in tall structures where scaffolding or hoists are required. This project focused on the development of a UAV for the novel application of semi-autonomously navigating and inspecting these structures without the need for personnel to enter the building. Development exposed a significant gap in knowledge concerning indoor localisation, specifically Simultaneous Localisation and Mapping (SLAM) for use on-board UAVs. To lower the on-board processing requirements of SLAM, other UAV research groups have employed techniques such as off-board processing, reduced dimensionality or prior knowledge of the structure, techniques not suitable to this application given the unknown nature of the structures and the risk of radio-shadows. In this thesis a novel localisation algorithm, which enables real-time and threedimensional SLAM running solely on-board a computationally constrained UAV in heavily cluttered and unknown environments is proposed. The algorithm, based on the Iterative Closest Point (ICP) method utilising approximate nearest neighbour searches and point-cloud decimation to reduce the processing requirements has successfully been tested in environments similar to that specified by Sellafield Ltd

Aerial Robotics for Inspection and Maintenance

Aerial robots with perception, navigation, and manipulation capabilities are extending the range of applications of drones, allowing the integration of different sensor devices and robotic manipulators to perform inspection and maintenance operations on infrastructures such as power lines, bridges, viaducts, or walls, involving typically physical interactions on flight. New research and technological challenges arise from applications demanding the benefits of aerial robots, particularly in outdoor environments. This book collects eleven papers from different research groups from Spain, Croatia, Italy, Japan, the USA, the Netherlands, and Denmark, focused on the design, development, and experimental validation of methods and technologies for inspection and maintenance using aerial robots

Optic Flow for Obstacle Avoidance and Navigation: A Practical Approach

This thesis offers contributions and innovations to the development of vision-based autonomous flight control systems for small unmanned aerial vehicles operating in cluttered urban environments. Although many optic flow algorithms have been reported, almost none have addressed the critical issue of accuracy and reliability over a wide dynamic range of optic flow. My aim is to rigorously develop improved optic flow sensing to meet realistic mission requirements for autonomous navigation and collision avoidance. A review of related work enabled development of a new hybrid optic flow algorithm concept combining the best properties of image correlation and interpolation with additional innovations to enhance accuracy, computational speed and reliability. Key analytical work yielded a methodology for determining optic flow dynamic range requirements from system and sensor design parameters and a technique enabling a video sensor to operate as a passive ranging system for closed loop flight control. Detailed testing led to development of the hybrid image interpolation algorithm (HI2A) using improved correlation search strategies, sparse images to reduce processing loads, a solution tracking loop to bypass the more intensive initial estimation process, a frame look-back method to improve accuracy at low optic flow, a modified interpolation technique to improve robustness and an extensive error checking system for validating outputs. A realistic simulation system was developed incorporating independent, precision ground truthing to assess algorithm accuracy. Comparison testing of the HI2A against the commonly-used Lucas Kanade algorithm demonstrates major improvement in accuracy over greatly expanded dynamic range. A reactive flight controller using ranging data from a monocular, forward looking video sensor and rules-based logic was developed and tested in Monte Carlo simulations of a hundred flights. At higher flight speeds than reported in similar tests, collision-free results were obtained in a realistic urban canyon environment. The HI2A algorithm and flight controller software performance on a common PC was up to eight times faster than real-time for outputs of 250 measurements at 50 Hz. The feasibility of terrain mapping in real-time was demonstrated using 3D ranging data from optic flow in an overflight of the urban simulation environment indicating the potential for its use in path planning approaches to navigation and collision avoidance

NASA Tech Briefs Index, 1977, volume 2, numbers 1-4

Announcements of new technology derived from the research and development activities of NASA are presented. Abstracts, and indexes for subject, personal author, originating center, and Tech Brief number are presented for 1977

Development of an Autonomous Blimp

The purpose of this project was to design and fabricate an autonomous dirigible-based platform that could be used to enable development of navigational controllers and provide multi-mission capability through modularity. The platform was designed to carry and interface with a variety of mission specific hardware through a standard interface. A customized hardware platform was designed including a propulsion system and integrated sensor suite. Multiple ground level tests were undertaken to determine sensor performance and the capabilities of the navigational programs