FBG-based sensing system to improve tactile sensitivity of robotic manipulators working in unstructured environments

The emergence of Industry 4.0 has brought new concepts to the factories that optimize and improve conventional processes. These technologies have brought assignments to the industrial robots that allow them to perform tasks faster and more precisely. The improvement of the robot’s proprioception capacity and tactile sensitivity using sensors is a useful approach to achieve those goals. Optical fibers are a viable technology to be used as sensors in robotic devices because they are electrically passive and present electromagnetic immunity. This paper proposes a Fiber Bragg Grating (FBG) based sensing system to monitor robotic manipulators during their operation. It corresponds to smart textiles installed on the robot’s body to detect interactions with the environment. A mathematical model is proposed to find what should be the greatest distance between adjacent FBGs to detect contact at any point between them. From this, it is possible to obtain a minimum number of sensors to detect contact at any point and guarantee the highest spatial resolution of the system with lower costs. The tactile system is formed of a group of optical fibers with multiplexed FBGs embedded in silicone rubber. The optical fibers with the sensors are positioned between layers of polyethylene foam and cotton fabric. After the manufacturing process, temperature and force characterization were done on the sensors which make up the smart textiles. In the characterization results, almost all the FBG presented values of R² on the linear regression superior to 0.94. Individual analysis is performed for the sensors which present a low coefficient of determination. Finally, the system was tested in an experimental validation in which the robot was hit while executing a task. From the results, it can be observed that the system can provide the position on the robot’s body, the amplitude in terms of force and the instant of time in which an external impact occurred.publishe

Development of a fiber-based shape sensor for navigating flexible medical tools

Robot-assisted minimally invasive surgical procedure (RAMIS) is a subfield of minimally invasive surgeries with enhanced manual dexterity, manipulability, and intraoperative image guidance. In typical robotic surgeries, it is common to use rigid instruments with functional articulating tips. However, in some operations where no adequate and direct access to target anatomies is available, continuum robots can be more practical, as they provide curvilinear and flexible access. However, their inherent deformable design makes it difficult to accurately estimate their 3D shape during the operation in real-time. Despite extensive model-based research that relies on kinematics and mechanics, accurate shape sensing of continuum robots remains challenging. The state-of-the-art tracking technologies, including optical trackers, EM tracking systems, and intraoperative imaging modalities, are also unsuitable for this task, as they all have shortcomings. Optical fiber shape sensing solutions offer various advantages compared to other tracking modalities and can provide high-resolution shape measurements in real-time. However, commercially available fiber shape sensors are expensive and have limited accuracy. In this thesis, we propose two cost-effective fiber shape sensing solutions based on multiple single-mode fibers with FBG (fiber Bragg grating) arrays and eccentric FBGs. First, we present the fabrication and calibration process of two shape sensing prototypes based on multiple single-mode fibers with semi-rigid and super-elastic substrates. Then, we investigate the sensing mechanism of edge-FBGs, which are eccentric Bragg gratings inscribed off-axis in the fiber's core. Finally, we present a deep learning algorithm to model edge-FBG sensors that can directly predict the sensor's shape from its signal and does not require any calibration or shape reconstruction steps. In general, depending on the target application, each of the presented fiber shape sensing solutions can be used as a suitable tracking device. The developed fiber sensor with the semi-rigid substrate has a working channel in the middle and can accurately measure small deflections with an average tip error of 2.7 mm. The super-elastic sensor is suitable for measuring medium to large deflections, where a centimeter range tip error is still acceptable. The tip error in such super-elastic sensors is higher compared to semi-rigid sensors (9.9-16.2 mm in medium and large deflections, respectively), as there is a trade-off between accuracy and flexibility in substrate-based fiber sensors. Edge-FBG sensor, as the best performing sensing mechanism among the investigated fiber shape sensors, can achieve a tip accuracy of around 2 mm in complex shapes, where the fiber is heavily deflected. The developed edge-FBG shape sensing solution can compete with the state-of-the-art distributed fiber shape sensors that cost 30 times more

Recent developments in fibre optic shape sensing

This paper presents a comprehensive critical review of technologies used in the development of fibre optic shape sensors (FOSSs). Their operation is based on multi-dimensional bend measurements using a series of fibre optic sensors. Optical fibre sensors have experienced tremendous growth from simple bend sensors in 1980s to full three-dimensional FOSSs using multicore fibres in recent years. Following a short review of conventional contact-based shape sensor technologies, the evolution trend and sensing principles of FOSSs are presented. This paper identifies the major optical fibre technologies used for shape sensing and provides an account of the challenges and emerging applications of FOSSs in various industries such as medical robotics, industrial robotics, aerospace and mining industry

Macrobend optical sensing for pose measurement in soft robot arms

This paper introduces a pose-sensing system for soft robot arms integrating a set of macrobend stretch sensors. The macrobend sensory design in this study consists of optical fibres and is based on the notion that bending an optical fibre modulates the intensity of the light transmitted through the fibre. This sensing method is capable of measuring bending, elongation and compression in soft continuum robots and is also applicable to wearable sensing technologies, e.g. pose sensing in the wrist joint of a human hand. In our arrangement, applied to a cylindrical soft robot arm, the optical fibres for macrobend sensing originate from the base, extend to the tip of the arm, and then loop back to the base. The connectors that link the fibres to the necessary opto-electronics are all placed at the base of the arm, resulting in a simplified overall design. The ability of this custom macrobend stretch sensor to flexibly adapt its configuration allows preserving the inherent softness and compliance of the robot which it is installed on. The macrobend sensing system is immune to electrical noise and magnetic fields, is safe (because no electricity is needed at the sensing site), and is suitable for modular implementation in multi-link soft continuum robotic arms. The measurable light outputs of the proposed stretch sensor vary due to bend-induced light attenuation (macrobend loss), which is a function of the fibre bend radius as well as the number of repeated turns. The experimental study conducted as part of this research revealed that the chosen bend radius has a far greater impact on the measured light intensity values than the number of turns (if greater than five). Taking into account that the bend radius is the only significantly influencing design parameter, the macrobend stretch sensors were developed to create a practical solution to the pose sensing in soft continuum robot arms. Henceforward, the proposed sensing design was benchmarked against an electromagnetic tracking system (NDI Aurora) for validation

Three-Axis Fiber-Optic Body Force Sensor for Flexible Manipulators

This paper proposes a force/torque sensor structure that can be easily integrated into a flexible manipulator structure. The sensor's ring-like structure with its hollow inner section provides ample space for auxiliary components, such as cables and tubes, to be passed through and, hence, is very suitable for integration with tendon-driven and fluid-actuated manipulators. The sensor structure can also accommodate the wiring for a distributed sensor system as well as for diagnostic instruments that may be incorporated in the manipulator. Employing a sensing approach based on optical fibers as done here allows for the creation of sensors that are free of electrical currents at the point of sensing and immune to magnetic fields. These sensors are inherently safe when used in the close vicinity of humans and their measuring performance is not impaired when they are operated in or nearby machines, such as magnetic resonance imaging scanners. This type of sensor concept is particularly suitable for inclusion in instruments and robotic tools for minimally invasive surgery. This paper summarizes the design, integration challenges, and calibration of the proposed optical three-axis force sensor. The experimental results confirm the effectiveness of our optical sensing approach and show that after calibrating its stiffness matrix, force and momentum components can be determined accurately

Three-Axis Fiber-Optic Body Force Sensor for Flexible Manipulators

This paper proposes a force/torque sensor structure that can be easily integrated with a flexible manipulator structure. The sensor’s ring-like structure with its hollow inner section provides ample space for auxiliary components, such as cables and tubes, to be passed through and, hence, is very suitable for integration with tendon-driven and fluid-actuated manipulators. The sensor structure can also accommodate the wiring for a distributed sensor system as well as for diagnostic instruments that may be incorporated in the manipulator. Employing a sensing approach based on optical fibers as done here allows for the creation of sensors that are free of electrical currents at the point of sensing and immune to magnetic fields. These sensors are inherently safe when used in the close vicinity of humans and their measuring performance is not impaired when they are operated in or nearby machines such as magnetic resonance imaging (MRI) scanners. This type of sensor concept is particularly suitable for inclusion in instruments and robotic tools for minimally invasive surgery (MIS). The paper summarizes the design, integration challenges and calibration of the proposed optical three-axis force sensor. The experimental results confirm the effectiveness of our optical sensing approach and show that after calibrating its stiffness matrix, force and momentum components can be determined accurately

Low Profile Stretch Sensor for Soft Wearable Robotics

This paper presents a low profile stretch sensor for integration into soft structures, robots and wearables. The sensor mechanism uses a single piece of highly flexible and light weight optical fibre and is based on the notion that bending an optical fibre modulates the intensity of the light transmitted through the fibre, a technique often referred as macrobending light loss. In this arrangement, the optical fibre originates from sensor’s electronic unit, passes through a stretchable encasing structure in a macrobend pattern, and then loop back to the same unit resulting in a simplified electrical and optical design; the closed optical loop allows for no electronics at one end of the sensor making it safe for human robotics applications, and no optical interference with the external environment eliminating the need for complex conditioning circuitries. Of particular interest of the soft robotics community, the ability of this custom macrobend stretch sensor to flexibly adapt its configuration allows preserving the inherent softness and compliance of the robot which it is installed on. Our experimental results indicate that the optical fibre’s bending radius is the dominant design parameter for sufficiently complex patterns, a finding that can facilitate generalisation of the sensing methods across different scales. The measurement performance of the mechanism and its impact on the stiffness of the encasing structure is benchmarked against a custom calibration and testing system

FBG-Based Triaxial Force Sensor Integrated with an Eccentrically Configured Imaging Probe for Endoluminal Optical Biopsy

Accurate force sensing is important for endoluminal intervention in terms of both safety and lesion targeting. This paper develops an FBG-based force sensor for robotic bronchoscopy by configuring three FBG sensors at the lateral side of a conical substrate. It allows a large and eccentric inner lumen for the interventional instrument, enabling a flexible imaging probe inside to perform optical biopsy. The force sensor is embodied with a laser-profiled continuum robot and thermo drift is fully compensated by three temperature sensors integrated on the circumference surface of the sensor substrate. Different decoupling approaches are investigated, and nonlinear decoupling is adopted based on the cross-validation SVM and a Gaussian kernel function, achieving an accuracy of 10.58 mN, 14.57 mN and 26.32 mN along X, Y and Z axis, respectively. The tissue test is also investigated to further demonstrate the feasibility of the developed triaxial force senso