Force-Torque Sensing in Robotics

Being able to perform dynamic motions repeatably and reliably is an active research topic. The present thesis aims to contribute to this by improving the accuracy of force-torque sensing in robots. It focuses primarily on six axis force-torque sensors, although other sources of force-torque sensing are explored. Force sensing technologies, calibration procedures of these sensors and the use of force-torque sensing in robotics are described with the aim to familiarize the reader with the problem to solve. The problem is tackled in two ways: improving the accuracy of six axis force-torque sensors and exploring the use of tactile sensor arrays as force-torque sensors. The contributions of this thesis are : the development of the Model Based In situ calibration method for improving measurements of sensors already mounted on robots and the improvement in performance of the robot as a consequence; the design of a calibration device to improve the reliability and speed of calibration; and the improvement of force sensing information of a capacitive tactile array and its use on a robot as force-torque information source. The developed algorithms were tested on the humanoid robotic platform iCub

Nonlinear In-situ Calibration of Strain-Gauge Force/Torque Sensors for Humanoid Robots

High force/torque (F/T) sensor calibration accuracy is crucial to achieving successful force estimation/control tasks with humanoid robots. State-of-the-art affine calibration models do not always approximate correctly the physical phenomenon of the sensor/transducer, resulting in inaccurate F/T measurements for specific applications such as thrust estimation of a jet-powered humanoid robot. This paper proposes and validates nonlinear polynomial models for F/T calibration, increasing the number of model coefficients to minimize the estimation residuals. The analysis of several models, based on the data collected from experiments with the iCub3 robot, shows a significant improvement in minimizing the force/torque estimation error when using higher-degree polynomials. In particular, when using a 4th-degree polynomial model, the Root Mean Square error (RMSE) decreased to 2.28N from the 4.58N obtained with an affine model, and the absolute error in the forces remained under 6N while it was reaching up to 16N with the affine model

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

Design of Novel Sensors and Instruments for Minimally Invasive Lung Tumour Localization via Palpation

Minimally Invasive Thoracoscopic Surgery (MITS) has become the treatment of choice for lung cancer. However, MITS prevents the surgeons from using manual palpation, thereby often making it challenging to reliably locate the tumours for resection. This thesis presents the design, analysis and validation of novel tactile sensors, a novel miniature force sensor, a robotic instrument, and a wireless hand-held instrument to address this limitation. The low-cost, disposable tactile sensors have been shown to easily detect a 5 mm tumour located 10 mm deep in soft tissue. The force sensor can measure six degrees of freedom forces and torques with temperature compensation using a single optical fiber. The robotic instrument is compatible with the da Vinci surgical robot and allows the use of tactile sensing, force sensing and ultrasound to localize the tumours. The wireless hand-held instrument allows the use of tactile sensing in procedures where a robot is not available

Development of an integrated robotic polishing system

This thesis presents research carried out as part of a project undertaken in fulfilment of the requirements of Loughborough University for the award of Philosophical Doctorate. The main focus of this research is to investigate and develop an appropriate level of automation to the existing manual finishing operations of small metallic components to achieve required surface quality and to remove superficial defects. In the manufacturing industries, polishing processes play a vital role in the development of high precision products, to give a desired surface finish, remove defects, break sharp edges, extend the working life cycle, and meet mechanical specification. The polishing operation is generally done at the final stage of the manufacturing process and can represent up to a third of the production time. Despite the growth automated technology in industry, polishing processes are still mainly carried out manually, due to the complexity and constraints of the process. Manual polishing involves a highly qualified worker polishing the workpiece by hand. These processes are very labour intensive, highly skill dependent, costly, error-prone, environmentally hazardous due to abrasive dust, and - in some cases - inefficient with long process times. In addition, the quality of the finishing is dependent on the training, experience, fatigue, physical ability, and expertise of the operator. Therefore, industries are seeking alternative solutions to be implemented within their current processes. These solutions are mainly aimed at replacing the human operator to improve the health and safety of their workforce and improve their competitiveness. Some automated solutions have already been proposed to assist or replace manual polishing processes. These solutions provide limited capabilities for specific processes or components, and a lack of flexibility and dexterity. One of the reasons for their lack of success is identified as neglecting the study and implementing the manual operations. This research initially hypothesised that for an effective development, an automated polishing system should be designed based on the manual polishing operations. Therefore, a successful implementation of an automated polishing system requires a thorough understanding of the polishing process and their operational parameters. This study began by collaborating with an industrial polishing company. The research was focused on polishing complex small components, similar to the parts typically used in the aerospace industry. The high level business processes of the polishing company were capture through several visits to the site. The low level operational parameters and the understanding of the manual operations were also captured through development of a devices that was used by the expert operators. A number of sensors were embedded to the device to facilitate recording the manual operations. For instance, the device captured the force applied by the operator (avg. 10 N) and the cycle time (e.g. 1 pass every 5 sec.). The capture data was then interpreted to manual techniques and polishing approaches that were used in developing a proof-of-concept Integrated Robotic Polishing System (IRPS). The IRPS was tested successfully through several laboratory based experiments by expert operators. The experiment results proved the capability of the proposed system in polishing a variety of part profiles, without pre-existing geometrical information about the parts. One of the main contributions made by this research is to propose a novel approach for automated polishing operations. The development of an integrated robotic polishing system, based on the research findings, uses a set of smart sensors and a force-position-by-increment control algorithm, and transpose the way that skilled workers carry out polishing processes

SEIS: Insight's Seismic Experiment for Internal Structure of Mars.

By the end of 2018, 42 years after the landing of the two Viking seismometers on Mars, InSight will deploy onto Mars' surface the SEIS (Seismic Experiment for Internal Structure) instrument; a six-axes seismometer equipped with both a long-period three-axes Very Broad Band (VBB) instrument and a three-axes short-period (SP) instrument. These six sensors will cover a broad range of the seismic bandwidth, from 0.01 Hz to 50 Hz, with possible extension to longer periods. Data will be transmitted in the form of three continuous VBB components at 2 sample per second (sps), an estimation of the short period energy content from the SP at 1 sps and a continuous compound VBB/SP vertical axis at 10 sps. The continuous streams will be augmented by requested event data with sample rates from 20 to 100 sps. SEIS will improve upon the existing resolution of Viking's Mars seismic monitoring by a factor of ∼ 2500 at 1 Hz and ∼ 200 000 at 0.1 Hz. An additional major improvement is that, contrary to Viking, the seismometers will be deployed via a robotic arm directly onto Mars' surface and will be protected against temperature and wind by highly efficient thermal and wind shielding. Based on existing knowledge of Mars, it is reasonable to infer a moment magnitude detection threshold of M w ∼ 3 at 40 ∘ epicentral distance and a potential to detect several tens of quakes and about five impacts per year. In this paper, we first describe the science goals of the experiment and the rationale used to define its requirements. We then provide a detailed description of the hardware, from the sensors to the deployment system and associated performance, including transfer functions of the seismic sensors and temperature sensors. We conclude by describing the experiment ground segment, including data processing services, outreach and education networks and provide a description of the format to be used for future data distribution.Electronic supplementary materialThe online version of this article (10.1007/s11214-018-0574-6) contains supplementary material, which is available to authorized users

Design and application of a wireless torque sensor for CNC milling

A Smart Machining System for Computer Numerical Control (CNC) Milling continually adjusts the cutting process parameters to optimize for cutting tool life and material removal rate. The system depends on sensors to gather information from the machine during cutting, but commercially available sensors detract from the effectiveness of the cutting system by lowering the system stiffness. This research focuses on the development of the electronics for a Smart Tool Holder (STH) and potential applications such as measurement of mechanical cutting power and suppression of chatter. The STH is a standard milling tool holder modified to hold a torque strain gauge bridge, a thermocouple and a Bluetooth radio transmitter. The STH is meant to overcome some of the different limitations imposed by bed dynamometers, microphones and spindle power sensors without reducing the system stiffness. Comparison of the mechanical power estimates from the STH and a conventional power sensor showed 10% difference

Robotic manipulators for single access surgery

This thesis explores the development of cooperative robotic manipulators for enhancing surgical precision and patient outcomes in single-access surgery and, specifically, Transanal Endoscopic Microsurgery (TEM). During these procedures, surgeons manipulate a heavy set of instruments via a mechanical clamp inserted in the patient’s body through a surgical port, resulting in imprecise movements, increased patient risks, and increased operating time. Therefore, an articulated robotic manipulator with passive joints is initially introduced, featuring built-in position and force sensors in each joint and electronic joint brakes for instant lock/release capability. The articulated manipulator concept is further improved with motorised joints, evolving into an active tool holder. The joints allow the incorporation of advanced robotic capabilities such as ultra-lightweight gravity compensation and hands-on kinematic reconfiguration, which can optimise the placement of the tool holder in the operating theatre. Due to the enhanced sensing capabilities, the application of the active robotic manipulator was further explored in conjunction with advanced image guidance approaches such as endomicroscopy. Recent advances in probe-based optical imaging such as confocal endomicroscopy is making inroads in clinical uses. However, the challenging manipulation of imaging probes hinders their practical adoption. Therefore, a combination of the fully cooperative robotic manipulator with a high-speed scanning endomicroscopy instrument is presented, simplifying the incorporation of optical biopsy techniques in routine surgical workflows. Finally, another embodiment of a cooperative robotic manipulator is presented as an input interface to control a highly-articulated robotic instrument for TEM. This master-slave interface alleviates the drawbacks of traditional master-slave devices, e.g., using clutching mechanics to compensate for the mismatch between slave and master workspaces, and the lack of intuitive manipulation feedback, e.g. joint limits, to the user. To address those drawbacks a joint-space robotic manipulator is proposed emulating the kinematic structure of the flexible robotic instrument under control.Open Acces