A Tutorial on Learning Human Welder\u27s Behavior: Sensing, Modeling, and Control

Human welder\u27s experiences and skills are critical for producing quality welds in manual GTAW process. Learning human welder\u27s behavior can help develop next generation intelligent welding machines and train welders faster. In this tutorial paper, various aspects of mechanizing the welder\u27s intelligence are surveyed, including sensing of the weld pool, modeling of the welder\u27s adjustments and this model-based control approach. Specifically, different sensing methods of the weld pool are reviewed and a novel 3D vision-based sensing system developed at University of Kentucky is introduced. Characterization of the weld pool is performed and human intelligent model is constructed, including an extensive survey on modeling human dynamics and neuro-fuzzy techniques. Closed-loop control experiment results are presented to illustrate the robustness of the model-based intelligent controller despite welding speed disturbance. A foundation is thus established to explore the mechanism and transformation of human welder\u27s intelligence into robotic welding system. Finally future research directions in this field are presented

Relaxing Fundamental Assumptions in Iterative Learning Control

Iterative learning control (ILC) is perhaps best decribed as an open loop feedforward control technique where the feedforward signal is learned through repetition of a single task. As the name suggests, given a dynamic system operating on a finite time horizon with the same desired trajectory, ILC aims to iteratively construct the inverse image (or its approximation) of the desired trajectory to improve transient tracking. In the literature, ILC is often interpreted as feedback control in the iteration domain due to the fact that learning controllers use information from past trials to drive the tracking error towards zero. However, despite the significant body of literature and powerful features, ILC is yet to reach widespread adoption by the control community, due to several assumptions that restrict its generality when compared to feedback control. In this dissertation, we relax some of these assumptions, mainly the fundamental invariance assumption, and move from the idea of learning through repetition to two dimensional systems, specifically repetitive processes, that appear in the modeling of engineering applications such as additive manufacturing, and sketch out future research directions for increased practicality: We develop an L1 adaptive feedback control based ILC architecture for increased robustness, fast convergence, and high performance under time varying uncertainties and disturbances. Simulation studies of the behavior of this combined L1-ILC scheme under iteration varying uncertainties lead us to the robust stability analysis of iteration varying systems, where we show that these systems are guaranteed to be stable when the ILC update laws are designed to be robust, which can be done using existing methods from the literature. As a next step to the signal space approach adopted in the analysis of iteration varying systems, we shift the focus of our work to repetitive processes, and show that the exponential stability of a nonlinear repetitive system is equivalent to that of its linearization, and consequently uniform stability of the corresponding state space matrix.PhDElectrical Engineering: SystemsUniversity of Michigan, Horace H. Rackham School of Graduate Studieshttp://deepblue.lib.umich.edu/bitstream/2027.42/133232/1/altin_1.pd

Virtualized Welding Based Learning of Human Welder Behaviors for Intelligent Robotic Welding

Combining human welder (with intelligence and sensing versatility) and automated welding robots (with precision and consistency) can lead to next generation intelligent welding systems. In this dissertation intelligent welding robots are developed by process modeling / control method and learning the human welder behavior. Weld penetration and 3D weld pool surface are first accurately controlled for an automated Gas Tungsten Arc Welding (GTAW) machine. Closed-form model predictive control (MPC) algorithm is derived for real-time welding applications. Skilled welder response to 3D weld pool surface by adjusting the welding current is then modeled using Adaptive Neuro-Fuzzy Inference System (ANFIS), and compared to the novice welder. Automated welding experiments confirm the effectiveness of the proposed human response model. A virtualized welding system is then developed that enables transferring the human knowledge into a welding robot. The learning of human welder movement (i.e., welding speed) is first realized with Virtual Reality (VR) enhancement using iterative K-means based local ANFIS modeling. As a separate effort, the learning is performed without VR enhancement utilizing a fuzzy classifier to rank the data and only preserve the high ranking “correct” response. The trained supervised ANFIS model is transferred to the welding robot and the performance of the controller is examined. A fuzzy weighting based data fusion approach to combine multiple machine and human intelligent models is proposed. The data fusion model can outperform individual machine-based control algorithm and welder intelligence-based models (with and without VR enhancement). Finally a data-driven approach is proposed to model human welder adjustments in 3D (including welding speed, arc length, and torch orientations). Teleoperated training experiments are conducted in which a human welder tries to adjust the torch movements in 3D based on his observation on the real-time weld pool image feedback. The data is off-line rated by the welder and a welder rating system is synthesized. ANFIS model is then proposed to correlate the 3D weld pool characteristic parameters and welder’s torch movements. A foundation is thus established to rapidly extract human intelligence and transfer such intelligence into welding robots

Human adaptive mechatronics methods for mobile working machines

Despite the trend of increasing automation degree in control systems, human operators are still needed in applications such as aviation and surgery, or machines used in remote mining, forestry, construction, and agriculture, just to name a few. Although there are research results showing that the performance between the operators of working machines differ significantly, there are currently no means to improve the performance of the human-machine system automatically based on the skill and working differences of the operators. Traditionally the human-machine systems are designed so that the machine is "constant" for every operator. On the contrary, the Human Adaptive Mechatronics (HAM) approach focuses on individual design, taking into account the skill differences and preferences of the operators. This thesis proposes a new type of a HAM system for mobile working machines called Human Adaptive Mechatronics and Coaching (HAMC) system that is designed to account for the challenges regarding to the measurement capability and the work complexity in the real-life machines. Moreover, the related subproblems including intent recognition, skill evaluation, human operator modeling, intelligent coaching and skill adaptivity are described. The intent recognition is solved using a Hidden Markov model (HMM) based work cycle modeling method, which is a basis for the skill evaluation. The methods are implemented in three industrial applications. The human operator modeling problem is studied from the structural models' perspective. The structural models can be used to describe a continuum of human operator models with respect to the operating points of the controlled machine. Several extensions and new approaches which enable more efficient parameter estimation using the experimental data are described for the conventional Modified Optimal Control Model (MOCM) of human operator. The human operator modeling methods are implemented to model a human operator controlling a trolley crane simulator. Finally, the concept of human adaptive Human-Machine Interface (HMI) is described. The analytic and knowledge-based approaches for realizing the HMI adaptation are presented and implemented for trolley crane simulator control