Design of a modular solution for an autonomous vehicle for cargo transport and handling

Due to the globalization of markets, the industrial competitiveness has increased significantly in the recent years. Within this scope, the transportation of products inside industrial parks acquires special relevancy. One of the solutions is the use of autonomous guided vehicles. This work presents the design of a modular autonomous vehicle, capable of carrying heavy loads, which will improve the performance of industrial parks. This is a compact vehicle with low associated costs and good transport speeds. A drive system was designed, which will be capable of transporting the proposed loads. This design was carried out using simulations of the transport with loads, either in plane ground or in an industrial park. A structural analysis to the vehicle was also undertaken by the Finite Element Method, showing the points of the structure that require reinforcement for the different load cases. Finally, the required corrections were implemented, giving to the structure the ability to carry the desired loads. The end result was an autonomous vehicle with capacity to safely transport the imposed loads in the most efficient possible manner.info:eu-repo/semantics/publishedVersio

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

Parameter tuning and cooperative control for automated guided vehicles

For several practical control engineering applications it is desirable that multiple systems can operate independently as well as in cooperation with each other. Especially when the transition between individual and cooperative behavior and vice versa can be carried out easily, this results in ??exible and scalable systems. A subclass is formed by systems that are physically separated during individual operation, and very tightly coupled during cooperative operation. One particular application of multiple systems that can operate independently as well as in concert with each other is the cooperative transportation of a large object by multiple Automated Guided Vehicles (AGVs). AGVs are used in industry to transport all kinds of goods, ranging from small trays of compact and video discs to pallets and 40-tonne coils of steel. Current applications typically comprise a ??eet of AGVs, and the vehicles transport products on an individual basis. Recently there has been an increasing demand to transport very large objects such as sewer pipes, rotor blades of wind turbines and pieces of scenery for theaters, which may reach lengths of over thirty meters. A realistic option is to let several AGVs operate together to handle these types of loads. This Ph.D. thesis describes the development, implementation, and testing of distributed control algorithms for transporting a load by two or more Automated Guided Vehicles in industrial environments. We focused on the situations where the load is connected to the AGVs by means of (semi-)rigid interconnections. Attention was restricted to control on the velocity level, which we regard as an intermediate step for achieving fully automatic operation. In our setup the motion setpoint is provided by an external host. The load is assumed to be already present on the vehicles. Docking and grasping procedures are not considered. The project is a collaboration between the company FROG Navigation Systems (Utrecht, The Netherlands) and the Control Systems group of the Technische Universiteit Eindhoven. FROG provided testing facilities including two omni-directional AGVs. Industrial AGVs are custom made for the transportation tasks at hand and come in a variety of forms. To reduce development times it is desirable to follow a model-based control design approach as this allows generalization to a broad class of vehicles. We have adopted rigid body modeling techniques from the ??eld of robotic manipulators to derive the equations of motion for the AGVs and load in a systematic way. These models are based on physical considerations such as Newton's second law and the positions and dimensions of the wheels, sensors, and actuators. Special emphasis is put on the modeling of the wheel-??oor interaction, for which we have adopted tire models that stem from the ??eld of vehicle dynamics. The resulting models have a clear physical interpretation and capture a large class of vehicles with arbitrary wheel con??gurations. This ensures us that the controllers, which are based on these models, are applicable to a broad class of vehicles. An important prerequisite for achieving smooth cooperative behavior is that the individual AGVs operate at the required accuracy. The performance of an individual AGV is directly related to the precision of the estimates for the odometric parameters, i.e. the effective wheel diameters and the offsets of the encoders that measure the steering angles of the wheels. Cooperative transportation applications will typically require AGVs that are highly maneuverable, which means that all the wheels of an individual AGV ahould be able to steer. Since there will be more than one steering angle encoder, the identi??cation of the odometric parameters is substantially more dif??cult for these omni-directional AGVs than for the mobile wheeled robots that are commonly seen in literature and laboratory settings. In this thesis we present a novel procedure for simultaneously estimating effective wheel diameters and steering angle encoder offsets by driving several pure circle segments. The validity of the tuning procedure is con??rmed by experiments with the two omni-directional test vehicles with varying loads. An interesting result is that the effective wheel diameters of the rubber wheels of our AGVs increase with increasing load. A crucial aspect in all control designs is the reconstruction of the to-be-controlled variables from measurement data. Our to-be-controlled variables are the planar motion of the load and the motions of the AGVs with respect to the load, which have to be reconstruct from the odometric sensor information. The odometric sensor information consists of the drive encoder and steering encoder readings. We analyzed the observability of an individual AGV and proved that it is theoretically possible to reconstruct its complete motion from the odometric measurements. Due to practical considerations, we pursued a more pragmatic least-squares based observer design. We show that the least-squares based motion estimate is independent of the coordinate system that is being used. The motion estimator was subsequently analyzed in a stochastic setting. The relation between the motion estimator and the estimated velocity of an arbitrary point on the vehicle was explored. We derived how the covariance of the velocity estimate of an arbitrary point on the vehicle is related to the covariance of the motion estimate. We proved that there is one unique point on the vehicle for which the covariance of the estimated velocity is minimal. Next, we investigated how the local motion estimates of the individual AGVs can be combined to yield one global estimate. When the load and AGVs are rigidly interconnected, it suf??ces that each AGVs broadcasts its local motion estimate and receives the estimates of the other AGVs. When the load is semi-rigidly interconnected to the AGVs, e.g. by means of revolute or prismatic joints, then generally each AGV needs to broadcasts the corresponding information matrix as well. We showed that the information matrix remains constant when the load is connected to the AGV with a revolute joint that is mounted at the aforementioned unique point with the smallest velocity estimate covariance. This means that the corresponding AGV does not have to broadcast its information matrix for this special situation. The key issue in the control design for cooperative transportation tasks is that the various AGVs must not counteract each others' actions. The decentralized controller that we derived makes the AGVs track an externally provided planar motion setpoint while minimizing the interconnection forces between the load and the vehicles. Although the control design is applicable to cooperative transportation by multiple AGVs with arbitrary semi-rigid AGV-load interconnections, it is noteworthy that a particularly elegant solution arises when all interconnections are completely rigid. Then the derived local controllers have the same structure as the controllers that are normally used for individual operation. As a result, changing a few parameter settings and providing the AGVs with identical setpoints is all that is required to achieve cooperative behavior on the velocity level for this situation. The observer and controller designs for the case that the AGVs are completely rigidly interconnected to the load were successfully implemented on the two test vehicles. Experi ments were carried out with and without a load that consisted of a pallet with 300 kg pave stones. The results were reproducible and illustrated the practical validity of the observer and controller designs. There were no substantial drawbacks when the local observers used only their local sensor information, which means that our setup can also operate satisfactory when the velocity estimates are not shared with the other vehicles

Design and Development of Climbing Robotic Systems for Automated Inspection of Steel Structures and Bridges

Steel structures are indispensable parts of modern civilization, with typical civil infrastructures including bridges, wind turbines, electric towers, oil rigs, ships, and submarines, all made of steel. These structures require frequent maintenance to ensure safety and longevity. Steel bridges are the most challenging architectures due totheir complexity and height. Most inspections are conducted manually by professional human inspectors with special devices to inspect visible damages and defects on or inside these structures. However, this procedure is usually highly time-consuming, costly, and risky. Automated solutions are desired to address this problem. However, arduous engineering is delaying progress. A complete system needs to deal with three main problems: (1) locomotive performance for the high complexity of steel bridges, including differential curvatures, transitions between beams, and obstacles; (2) data collection capability, inclusive of visible and invisible damages, in-depth information such as vibration, coat, and material thickness, etc.; and (3) working conditions made up of gust winds. To achieve such a complete system, this dissertation presents novel developments of inspection-climbing robots. Five different robot versions are designed to find the simplest and most effective configuration as well as control manner. Our approach started with (1) a transformable tank-like robot integrated with a haptic device and ii two natural-inspired locomotion, (2) a roller chain-like robot, (3) a hybrid worming mobile robot, (4) a multi-directional bicycle robot, and (5) an omni-directional climbing Robot, identified as the most potential solution for automated steel bridge inspection. For each robotic development, detailed mechanical analysis frameworks are presented. Both lab tests and field deployments of these robotic systems have been conducted to validate the proposed designs

Sensors-based Mobile Robot for Harsh Environments: Functionalities, Energy Consumption Analysis and Characterization

none8siMobile robots, especially, mini-robots and mini-rovers are playing an important role in different industrial applications. Under certain constraints, they are mostly suitable for harsh environments where hard conditions take place such as to be unfit for the protracted human activity, or even where this latter is not allowed. In many circumstances, the energy issues for autonomous and wheeled mobile robots need to be optimized taking into account the mechanical and electrical consumptions. The paper illustrates the design of a semi-custom wheeled mobile robot with integrated a photovoltaic (PV) system on the roof, namely a high-efficiency mono- or poly-crystalline PV panel, for supporting the Li-Ion batteries during particular tasks (rough terrain, obstacles or paths with steep slopes), in order to extend the robot autonomy. An electronic control has been designed and data acquisitions, related to power consumption, have been performed by means of a specific experimental setup. The robot was used for detecting different parameters such as temperature, humidity, concentrations of toxic gas species, and presence of flames, therefore particularly suitable for contaminated environments or industrial plants. For this aim, the mobile robot has been equipped with a wide range of commercial sensors and a Global Positioning System (GPS) receiver for keeping track of the robotic vehicle position. In addition, the robot is equipped with a HC-06 Bluetooth transceiver for sending the acquired data to the developed IoTool smartphone application where they are displayed to be analyzed by the user, and for receiving commands and instructions.Article 29openR. De Fazio, D. M. Katamba, A. Lay Ekuakille, M. J. Ferreira, S. Kidiamboko, N.I. Giannoccaro, R. Velazquez, P. ViscontiDe Fazio, R.; Katamba, D. M.; Lay Ekuakille, A.; Ferreira, M. J.; Kidiamboko, S.; Giannoccaro, N. I.; Velazquez, R.; Visconti, P

Mobile robot transportation in laboratory automation

In this dissertation a new mobile robot transportation system is developed for the modern laboratory automation to connect the distributed automated systems and workbenches. In the system, a series of scientific and technical robot indoor issues are presented and solved, including the multiple robot control strategy, the indoor transportation path planning, the hybrid robot indoor localization, the recharging optimization, the robot-automated door interface, the robot blind arm grasping & placing, etc. The experiments show the proposed system and methods are effective and efficient