A survey of robot manipulation in contact

In this survey, we present the current status on robots performing manipulation tasks that require varying contact with the environment, such that the robot must either implicitly or explicitly control the contact force with the environment to complete the task. Robots can perform more and more manipulation tasks that are still done by humans, and there is a growing number of publications on the topics of (1) performing tasks that always require contact and (2) mitigating uncertainty by leveraging the environment in tasks that, under perfect information, could be performed without contact. The recent trends have seen robots perform tasks earlier left for humans, such as massage, and in the classical tasks, such as peg-in-hole, there is a more efficient generalization to other similar tasks, better error tolerance, and faster planning or learning of the tasks. Thus, in this survey we cover the current stage of robots performing such tasks, starting from surveying all the different in-contact tasks robots can perform, observing how these tasks are controlled and represented, and finally presenting the learning and planning of the skills required to complete these tasks

Human-Robot Collaboration for Kinesthetic Teaching

Recent industrial interest in producing smaller volumes of products in shorter time frames, in contrast to mass production in previous decades, motivated the introduction of human–robot collaboration (HRC) in industrial settings, as an attempt to increase flexibility in manufacturing applications by incorporating human intelligence and dexterity to these processes. This thesis presents methods for improving the involvement of human operators in industrial settings where robots are present, with a particular focus on kinesthetic teaching, i.e., manually guiding the robot to define or correct its motion, since it can facilitate non-expert robot programming.To increase flexibility in the manufacturing industry implies a loss of a fixed structure of the industrial environment, which increases the uncertainties in the shared workspace between humans and robots. Two methods have been proposed in this thesis to mitigate such uncertainty. First, null-space motion was used to increase the accuracy of kinesthetic teaching by reducing the joint static friction, or stiction, without altering the execution of the robotic task. This was possible since robots used in HRC, i.e., collaborative robots, are often designed with additional degrees of freedom (DOFs) for a greater dexterity. Second, to perform effective corrections of the motion of the robot through kinesthetic teaching in partially-unknown industrial environments, a fast identification of the source of robot–environment contact is necessary. Fast contact detection and classification methods in literature were evaluated, extended, and modified to use them in kinesthetic teaching applications for an assembly task. For this, collaborative robots that are made compliant with respect to their external forces/torques (as an active safety mechanism) were used, and only embedded sensors of the robot were considered.Moreover, safety is a major concern when robotic motion occurs in an inherently uncertain scenario, especially if humans are present. Therefore, an online variation of the compliant behavior of the robot during its manual guidance by a human operator was proposed to avoid undesired parts of the workspace of the robot. The proposed method used safety control barrier functions (SCBFs) that considered the rigid-body dynamics of the robot, and the method’s stability was guaranteed using a passivity-based energy-storage formulation that includes a strict Lyapunov function.All presented methods were tested experimentally on a real collaborative robot

On Robotic Work-Space Sensing and Control

Industrial robots are fast and accurate when working with known objects at precise locations in well-structured manufacturing environments, as done in the classical automation setting. In one sense, limited use of sensors leaves robots blind and numb, unaware of what is happening in their surroundings. Whereas equipping a system with sensors has the potential to add new functionality and increase the set of uncertainties a robot can handle, it is not as simple as that. Often it is difficult to interpret the measurements and use them to draw necessary conclusions about the state of the work space. For effective sensor-based control, it is necessary to both understand the sensor data and to know how to act on it, giving the robot perception-action capabilities. This thesis presents research on how sensors and estimation techniques can be used in robot control. The suggested methods are theoretically analyzed and evaluated with a large focus on experimental verification in real-time settings. One application class treated is the ability to react fast and accurately to events detected by vision, which is demonstrated by the realization of a ball-catching robot. A new approach is proposed for performing high-speed color-based image analysis that is robust to varying illumination conditions and motion blur. Furthermore, a method for object tracking is presented along with a novel way of Kalman-filter initialization that can handle initial-state estimates with infinite variance. A second application class treated is robotic assembly using force control. A study of two assembly scenarios is presented, investigating the possibility of using force-controlled assembly in industrial robotics. Two new approaches for robotic contact-force estimation without any force sensor are presented and validated in assembly operations. The treated topics represent some of the challenges in sensor-based robot control, and it is demonstrated how they can be used to extend the functionality of industrial robots

Collaborative and Cooperative Robotics Applications using Visual Perception

The objective of this Thesis is to develop novel integrated strategies for collaborative and cooperative robotic applications. Commonly, industrial robots operate in structured environments and in work-cell separated from human operators. Nowadays, collaborative robots have the capacity of sharing the workspace and collaborate with humans or other robots to perform complex tasks. These robots often operate in an unstructured environment, whereby they need sensors and algorithms to get information about environment changes. Advanced vision and control techniques have been analyzed to evaluate their performance and their applicability to industrial tasks. Then, some selected techniques have been applied for the first time to an industrial context. A Peg-in-Hole task has been chosen as first case study, since it has been extensively studied but still remains challenging: it requires accuracy both in the determination of the hole poses and in the robot positioning. Two solutions have been developed and tested. Experimental results have been discussed to highlight the advantages and disadvantages of each technique. Grasping partially known objects in unstructured environments is one of the most challenging issues in robotics. It is a complex task and requires to address multiple subproblems, in order to be accomplished, including object localization and grasp pose detection. Also for this class of issues some vision techniques have been analyzed. One of these has been adapted to be used in industrial scenarios. Moreover, as a second case study, a robot-to-robot object handover task in a partially structured environment and in the absence of explicit communication between the robots has been developed and validated. Finally, the two case studies have been integrated in two real industrial setups to demonstrate the applicability of the strategies to solving industrial problems

Planning and control of robotic manipulation actions for extreme environments

A large societal and economic need arises for advanced robotic capabilities, where we need to perform complex human-like tasks such as tool-use, in environments that are hazardous for human workers. This thesis addresses a collection of problems, which arise when robotic manipulators must perform complex tasks in cluttered and constrained environments. The work is illustrated by example scenarios of robotic tool use, grasping and manipulating, motivated by the challenges of dismantling operations in the extreme environments of nuclear decommissioning Contrary to popular assumptions, legacy nuclear facilities (which can date back three-quarters of a century in the UK) can be highly unstructured and uncertain environments, with insufficient a-priori information available for e.g. conventional pre-programming of robot tasks. Meanwhile, situational awareness and direct teleoperation can be extremely difficult for human operators working in a safe zone that is physically remote from the robot. This engenders a need for significant autonomous capabilities. Robots must use vision and sensory systems to perceive their environment, plan and execute complex actions on complex objects in cluttered and constrained environments. Significant radiation, of different types and intensities, provides further challenges in terms of sensor noise. Perception uncertainty can also result from e.g. vision systems observing shiny featureless metal structures. Robotic actions therefore need to be: i) planned in ways that are robust to uncertainties; and ii) controlled in ways which enable the robust reaction to disturbances. In particular, we investigate motion planning and control in tasks where the robot must: maintain contact while moving over arbitrarily shaped surfaces with end-effector tools; exert forces and withstand perturbations during forceful contact actions; while also avoiding collisions with obstacles; avoiding singularity configurations; and increasing robustness by maximising manipulability during task execution. Furthermore, we consider the issues of robust planning and control with respect to uncertain information, derived from noisy sensors in challenging environments. We explore the Riemannian geometry and robot's manipulability to yield path planners that produce paths for both fixed-based and floating-based robots, whose tools always stay in contact with the object's surface. Our planners overcome disturbances in the perception and account for robot/environment interactions that may demand unexpected forces. The task execution is entrusted to a hybrid force/motion controller whose motion space behaves with compliance to accommodate unexpected stiffness changes throughout the contact. We examine the problem of grasping a tool for performing a task. Firstly, we introduce a method for selecting the grasp candidate onto an object yielding collision-free motion for the robot in the post-grasp movements. Furthermore, we study the case of a dual-arm robot performing full-force tasks on an object and slippage on the grasping is allowed. We account for the slippage throughout the task execution using a novel controller based on the sliding mode controllers

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

Mechatronics applied to scale model decoration

The European toy industry is very heavily dependent on manual labour and therefore vulnerable to Far Eastern competitors, who have the advantage of lower labour costs. Automation is Europe's best hope of beating off this oriental challenge. The aim of the project described within this thesis is to investigate the replacement of a traditionally manual series of operations by flexible automation to provide the basis for higher productivity and a greater degree of responsiveness to product change, leading to Just In Time Manufacture with reduced Work In Progress, while still retaining the high quality traditionally associated with the product. This thesis presents one of the first working attempts to this end, represented by a proof-of­concept cell designed and commissioned for investigating the many problems and possibilities associated with the decoration of scale models of cars and trains. The cell was designed using the Mechatronics approach which means that the various mechanical, electrical and electronic and computing possibilities have been taken into account from the start of the design stage. The proof-of-concept cell consists of five stations which provide the necessary means of loading the models in the cell, identifying the models and their orientation, decorating the models, inspecting the decorated models and finally palletising them for assembly. The industrial partners for the project were Hornby Hobbies Limited, J-L Automation and Staubli Unimation. Because this project centres around the present decoration operations at Hornby Hobbies Limited, which is heavily dependant on pad printing, an overview of pad printing is included. This will give the reader a background to the problems faced during the project. Before describing the proof-of-concept cell and its hardware and software components, the present factory based method and the constraints put on the project by Hornby Hobbies Limited are explained so that the reasons for choices within the cell will be more readily understood. A brief history of Scalextric is also included so that the reader may also understand some of the historical problems associated with the product. The result of this mechatronic approach are two fold: a) the efficiency of the cell is improved because the individual parts are working at optimal efficiency b) the cell has a greater degree of flexibility because of the re-programming facilities embedded in each of its component parts. This Mechatronic investigation has led to new concepts for pad printing and assembly operations and these are described in detail in the conclusions