Graphical modelling of modular machines

This research is aimed at advancing machine design through specifying and implementing (in "proof of concept" form) a set of tools which graphically model modular machines. The tools allow mechanical building elements (or machine modules) to be selected and configured together in a highly flexible manner so that operation of the chosen configuration can be simulated and performance properties evaluated. Implementation of the tools has involved an extension in capability of a proprietary robot simulation system. This research has resulted in a general approach to graphically modelling manufacturing machines built from modular elements. A focus of study has been on a decomposition of machine functionality leading to the establishment of a library of modular machine primitives. This provides a useful source of commonly required machine building elements for use by machine designers. Study has also focussed on the generation of machine configuration tools which facilitate the construction of a simulation model and ultimately the physical machine itself. Simulation aspects of machine control are also considered which depict methods of manipulating a machine model in the simulation phase. In addition methods of achieving machine programming have been considered which specify the machine and its operational tasks. Means of adopting common information data structures are also considered which can facilitate interfacing with other systems, including the physical machine system constructed as an issue of the simulation phase. Each of these study areas is addressed in its own context, but collectively they provide a means of creating a complete modular machine design environment which can provide significant assistance to machine designers. Part of the methodology employed in the study is based on the use of the discrete event simulation technique. To easily and effectively describe a modular machine and its activity in a simulation model, a hierarchical ring and tree data structure has been designed and implemented. The modularity and reconfigurability are accommodated by the data structure, and homogeneous transformations are adopted to determine the spatial location and orientation of each of the machine elements. A three-level machine task programming approach is used to describe the machine's activities. A common data format method is used to interface the machine design environment with the physical machine and other building blocks of manufacturing systems (such as CAD systems) where systems integration approaches can lead to enhanced product realisation. The study concludes that a modular machine design environment can be created by employing the graphical simulation approach together with a set of comprehensive configuration. tools. A generic framework has been derived which outlines the way in which machine design environments can be constructed and suggestions are made as to how the proof of concept design environment implemented in this study can be advanced

Human-Machine Interface for Remote Training of Robot Tasks

Regardless of their industrial or research application, the streamlining of robot operations is limited by the proximity of experienced users to the actual hardware. Be it massive open online robotics courses, crowd-sourcing of robot task training, or remote research on massive robot farms for machine learning, the need to create an apt remote Human-Machine Interface is quite prevalent. The paper at hand proposes a novel solution to the programming/training of remote robots employing an intuitive and accurate user-interface which offers all the benefits of working with real robots without imposing delays and inefficiency. The system includes: a vision-based 3D hand detection and gesture recognition subsystem, a simulated digital twin of a robot as visual feedback, and the "remote" robot learning/executing trajectories using dynamic motion primitives. Our results indicate that the system is a promising solution to the problem of remote training of robot tasks.Comment: Accepted in IEEE International Conference on Imaging Systems and Techniques - IST201

Intuitive Instruction of Industrial Robots : A Knowledge-Based Approach

With more advanced manufacturing technologies, small and medium sized enterprises can compete with low-wage labor by providing customized and high quality products. For small production series, robotic systems can provide a cost-effective solution. However, for robots to be able to perform on par with human workers in manufacturing industries, they must become flexible and autonomous in their task execution and swift and easy to instruct. This will enable small businesses with short production series or highly customized products to use robot coworkers without consulting expert robot programmers. The objective of this thesis is to explore programming solutions that can reduce the programming effort of sensor-controlled robot tasks. The robot motions are expressed using constraints, and multiple of simple constrained motions can be combined into a robot skill. The skill can be stored in a knowledge base together with a semantic description, which enables reuse and reasoning. The main contributions of the thesis are 1) development of ontologies for knowledge about robot devices and skills, 2) a user interface that provides simple programming of dual-arm skills for non-experts and experts, 3) a programming interface for task descriptions in unstructured natural language in a user-specified vocabulary and 4) an implementation where low-level code is generated from the high-level descriptions. The resulting system greatly reduces the number of parameters exposed to the user, is simple to use for non-experts and reduces the programming time for experts by 80%. The representation is described on a semantic level, which means that the same skill can be used on different robot platforms. The research is presented in seven papers, the first describing the knowledge representation and the second the knowledge-based architecture that enables skill sharing between robots. The third paper presents the translation from high-level instructions to low-level code for force-controlled motions. The two following papers evaluate the simplified programming prototype for non-expert and expert users. The last two present how program statements are extracted from unstructured natural language descriptions

Cognitive Task Planning for Smart Industrial Robots

This research work presents a novel Cognitive Task Planning framework for Smart Industrial Robots. The framework makes an industrial mobile manipulator robot Cognitive by applying Semantic Web Technologies. It also introduces a novel Navigation Among Movable Obstacles algorithm for robots navigating and manipulating inside a firm. The objective of Industrie 4.0 is the creation of Smart Factories: modular firms provided with cyber-physical systems able to strong customize products under the condition of highly flexible mass-production. Such systems should real-time communicate and cooperate with each other and with humans via the Internet of Things. They should intelligently adapt to the changing surroundings and autonomously navigate inside a firm while moving obstacles that occlude free paths, even if seen for the first time. At the end, in order to accomplish all these tasks while being efficient, they should learn from their actions and from that of other agents. Most of existing industrial mobile robots navigate along pre-generated trajectories. They follow ectrified wires embedded in the ground or lines painted on th efloor. When there is no expectation of environment changes and cycle times are critical, this planning is functional. When workspaces and tasks change frequently, it is better to plan dynamically: robots should autonomously navigate without relying on modifications of their environments. Consider the human behavior: humans reason about the environment and consider the possibility of moving obstacles if a certain goal cannot be reached or if moving objects may significantly shorten the path to it. This problem is named Navigation Among Movable Obstacles and is mostly known in rescue robotics. This work transposes the problem on an industrial scenario and tries to deal with its two challenges: the high dimensionality of the state space and the treatment of uncertainty. The proposed NAMO algorithm aims to focus exploration on less explored areas. For this reason it extends the Kinodynamic Motion Planning by Interior-Exterior Cell Exploration algorithm. The extension does not impose obstacles avoidance: it assigns an importance to each cell by combining the efforts necessary to reach it and that needed to free it from obstacles. The obtained algorithm is scalable because of its independence from the size of the map and from the number, shape, and pose of obstacles. It does not impose restrictions on actions to be performed: the robot can both push and grasp every object. Currently, the algorithm assumes full world knowledge but the environment is reconfigurable and the algorithm can be easily extended in order to solve NAMO problems in unknown environments. The algorithm handles sensor feedbacks and corrects uncertainties. Usually Robotics separates Motion Planning and Manipulation problems. NAMO forces their combined processing by introducing the need of manipulating multiple objects, often unknown, while navigating. Adopting standard precomputed grasps is not sufficient to deal with the big amount of existing different objects. A Semantic Knowledge Framework is proposed in support of the proposed algorithm by giving robots the ability to learn to manipulate objects and disseminate the information gained during the fulfillment of tasks. The Framework is composed by an Ontology and an Engine. The Ontology extends the IEEE Standard Ontologies for Robotics and Automation and contains descriptions of learned manipulation tasks and detected objects. It is accessible from any robot connected to the Cloud. It can be considered a data store for the efficient and reliable execution of repetitive tasks; and a Web-based repository for the exchange of information between robots and for the speed up of the learning phase. No other manipulation ontology exists respecting the IEEE Standard and, regardless the standard, the proposed ontology differs from the existing ones because of the type of features saved and the efficient way in which they can be accessed: through a super fast Cascade Hashing algorithm. The Engine lets compute and store the manipulation actions when not present in the Ontology. It is based on Reinforcement Learning techniques that avoid massive trainings on large-scale databases and favors human-robot interactions. The overall system is flexible and easily adaptable to different robots operating in different industrial environments. It is characterized by a modular structure where each software block is completely reusable. Every block is based on the open-source Robot Operating System. Not all industrial robot controllers are designed to be ROS-compliant. This thesis presents the method adopted during this research in order to Open Industrial Robot Controllers and create a ROS-Industrial interface for them

Robot Composite Learning and the Nunchaku Flipping Challenge

Advanced motor skills are essential for robots to physically coexist with humans. Much research on robot dynamics and control has achieved success on hyper robot motor capabilities, but mostly through heavily case-specific engineering. Meanwhile, in terms of robot acquiring skills in a ubiquitous manner, robot learning from human demonstration (LfD) has achieved great progress, but still has limitations handling dynamic skills and compound actions. In this paper, we present a composite learning scheme which goes beyond LfD and integrates robot learning from human definition, demonstration, and evaluation. The method tackles advanced motor skills that require dynamic time-critical maneuver, complex contact control, and handling partly soft partly rigid objects. We also introduce the "nunchaku flipping challenge", an extreme test that puts hard requirements to all these three aspects. Continued from our previous presentations, this paper introduces the latest update of the composite learning scheme and the physical success of the nunchaku flipping challenge

Adaptive Robot Framework: Providing Versatility and Autonomy to Manufacturing Robots Through FSM, Skills and Agents

207 p.The main conclusions that can be extracted from an analysis of the current situation and future trends of the industry,in particular manufacturing plants, are the following: there is a growing need to provide customization of products, ahigh variation of production volumes and a downward trend in the availability of skilled operators due to the ageingof the population. Adapting to this new scenario is a challenge for companies, especially small and medium-sizedenterprises (SMEs) that are suffering first-hand how their specialization is turning against them.The objective of this work is to provide a tool that can serve as a basis to face these challenges in an effective way.Therefore the presented framework, thanks to its modular architecture, allows focusing on the different needs of eachparticular company and offers the possibility of scaling the system for future requirements. The presented platform isdivided into three layers, namely: interface with robot systems, the execution engine and the application developmentlayer.Taking advantage of the provided ecosystem by this framework, different modules have been developed in order toface the mentioned challenges of the industry. On the one hand, to address the need of product customization, theintegration of tools that increase the versatility of the cell are proposed. An example of such tools is skill basedprogramming. By applying this technique a process can be intuitively adapted to the variations or customizations thateach product requires. The use of skills favours the reuse and generalization of developed robot programs.Regarding the variation of the production volumes, a system which permits a greater mobility and a faster reconfigurationis necessary. If in a certain situation a line has a production peak, mechanisms for balancing the loadwith a reasonable cost are required. In this respect, the architecture allows an easy integration of different roboticsystems, actuators, sensors, etc. In addition, thanks to the developed calibration and set-up techniques, the system canbe adapted to new workspaces at an effective time/cost.With respect to the third mentioned topic, an agent-based monitoring system is proposed. This module opens up amultitude of possibilities for the integration of auxiliary modules of protection and security for collaboration andinteraction between people and robots, something that will be necessary in the not so distant future.For demonstrating the advantages and adaptability improvement of the developed framework, a series of real usecases have been presented. In each of them different problematic has been resolved using developed skills,demonstrating how are adapted easily to the different casuistic