Human-Robot Collaborations in Industrial Automation

Technology is changing the manufacturing world. For example, sensors are being used to track inventories from the manufacturing floor up to a retail shelf or a customer’s door. These types of interconnected systems have been called the fourth industrial revolution, also known as Industry 4.0, and are projected to lower manufacturing costs. As industry moves toward these integrated technologies and lower costs, engineers will need to connect these systems via the Internet of Things (IoT). These engineers will also need to design how these connected systems interact with humans. The focus of this Special Issue is the smart sensors used in these human–robot collaborations

Neuro-fuzzy modelling and control of robotic manipulators

The work reported in this thesis aims to design and develop a new neuro-fuzzy control system for robotic manipulators using Machine Learning Techniques, Fuzzy Logic Controllers, and Fuzzy Neural Networks. The main idea is to integrate these intelligent techniques to develop an adaptive position controller for robotic manipulators. This will finally lead to utilising one or two coordinated manipulators to perform upper-limb rehabilitation. The main target is to benefit from these intelligent techniques in a systematic way that leads to an efficient control and coordination system. The suggested control system possesses self-learning features so that it can maintain acceptable performance in the presence of uncertain loads. Simulation and modelling stages were performed using dynamical virtual reality programs to demonstrate the ideas of the control and coordination techniques. The first part of the thesis focuses on the development of neuro-fuzzy models that meet the above requirement of mimicking both kinematics and dynamics behaviour of the manipulator. For this purpose, an initial stage for data collection from the motion of the manipulator along random trajectories was performed. These data were then compacted with the help of inductive learning techniques into two sets of if-then rules that form approximation for both of the inverse kinematics and inverse dynamics of the manipulator. These rules were then used in fuzzy neural networks with differentiation characteristics to achieve online tuning of the network adjustable parameters. The second part of the thesis introduces the proposed adaptive neuro-fuzzy joint-based controller. To achieve this target, a feedback Fuzzy-Proportional-Integral-Derivative incremental controller was developed. This controller was then applied as a joint servo-controller for each robot link in addition to the main neuro-fuzzy feedforward controller used to compensate for the dynamics interactions between robot links. A feedback error learning scheme was applied to tune the feedforward neuro-fuzzy controller online using the error back-propagation algorithm. The third part of the thesis presents a neuro-fuzzy Cartesian internal model control system for robotic manipulators. The neuro-fuzzy inverse kinematics model of the manipulator was used in addition to the joint-based controller proposed and the forward mathematical model of the manipulator in an adaptive internal model controller structure. Feedback-error learning scheme was extended to tune both of the joint-based neuro-fuzzy controller and the neuro-fuzzy internal model controller online. The fourth part of the thesis suggests a simple fuzzy hysteresis coordination scheme for two position-controlled robot manipulators. The coordination scheme is based on maintaining certain kinematic relationships between the two manipulators using reference motion synchronisation without explicitly involving the hybrid position/force control or modifying the existing controller structure for either of the manipulators. The key to the success of the new method is to ensure that each manipulator is capable of tracking its own desired trajectory using its own position controller, while synchronizing its motion with the other manipulator motion so that the differential position error between the two manipulators is reduced to zero or kept within acceptable limits. A simplified test-bench emulating upper-limb rehabilitation was used to test the proposed coordination technique experimentally

Proceedings of the NASA Conference on Space Telerobotics, volume 1

The theme of the Conference was man-machine collaboration in space. Topics addressed include: redundant manipulators; man-machine systems; telerobot architecture; remote sensing and planning; navigation; neural networks; fundamental AI research; and reasoning under uncertainty

Multi-scale metrology for automated non-destructive testing systems

This thesis was previously held under moratorium from 5/05/2020 to 5/05/2022The use of lightweight composite structures in the aerospace industry is now commonplace. Unlike conventional materials, these parts can be moulded into complex aerodynamic shapes, which are diffcult to inspect rapidly using conventional Non-Destructive Testing (NDT) techniques. Industrial robots provide a means of automating the inspection process due to their high dexterity and improved path planning methods. This thesis concerns using industrial robots as a method for assessing the quality of components with complex geometries. The focus of the investigations in this thesis is on improving the overall system performance through the use of concepts from the field of metrology, specifically calibration and traceability. The use of computer vision is investigated as a way to increase automation levels by identifying a component's type and approximate position through comparison with CAD models. The challenges identified through this research include developing novel calibration techniques for optimising sensor integration, verifying system performance using laser trackers, and improving automation levels through optical sensing. The developed calibration techniques are evaluated experimentally using standard reference samples. A 70% increase in absolute accuracy was achieved in comparison to manual calibration techniques. Inspections were improved as verified by a 30% improvement in ultrasonic signal response. A new approach to automatically identify and estimate the pose of a component was developed specifically for automated NDT applications. The method uses 2D and 3D camera measurements along with CAD models to extract and match shape information. It was found that optical large volume measurements could provide suffciently high accuracy measurements to allow ultrasonic alignment methods to work, establishing a multi-scale metrology approach to increasing automation levels. A classification framework based on shape outlines extracted from images was shown to provide over 88% accuracy on a limited number of samples.The use of lightweight composite structures in the aerospace industry is now commonplace. Unlike conventional materials, these parts can be moulded into complex aerodynamic shapes, which are diffcult to inspect rapidly using conventional Non-Destructive Testing (NDT) techniques. Industrial robots provide a means of automating the inspection process due to their high dexterity and improved path planning methods. This thesis concerns using industrial robots as a method for assessing the quality of components with complex geometries. The focus of the investigations in this thesis is on improving the overall system performance through the use of concepts from the field of metrology, specifically calibration and traceability. The use of computer vision is investigated as a way to increase automation levels by identifying a component's type and approximate position through comparison with CAD models. The challenges identified through this research include developing novel calibration techniques for optimising sensor integration, verifying system performance using laser trackers, and improving automation levels through optical sensing. The developed calibration techniques are evaluated experimentally using standard reference samples. A 70% increase in absolute accuracy was achieved in comparison to manual calibration techniques. Inspections were improved as verified by a 30% improvement in ultrasonic signal response. A new approach to automatically identify and estimate the pose of a component was developed specifically for automated NDT applications. The method uses 2D and 3D camera measurements along with CAD models to extract and match shape information. It was found that optical large volume measurements could provide suffciently high accuracy measurements to allow ultrasonic alignment methods to work, establishing a multi-scale metrology approach to increasing automation levels. A classification framework based on shape outlines extracted from images was shown to provide over 88% accuracy on a limited number of samples

Nonlinear control of multiple mobile manipulator robots transporting a rigid object in coordination

This doctoral thesis proposes and validates experimentally nonlinear control strategies for a group of mobile manipulator robots transporting a rigid object in coordination. This developed approach ensures trajectory tracking in Cartesian space in the presence of parameter uncertainty and undesirable disturbances. The objective of the creation of robots in the early sixties was to relieve man of certain hard jobs such as: handling a heavy object, and repetitive tasks which are often tiring or even sometimes infeasible manually. Following this situation, several types of manipulator robots were created. Naturally, the need for robots having both locomotion and manipulation capabilities has led to the creation of the mobile manipulators. Typical examples of mobile manipulators, more or less automated, are the cranes mounted on trucks , the satellite arms, the deep-sea exploration submarines, or extra-planetary exploration vehicles. Some operations requiring the handling of a heavy object are difficult to achieve by a single mobile manipulator. These operations require a coordination of several mobile manipulators to move or transport a heavy object in common. However, this complicates the robotic system as its control design complexity increases greatly. The problem of controlling the mechanical system forming a closed kinematic chain mechanism lies in the fact that it imposes a set of kinematic constraints on the coordination of the position and velocity of the mobile manipulator. Therefore, there is a reduction in the degrees of freedom for the entire system. Further, the internal forces of the object produced by all mobile manipulators should be controlled. This thesis work was focused on developing a consistent control technique for a group of mobile manipulator robots executing a task in coordination. Different nonlinear controllers were simulated and experimentally applied to multiple mobile manipulator system transporting a rigid object in coordination. To achieve all objectives of this thesis, as a first step, an experimental platform was developed and mounted in the laboratory of GREPCI-ETS to implement and validate the different designed control laws. In the second step, several adaptive coordinated motion/force tracking control laws were applied, ensuring that the desired trajectory can excellently tracked under uncertainties parameters and disturbances

EFFICIENCY OF FLEXIBLE FIXTURES: DESIGN AND CONTROL

The manufacturing industries have been using flexible production technologies to meet the demand for customisation. As a part of production, fixtures have remained limited to dedicated technologies, even though numerous flexible fixtures have been studied and proposed by both academia and industry. The integration of flexible fixtures has shown that such efforts did not yield the anticipated performance and resulted in inefficiencies of cost and time. The fundamental formulation of this thesis addresses this issue and aims to increase the efficiency of flexible fixtures.To realise this aim, the research in this thesis poses three research questions. The first research question investigates the efficiency description of flexible fixtures in terms of the criteria. Relative to this, the second research question investigates the use of efficiency metrics to integrate efficiency criteria into a design procedure. Once the efficiency and design aspects have been established, the third research question investigates the active control of flexible fixtures to increase their efficiency. The results of this thesis derive from the outcome of seven studies investigating the automotive and aerospace industries. The results that answer the first research question use five criteria to establish the efficiency of flexible fixtures. These are: fundamental, flexibility, cost, time and quality. By incorporating design characteristics in respect of production system paradigms, each criterion is elaborated upon using relevant sub-criteria and metrics. Moreover, a comparative design procedure is presented for the second research question and comprising four stages (including mechanical, control and software aspects). Initially, the design procedure proposes conceptual design and verification stages to determine the most promising flexible fixture for a target production system. By executing detailed design and verification, the design procedure enables a fixture designer to finalise the flexible fixture and determine its efficiency. Furthermore, a novel parallel kinematics machine is presented to demonstrate the applicability of the design procedure’s analytical steps and illustrate how appropriate kinematic structures can facilitate the efficiency-orientated design of flexible fixtures.Based on the correlation established by the controller software’s design procedure, the active control of flexible fixtures directly affects the quality criterion of flexible fixture efficiency. This provides the answer to the third research question, on general control strategies for active control of flexible fixtures. The introduction of a system model and manipulator dynamics proposes force and position control strategies. It is shown that any flexible fixture using a kinematic class can be controlled, to regulate the force and position of a workpiece and ensure that process nominals are preserved. Moreover, using both direct and indirect force control strategies, a flexible fixture’s role in active control can be expanded into a system of actively controlled fixtures that are useful in various processes. Finally, a position controller is presented which has the capacity to regulate both periodic and non-periodic signals. This controller uses an additional feedforward scheme (based on the Hilbert transform) in parallel with a feedback mechanism. Thus, the position controller enables flexible fixtures to regulate the position of a workpiece in respect of any kind of disturbance

Industrial Robotics

This book covers a wide range of topics relating to advanced industrial robotics, sensors and automation technologies. Although being highly technical and complex in nature, the papers presented in this book represent some of the latest cutting edge technologies and advancements in industrial robotics technology. This book covers topics such as networking, properties of manipulators, forward and inverse robot arm kinematics, motion path-planning, machine vision and many other practical topics too numerous to list here. The authors and editor of this book wish to inspire people, especially young ones, to get involved with robotic and mechatronic engineering technology and to develop new and exciting practical applications, perhaps using the ideas and concepts presented herein