Collision Detection and Reaction: A Contribution to Safe Physical Human-Robot Interaction

In the framework of physical Human-Robot Interaction (pHRI), methodologies and experimental tests are presented for the problem of detecting and reacting to collisions between a robot manipulator and a human being. Using a lightweight robot that was especially designed for interactive and cooperative tasks, we show how reactive control strategies can significantly contribute to ensuring safety to the human during physical interaction. Several collision tests were carried out, illustrating the feasibility and effectiveness of the proposed approach. While a subjective “safety” feeling is experienced by users when being able to naturally stop the robot in autonomous motion, a quantitative analysis of different reaction strategies was lacking. In order to compare these strategies on an objective basis, a mechanical verification platform has been built. The proposed collision detection and reactions methods prove to work very reliably and are effective in reducing contact forces far below any level which is dangerous to humans. Evaluations of impacts between robot and human arm or chest up to a maximum robot velocity of 2.7 m/s are presented

Working together: a review on safe human-robot collaboration in industrial environments

After many years of rigid conventional procedures of production, industrial manufacturing is going through a process of change toward flexible and intelligent manufacturing, the so-called Industry 4.0. In this paper, human-robot collaboration has an important role in smart factories since it contributes to the achievement of higher productivity and greater efficiency. However, this evolution means breaking with the established safety procedures as the separation of workspaces between robot and human is removed. These changes are reflected in safety standards related to industrial robotics since the last decade, and have led to the development of a wide field of research focusing on the prevention of human-robot impacts and/or the minimization of related risks or their consequences. This paper presents a review of the main safety systems that have been proposed and applied in industrial robotic environments that contribute to the achievement of safe collaborative human-robot work. Additionally, a review is provided of the current regulations along with new concepts that have been introduced in them. The discussion presented in this paper includes multidisciplinary approaches, such as techniques for estimation and the evaluation of injuries in human-robot collisions, mechanical and software devices designed to minimize the consequences of human-robot impact, impact detection systems, and strategies to prevent collisions or minimize their consequences when they occur

Human-friendly robotic manipulators: safety and performance issues in controller design

Recent advances in robotics have spurred its adoption into new application areas such as medical, rescue, transportation, logistics, personal care and entertainment. In the personal care domain, robots are expected to operate in human-present environments and provide non-critical assistance. Successful and flourishing deployment of such robots present different opportunities as well as challenges. Under a national research project, Bobbie, this dissertation analyzes challenges associated with these robots and proposes solutions for identified problems. The thesis begins by highlighting the important safety concern and presenting a comprehensive overview of safety issues in a typical domestic robot system. By using functional safety concept, the overall safety of the complex robotic system was analyzed through subsystem level safety issues. Safety regions in the world model of the perception subsystem, dependable understanding of the unstructured environment via fusion of sensory subsystems, lightweight and compliant design of mechanical components, passivity based control system and quantitative metrics used to assert safety are some important points discussed in the safety review. The main research focus of this work is on controller design of robotic manipulators against two conflicting requirements: motion performance and safety. Human-friendly manipulators used on domestic robots exhibit a lightweight design and demand a stable operation with a compliant behavior injected via a passivity based impedance controller. Effective motion based manipulation using such a controller requires a highly stiff behavior while important safety requirements are achieved with compliant behaviors. On the basis of this intuitive observation, this research identifies suitable metrics to identify the appropriate impedance for a given performance and safety requirement. This thesis also introduces a domestic robot design that adopts a modular design approach to minimize complexity, cost and development time. On the basis of functional modularity concept where each module has a unique functional contribution in the system, the robot “Bobbie-UT‿ is built as an interconnection of interchangeable mobile platform, torso, robotic arm and humanoid head components. Implementation of necessary functional and safety requirements, design of interfaces and development of suitable software architecture are also discussed with the design

Magneto-Rheological Actuators for Human-Safe Robots: Modeling, Control, and Implementation

In recent years, research on physical human-robot interaction has received considerable attention. Research on this subject has led to the study of new control and actuation mechanisms for robots in order to achieve intrinsic safety. Naturally, intrinsic safety is only achievable in kinematic structures that exhibit low output impedance. Existing solutions for reducing impedance are commonly obtained at the expense of reduced performance, or significant increase in mechanical complexity. Achieving high performance while guaranteeing safety seems to be a challenging goal that necessitates new actuation technologies in future generations of human-safe robots. In this study, a novel two degrees-of-freedom safe manipulator is presented. The manipulator uses magneto-rheological fluid-based actuators. Magneto-rheological actuators offer low inertia-to-torque and mass-to-torque ratios which support their applications in human-friendly actuation. As a key element in the design of the manipulator, bi-directional actuation is attained by antagonistically coupling MR actuators at the joints. Antagonistically coupled MR actuators at the joints allow using a single motor to drive multiple joints. The motor is located at the base of the manipulator in order to further reduce the overall weight of the robot. Due to the unique characteristic of MR actuators, intrinsically safe actuation is achieved without compromising high quality actuation. Despite these advantages, modeling and control of MR actuators present some challenges. The antagonistic configuration of MR actuators may result in limit cycles in some cases when the actuator operates in the position control loop. To study the possibility of limit cycles, describing function method is employed to obtain the conditions under which limit cycles may occur in the operation of the system. Moreover, a connection between the amplitude and the frequency of the potential limit cycles and the system parameters is established to provide an insight into the design of the actuator as well as the controller. MR actuators require magnetic fields to control their output torques. The application of magnetic field however introduces hysteresis in the behaviors of MR actuators. To this effect, an adaptive model is developed to estimate the hysteretic behavior of the actuator. The effectiveness of the model is evaluated by comparing its results with those obtained using the Preisach model. These results are then extended to an adaptive control scheme in order to compensate for the effect of hysteresis. In both modeling and control, stability of proposed schemes are evaluated using Lyapunov method, and the effectiveness of the proposed methods are validated with experimental results

Development of n-DoF preloaded structures for impact mitigation in cobots

A core issue in collaborative robotics is that of impact mitigation, especially when collisions happen with operators. Passively compliant structures can be used as the frame of the cobot, although usually they are implemented by means of a single DoF. However, n-DoF preloaded structures offer a number of advantages, in terms of flexibility in designing their behavior. In this work we propose a comprehensive framework for classifying n-DoF preloaded structures, including 1-, 2-, and 3-dimensional arrays. Also, we study the implications of the peculiar behavior of these structures - which present sharp stiff-to-compliant transitions at design-determined load thresholds - on impact mitigation. To this regard, an analytical n-DoF dynamic model was developed and numerically implemented. A prototype of a 10-DoF structure was tested under static and impact loads, showing a very good agreement with the model. Future developments will see the application of n-DoF preloaded structures to impact-mitigation on cobots and in the field of mobile robots, as well as to the field of novel architected materials

Development of n-DoF Preloaded structures for impact mitigation in cobots

A core issue in collaborative robotics is that of impact mitigation, especially when collisions happen with operators. Passively compliant structures can be used as the frame of the cobot, although, usually, they are implemented by means of a single-degree-offreedom (DoF). However, n-DoF preloaded structures offer a number of advantages in terms of flexibility in designing their behavior. In this work, we propose a comprehensive framework for classifying n-DoF preloaded structures, including one-, two-, and threedimensional arrays. Furthermore, we investigate the implications of the peculiar behavior of these structures-which present sharp stiff-to-compliant transitions at designdetermined load thresholds-on impact mitigation. To this regard, an analytical n-DoF dynamic model was developed and numerically implemented. A prototype of a 10DoF structure was tested under static and impact loads, showing a very good agreement with the model. Future developments will see the application of n-DoF preloaded structures to impact-mitigation on cobots and in the field of mobile robots, as well as to the field of novel architected materials

Safe and effective physical human-robot interaction: Approaches to variable compliance via soft joints and soft grippers

The work described in this thesis focusses on designing and building two novel physical devices in a robotic arm structure. The arm is intended for human-robot interaction in the domestic assistive robotics area. The first device aims at helping to ensure the safety of the human user. It acts as a mechanical fuse and disconnects the robotic arm link from its motor in case of collision. The device behaves in a rigid manner in normal operational times and in a compliant manner in case of potentially harmful collisions: it relies on a variable compliance. The second device is the end-effector of the robotic arm. It is a novel grasping device that aims at accommodating varying object shapes. This is achieved by the structure of the grasping device that is a soft structure with a compliant and a rigid phase. Its completely soft structure is able to mould to the object's shape in the compliant phase, while the rigid phase allows holding the object in a stable way.In this study, variable compliance is defined as a physical structure's change from a compliant to a rigid behaviour and vice versa. Due to its versatility and effectiveness, variable compliance has become the founding block of the design of the two devices in the robot arm physical structure. The novelty of the employment of variable compliance in this thesis resides in its use in both rigid and soft devices in order to help ensure both safety and adaptable grasping in one integrated physical structure, the robot arm.The safety device has been designed, modelled, produced, tested and physically embedded in the robot arm system. Compared to previous work in this field, the feature described in this thesis' work has a major advantage: its torque threshold can be actively regulated depending on the operational situation. The threshold torque is best described by an exponential curve in the mathematical model while it is best fit by a second order equation in the experimental data. The mismatch is more considerable for high values of threshold torque. However, both curves reflect that threshold torque magnitude increases by increasing the setting of the device. Testing of both the passive decoupling and active threshold torque regulation show that both are successfully obtained. The second novel feature of the robot arm is the soft grasping device inspired by hydrostatic skeletons. Its ability to passively adapts to complex shapes objects, reduces the complexity of the grasping action control. This gripper is low-cost, soft, cable-driven and it features no stiff sections. Its versatility, variable compliance and stable grasp are shown in several experiments. A model of the forward kinematics of the system is derived from observation of its bending behaviour.Variable compliance has shown to be a very relevant principle for the design and implementation of a robotic arm aimed at safely interacting with human users and that can reduce grasp control complexity by passively adapting to the object's shape