Genetic optimization of a manipulator: Comparison between straight, rounded, and curved mechanism links

There are several ubiquitous kinematic structures that are used in industrial robots, with the most prominent being a six-axis angular structure. However, researchers are experimenting with task-based mechanism synthesis that could provide higher efficiency with custom optimized manipulators. Many studies have focused on finding the most efficient optimization algorithm for task-based robot manipulators. These manipulators, however, are usually optimized from simple modular joints and links, without exploring more elaborate modules. Here, we show that link modules defined by small numbers of parameters have better performance than more complicated ones. We compare four different manipulator link types, namely basic predefined links with fixed dimensions, straight links that can be optimized for different lengths, rounded links, and links with a curvature defined by a Hermite spline. Manipulators are then built from these modules using a genetic algorithm and are optimized for three different tasks. The results demonstrate that manipulators built from simple links not only converge faster, which is expected given the fewer optimized parameters, but also converge on lower cost values.Web of Science116art. no. 247

Multirepresentations and multiconstraints approach to the numerical synthesis of serial kinematic structures of manipulators

This paper presents a set of algorithms for the synthesis of kinematic structures of serial manipulators using multiple constraint formulation and provides a performance comparison of different kinematic representations, the Denavit-Hartenberg notation, the Product of Exponentials (screws), and Roll-Pitch-Yaw angles with translation parameters. Synthesis is performed for five given tasks, and both revolute and prismatic joints can be synthesized. Two different non-linear programming optimization algorithms were used to support the findings. The results are compared and discussed. Data show that the choice of the constraint design method has a significant impact on the success rate of optimization convergence. The choice of representation has a lower impact on convergence, but there are differences in the optimization time and the length of the designed manipulators. Furthermore, the best results are obtained when multiple methodologies are used in combination. An arbitrary manipulator was designed and assembled based on a trajectory in the collision environment to demonstrate the advantages of the proposed methodology. The input/output data and synthesis methodology algorithms are provided through an open repository.Web of Science10689516893

Using virtual scanning to find optimal configuration of a 3D scanner turntable for scanning of mechanical parts

The article describes a method of simulated 3D scanning of triangle meshes based on ray casting which is used to find the optimal configuration of a real 3D scanner turntable. The configuration include the number of scanners, their elevation above the rotary table and the number of required rotation steps. The evaluation is based on the percentage of the part surface covered by the resulting point cloud, which determines the ability to capture all details of the shape. Principal component analysis is used as a secondary criterion to also evaluate the ability to capture the overall general proportions of the model.Web of Science2116art. no. 534

Increasing the reliability of data collection of laser line triangulation sensor by proper placement of the sensor

In this paper, we investigated the effect of the incidence angle of a laser ray on the reflected laser intensity. A dataset on this dependence is presented for materials usually used in the industry, such as transparent and non-transparent plastics and aluminum alloys with different surface roughness. The measurements have been performed with a laser line triangulation sensor and a UR10e robot. The presented results are proposing where to place the sensor relative to the scanned object, thus increasing the reliability of the sensor data collection.Web of Science218art. no. 289

Improved mutual understanding for human-robot collaboration: Combining human-aware motion planning with haptic feedback devices for communicating planned trajectory

In a collaborative scenario, the communication between humans and robots is a fundamental aspect to achieve good efficiency and ergonomics in the task execution. A lot of research has been made related to enabling a robot system to understand and predict human behaviour, allowing the robot to adapt its motion to avoid collisions with human workers. Assuming the production task has a high degree of variability, the robot's movements can be difficult to predict, leading to a feeling of anxiety in the worker when the robot changes its trajectory and approaches since the worker has no information about the planned movement of the robot. Additionally, without information about the robot's movement, the human worker cannot effectively plan own activity without forcing the robot to constantly replan its movement. We propose a novel approach to communicating the robot's intentions to a human worker. The improvement to the collaboration is presented by introducing haptic feedback devices, whose task is to notify the human worker about the currently planned robot's trajectory and changes in its status. In order to verify the effectiveness of the developed human-machine interface in the conditions of a shared collaborative workspace, a user study was designed and conducted among 16 participants, whose objective was to accurately recognise the goal position of the robot during its movement. Data collected during the experiment included both objective and subjective parameters. Statistically significant results of the experiment indicated that all the participants could improve their task completion time by over 45% and generally were more subjectively satisfied when completing the task with equipped haptic feedback devices. The results also suggest the usefulness of the developed notification system since it improved users' awareness about the motion plan of the robot.Web of Science2111art. no. 367

Structural optimization method of a FinRay finger for the best wrapping of object

Soft gripping, in which the gripper adapts to differently shaped objects, is in great demand for use in unknown or dynamically changing environments and is one of the main research subjects in soft robotics. Several systems have already been created, one of which is a passive shape-adaptable finger based on the FinRay effect. The geometric shape of this finger ensures that the finger wraps around the object it grips. FinRay fingers have been studied in several studies, which have changed the internal structure and examined how gripping force's dependence on finger deformation changes. So far, however, no specific way has been determined to evaluate the proposed finger regarding its ability to wrap around the object. This work comes up with a new and simple method to evaluate the finger's wrapping around the object mathematically. Based on this evaluation method, several different patterns of the internal structure of FinRay fingers were tested. The fingers were first tested in a simulation program, which simulated a steel roller indentation with a diameter of 20 mm in the middle of the finger's contact surface. Based on the simulation results, selected types of structure were made by the Fused Filament Fabrication method from a flexible filament and tested on a real test rig to verify the results of the simulation and compare it with the real behaviour. According to the methodology used, the results show that the most suitable structure of the selected tested fingers from the point of view of wrapping the finger around the object is a structure without internal filling. Designers can simply use the new evaluation method to compare their designed finger variants and select the most suitable one according to the ability to wrap around the gripped object. They can also use graphs from this work's results and determine the finger's dimensions without internal filling according to the required forces and deflection.Web of Science119art. no. 385

Method for robot manipulator joint wear reduction by finding the optimal robot placement in a robotic cell

We describe a method for robotic cell optimization by changing the placement of the robot manipulator within the cell in applications with a fixed end-point trajectory. The goal is to reduce the overall robot joint wear and to prevent uneven joint wear when one or several joints are stressed more than the other joints. Joint wear is approximated by calculating the integral of the mechanical work of each joint during the whole trajectory, which depends on the joint angular velocity and torque. The method relies on using a dynamic simulation for the evaluation of the torques and velocities in robot joints for individual robot positions. Verification of the method was performed using CoppeliaSim and a laboratory robotic cell with the collaborative robot UR3. The results confirmed that, with proper robot base placement, the overall wear of the joints of a robotic arm could be reduced from 22% to 53% depending on the trajectory.Web of Science1112art. no. 539

Optimization of a truss structure used to design of the manipulator arm from a set of components

The design of a manipulator arm, which is built from a construction kit, is presented in this article. The procedure is based on the results of the discrete optimization of a truss structure and its application to a simple component system (assuming a predefined shape and material of components). A genetic algorithm is used to optimize the truss structure, and the results of the solution are verified on a simple task used in literature (the code was written in the Python language). The construction kit was inspired by Merkur(R), and the article proposes several components with different shapes and materials. The construction kit and the optimization of the truss structure were used to design the manipulator arm. The truss topology has been predefined with respect to the construction set. The finite element method (software ANSYS(R)) was used to analyze the components (shell elements) and truss structures (linear analysis, buckling analysis, etc.). To validate the presented approach, the arm designed by topological optimization was used. The comparison shows that the use of components may be an alternative to topology optimization and additive manufacturing. The next step will be the modification of the presented method in order to minimize the differences between the simplified task used for optimization (truss structure-rod element) and the simulation composed of components (components assembly-shell element).Web of Science1121art. no. 1019

Chimney sweeping robot based on a pneumatic actuator

The need of improving the quality of professions led to the idea of simplification of processes during chimney sweeping. These processes have been essentially the same for tens of years. The goal of this paper is to bring an automation element into the chimney sweeping process, making the job easier for the chimney sweeper. In this paper, an essentially in-pipe robot is presented, which uses brushes to move while simultaneously cleaning the chimney or pipeline. The problem of the robot motion was reduced using an in-pipe robot due to the environments and obstacles that the robot has to face. An approach of using a pneumatic actuator for motion is presented along with the mechanical design. The next part of this paper is focused on the mathematical model of the robot motion, as well as its simulation and testing in the experimental pipeline. The simulations were compared with the experimental measurements and a few analyses were conducted describing the simulation model and its differences with the real robot, as well as considering certain parameters and their impact on the performance of the robot. The results are discussed at the end of the paper.Web of Science1111art. no. 487

Camera arrangement optimization for workspace monitoring in human-robot collaboration

Human-robot interaction is becoming an integral part of practice. There is a greater emphasis on safety in workplaces where a robot may bump into a worker. In practice, there are solutions that control the robot based on the potential energy in a collision or a robot re-planning the straight-line trajectory. However, a sensor system must be designed to detect obstacles across the human-robot shared workspace. So far, there is no procedure that engineers can follow in practice to deploy sensors ideally. We come up with the idea of classifying the space as an importance index, which determines what part of the workspace sensors should sense to ensure ideal obstacle sensing. Then, the ideal camera positions can be automatically found according to this classified map. Based on the experiment, the coverage of the important volume by the calculated camera position in the workspace was found to be on average 37% greater compared to a camera placed intuitively by test subjects. Using two cameras at the workplace, the calculated positions were 27% more effective than the subjects' camera positions. Furthermore, for three cameras, the calculated positions were 13% better than the subjects' camera positions, with a total coverage of more than 99% of the classified map.Web of Science231art. no. 29