The Application of Mixed Reality Within Civil Nuclear Manufacturing and Operational Environments

This thesis documents the design and application of Mixed Reality (MR) within a nuclear manufacturing cell through the creation of a Digitally Assisted Assembly Cell (DAAC). The DAAC is a proof of concept system, combining full body tracking within a room sized environment and bi-directional feedback mechanism to allow communication between users within the Virtual Environment (VE) and a manufacturing cell. This allows for training, remote assistance, delivery of work instructions, and data capture within a manufacturing cell. The research underpinning the DAAC encompasses four main areas; the nuclear industry, Virtual Reality (VR) and MR technology, MR within manufacturing, and finally the 4 th Industrial Revolution (IR4.0). Using an array of Kinect sensors, the DAAC was designed to capture user movements within a real manufacturing cell, which can be transferred in real time to a VE, creating a digital twin of the real cell. Users can interact with each other via digital assets and laser pointers projected into the cell, accompanied by a built-in Voice over Internet Protocol (VoIP) system. This allows for the capture of implicit knowledge from operators within the real manufacturing cell, as well as transfer of that knowledge to future operators. Additionally, users can connect to the VE from anywhere in the world. In this way, experts are able to communicate with the users in the real manufacturing cell and assist with their training. The human tracking data fills an identified gap in the IR4.0 network of Cyber Physical System (CPS), and could allow for future optimisations within manufacturing systems, Material Resource Planning (MRP) and Enterprise Resource Planning (ERP). This project is a demonstration of how MR could prove valuable within nuclear manufacture. The DAAC is designed to be low cost. It is hoped this will allow for its use by groups who have traditionally been priced out of MR technology. This could help Small to Medium Enterprises (SMEs) close the double digital divide between themselves and larger global corporations. For larger corporations it offers the benefit of being low cost, and, is consequently, easier to roll out across the value chain. Skills developed in one area can also be transferred to others across the internet, as users from one manufacturing cell can watch and communicate with those in another. However, as a proof of concept, the DAAC is at Technology Readiness Level (TRL) five or six and, prior to its wider application, further testing is required to asses and improve the technology. The work was patented in both the UK (S. R EDDISH et al., 2017a), the US (S. R EDDISH et al., 2017b) and China (S. R EDDISH et al., 2017c). The patents are owned by Rolls-Royce and cover the methods of bi-directional feedback from which users can interact from the digital to the real and vice versa. Stephen Reddish Mixed Mode Realities in Nuclear Manufacturing Key words: Mixed Mode Reality, Virtual Reality, Augmented Reality, Nuclear, Manufacture, Digital Twin, Cyber Physical Syste

Addressing Tasks Through Robot Adaptation

Developing flexible, broadly capable systems is essential for robots to move out of factories and into our daily lives, functioning as responsive agents that can handle whatever the world throws at them. This dissertation focuses on two kinds of robot adaptation. Modular self-reconfigurable robots (MSRR) adapt to the requirements of their task and environments by transforming themselves. By rearranging the connective structure of their component robot modules, these systems can assume different morphologies: for example, a cluster of modules might configure themselves into a car to maneuver on flat ground, a snake to climb stairs, or an arm to pick and place objects. Conversely, environment augmentation is a strategy in which the robot transforms its environment to meet its own needs, adding physical structures that allow it to overcome obstacles. In both areas, the presented work includes elements of hardware design, algorithms, and integrated systems, with the common goal of establishing these methods of adaptation as viable strategies to address tasks. The research takes a systems-level view of robotics, placing particular emphasis on experimental validation in hardware

A Common Digital Twin Platform for Education, Training and Collaboration

The world is in transition driven by digitalization; industrial companies and educational institutions are adopting Industry 4.0 and Education 4.0 technologies enabled by digitalization. Furthermore, digitalization and the availability of smart devices and virtual environments have evolved to pro- duce a generation of digital natives. These digital natives whose smart devices have surrounded them since birth have developed a new way to process information; instead of reading literature and writing essays, the digital native generation uses search engines, discussion forums, and on- line video content to study and learn. The evolved learning process of the digital native generation challenges the educational and industrial sectors to create natural training, learning, and collaboration environments for digital natives. Digitalization provides the tools to overcome the aforementioned challenge; extended reality and digital twins enable high-level user interfaces that are natural for the digital natives and their interaction with physical devices. Simulated training and education environments enable a risk-free way of training safety aspects, programming, and controlling robots. To create a more realistic training environment, digital twins enable interfacing virtual and physical robots to train and learn on real devices utilizing the virtual environment. This thesis proposes a common digital twin platform for education, training, and collaboration. The proposed solution enables the teleoperation of physical robots from distant locations, enabling location and time-independent training and collaboration in robotics. In addition to teleoperation, the proposed platform supports social communication, video streaming, and resource sharing for efficient collaboration and education. The proposed solution enables research collaboration in robotics by allowing collaborators to utilize each other’s equipment independent of the distance between the physical locations. Sharing of resources saves time and travel costs. Social communication provides the possibility to exchange ideas and discuss research. The students and trainees can utilize the platform to learn new skills in robotic programming, controlling, and safety aspects. Cybersecurity is considered from the planning phase to the implementation phase. Only cybersecure methods, protocols, services, and components are used to implement the presented platform. Securing the low-level communication layer of the digital twins is essential to secure the safe teleoperation of the robots. Cybersecurity is the key enabler of the proposed platform, and after implementation, periodic vulnerability scans and updates enable maintaining cybersecurity. This thesis discusses solutions and methods for cyber securing an online digital twin platform. In conclusion, the thesis presents a common digital twin platform for education, training, and collaboration. The presented solution is cybersecure and accessible using mobile devices. The proposed platform, digital twin, and extended reality user interfaces contribute to the transitions to Education 4.0 and Industry 4.0

Brownfield Factory Layout Planning using Realistic Virtual Models

To stay competitive in an increasingly digitalised and global context, manufacturing companies need to increase productivity and decrease waste. This means their production systems must improve; something they can achieve in a multitude of ways. For example, increasing the level of automation, improving scheduling and improving product and process flows. Often, these production system improvements entail redesigning the system to incorporate these ensuing changes; a unique and temporary endeavour that is often structured as a project. One part of the production system design process is layout planning, in which the positions of operators, workstations, machines and other parts of the system are decided. This planning process can have a major impact on the overall efficiency of operations.In industrial settings, factory layout planning is often conducted in brownfield settings. In other words, in operational facilities. Since every production system and facility is unique, so is every factory layout planning project. Each such project has different preconditions, existing knowledge, availability and quality of data, lead-times, expectations and driving forces, to name just a few. If factory layout planning were treated as a design problem (more subjective than mathematical in nature), it would be hard to produce a mathematical solution for an optimal layout that would also work in reality. Instead, if a layout is developed and adapted to all real constraints and factors while it is being developed, the result would more likely be installable and work as expected.The long-term vision of this thesis is of a future in which sustainable manufacturing industry continues playing a vital role in society, because its contribution is more than just economic. A future in which the manufacturing industry is appreciated and engaged with by the local community; in which high performance is connected to the successful adoption and efficient use of digital tools in developing and improving existing brownfield production systems. This thesis aims to ensure that manufacturing industry adopts realistic virtual models in its brownfield factory layout planning processes. It does this by identifying and describing common challenges and how they may be reduced by developing and using realistic virtual models. This leads to improvements in the planning, installation and operational phases of production systems.The findings of this thesis show that brownfield factory layout planning represents a significant proportion of industrial layout planning. Its challenges lie mainly in the areas of data accuracy and richness. There are difficulties in grasping scale and perspective, communicating ideas and gathering input in the layout planning phase. By applying 3D laser scanning to provide accurate data and virtual reality to provide immersion and scale, realistic virtual models have been created. These reduce or eliminate the challenges stated above and allow more employees to be involved in the layout planning process. This, in turn, results in the identification of flaws in the layout and improvements in the early stages, rather than during or after installation. There is also an overall improvement to brownfield factory change processes, with costs that pale by comparison to the total cost of layout changes

Flexible Automation and Intelligent Manufacturing: The Human-Data-Technology Nexus

This is an open access book. It gathers the first volume of the proceedings of the 31st edition of the International Conference on Flexible Automation and Intelligent Manufacturing, FAIM 2022, held on June 19 – 23, 2022, in Detroit, Michigan, USA. Covering four thematic areas including Manufacturing Processes, Machine Tools, Manufacturing Systems, and Enabling Technologies, it reports on advanced manufacturing processes, and innovative materials for 3D printing, applications of machine learning, artificial intelligence and mixed reality in various production sectors, as well as important issues in human-robot collaboration, including methods for improving safety. Contributions also cover strategies to improve quality control, supply chain management and training in the manufacturing industry, and methods supporting circular supply chain and sustainable manufacturing. All in all, this book provides academicians, engineers and professionals with extensive information on both scientific and industrial advances in the converging fields of manufacturing, production, and automation

Cyber physical approach and framework for micro devices assembly

The emergence of Cyber Physical Systems (CPS) and Internet-of-Things (IoT) based principles and technologies holds the potential to facilitate global collaboration in various fields of engineering. Micro Devices Assembly (MDA) is an emerging domain involving the assembly of micron sized objects and devices. In this dissertation, the focus of the research is the design of a Cyber Physical approach for the assembly of micro devices. A collaborative framework comprising of cyber and physical components linked using the Internet has been developed to accomplish a targeted set of MDA life cycle activities which include assembly planning, path planning, Virtual Reality (VR) based assembly analysis, command generation and physical assembly. Genetic algorithm and modified insertion algorithm based methods have been proposed to support assembly planning activities. Advanced VR based environments have been designed to support assembly analysis where plans can be proposed, compared and validated. The potential of next generation Global Environment for Network Innovation (GENI) networking technologies has also been explored to support distributed collaborations involving VR-based environments. The feasibility of the cyber physical approach has been demonstrated by implementing the cyber physical components which collaborate to assemble micro designs. The case studies conducted underscore the ability of the developed Cyber Physical approach and framework to support distributed collaborative activities for MDA process contexts

Soft Scalable Self-Reconfigurable Modular Cellbot

Hazardous environments such as disaster affected areas, outer space, and radiation affected areas are dangerous for humans. Autonomous systems which can navigate through these environments would reduce risk of life. The terrains in these applications are diverse and unknown, hence there is a requirement for a robot which can self-adapt its morphology and use suitable control to optimally move in the desired manner. Although there exist monolithic robots for some of these applications, such as the Curiosity rover for Mars exploration, a modular robot containing multiple simple units could increase the fault tolerance. A modular design also enables scaling up or down of the robot based on the current task, for example, scaling up by connecting multiple units to cover a wider area or scaling down to pass through a tight space.Taking bio-inspiration from cells, where – based on environmental conditions – cells come together to form different structures to carry out different tasks, a soft modular robot called Cellbot was developed which was composed of multiple units called ‘cells’. Tests were conducted to understand the cellbot movement over different frictional surfaces for different actuation functions, the number of cells connected in a line (1D), and the shapes formed by connecting cells in 2D. A simulation model was developed to test a large range of frictional values and actuation functions for different friction coefficients. Based on the obtained results, cells could be designed using a material with frictional properties lying in the optimal locomotion range. In other cases, where the application has diverse terrains, the number of connected units can be changed to optimise the robot locomotion. Initial tests were conducted using a ‘ball robot’, where the cellbot was designed using balls which touch ground to exploit friction and actuators to provide force to move the robot. The model was extended to develop, a ‘bellow robot’ which was fabricated using hyper-elastic bellows and employed pneumatic actuation. The amount of inflation of a cell and its neighbouring cells determined if the cell would touch the ground or be lifted up. This was used to change cell behaviour where a cell could be touching ground to provide anchoring friction, or lifted to push or pull the cells and thereby move the robot. The cells were connected by magnets which could be disconnected and reconnected by morphing the robot body. The cellbot can thus reconfigure by changing the number of connected units or its shape. The easy detachment can be used to remove and replace damaged cells. Complex cellbot movements can be achieved by either switching between different robot morphologies or by changing actuation control.Future cellbots will be controlled remotely to change their morphology, control, and number of connected cells, making them suitable for missions which require fault tolerance and autonomous shape adaptation. The proposed cellbot platform has the potential to reduce the energy, time and costs in comparison to traditional robots and has potential for applications such as exploration missions for outer space, search and rescue missions for disaster affected areas, internal medical procedures, and nuclear decommissioning.<br/

Flexible Automation and Intelligent Manufacturing: The Human-Data-Technology Nexus

This is an open access book. It gathers the first volume of the proceedings of the 31st edition of the International Conference on Flexible Automation and Intelligent Manufacturing, FAIM 2022, held on June 19 – 23, 2022, in Detroit, Michigan, USA. Covering four thematic areas including Manufacturing Processes, Machine Tools, Manufacturing Systems, and Enabling Technologies, it reports on advanced manufacturing processes, and innovative materials for 3D printing, applications of machine learning, artificial intelligence and mixed reality in various production sectors, as well as important issues in human-robot collaboration, including methods for improving safety. Contributions also cover strategies to improve quality control, supply chain management and training in the manufacturing industry, and methods supporting circular supply chain and sustainable manufacturing. All in all, this book provides academicians, engineers and professionals with extensive information on both scientific and industrial advances in the converging fields of manufacturing, production, and automation

Annals of Scientific Society for Assembly, Handling and Industrial Robotics 2021

This Open Access proceedings presents a good overview of the current research landscape of assembly, handling and industrial robotics. The objective of MHI Colloquium is the successful networking at both academic and management level. Thereby, the colloquium focuses an academic exchange at a high level in order to distribute the obtained research results, to determine synergy effects and trends, to connect the actors in person and in conclusion, to strengthen the research field as well as the MHI community. In addition, there is the possibility to become acquatined with the organizing institute. Primary audience is formed by members of the scientific society for assembly, handling and industrial robotics (WGMHI)