Multi-robot spot-welding cells: An integrated approach to cell design and motion planning

The necessity to manage several vehicle models on the same robotized assembly cell has made the cell design and the robot off-line motion planning two fundamental activities. Industrial practice and state-of-the-art methods focus on the technical issues of each activity, but no integrated approach has been yet proposed, resulting in a lack of optimality for the final cell configuration. The paper introduces a formalization of the whole process and proposes a heuristic multi-stage method for the identification of the optimal combination of cell design choices and motion planning. The proposed architecture is depicted through a real case for welding application

Multi-robot spot-welding cell design: Problem formalization and proposed architecture

The multi-robot cell design for car-body spot welding is faced by industry as a sequence of tasks, where researches are focused on issues of the problem as a whole. In authors’ knowledge, none work in literature have suggested any formalization for the complete process. This paper tries to bridges the gap proposing coherent process formalization, and presenting a corresponding innovative architecture for the automatic optimal cell design. Specifically, the formalization involves the identification and allocation of the resources in terms of a set of decisional variables (e.g. robot model/positioning/number, welding gun models/allocation/number, welding point allocation etc.); then, the design optimization process minimizes the investment costs granting the cycle time. The multi-loop optimization architecture integrates both new algorithms and existent procedures from different fields. Test-bed showing its feasibility is reported

robotic am system for plastic materials tuning and on line adjustment of process parameters

Abstract Additive Manufacturing (AM) techniques based on thermoplastic polymer extrusion allow the manufacture of complex parts, but their slow printing speed limits their use for mass production. To overcome this drawback, an industrial screw-based extruder has been mounted on an anthropomorphic robot, realizing a flexible AM platform for big objects. The most important process parameters have been set by a suitable experimental campaign, ensuring a regular deposited layer geometry. A closed-loop control has been implemented to further improve the process parameter setting based on data measured during the deposition, in this way compensating the material withdrawal or other unexpected defects

Seam tracking and gap bridging during robotic laser beam welding via grayscale imaging and wobbling

The use of laser beam welding with robotic manipulators is expanding towards wider industrial applications as the system availability increases with reduced capital costs. Conventionally, laser welding requires high positioning and coupling accuracy. Due to the variability in the part geometry and positioning, as well as the thermal deformation that may occur during the process, joint position and fit-up are not always acceptable nor predictable a-priori if simple fixtures are used. This makes the passage from virtual CAD/CAM environment to real production site not trivial, limiting applications where short part preparations are a need like small-batch productions. Solutions that render the laser welding operations feasible for production series with non-stringent tolerances are required to serve a wider range of industrial applications. Such solutions should be able to track the seam as well as tolerating variable gaps formed between the parts to be joined. In this work, an online correction for robot trajectory based on a greyscale coaxial vision system with external illumination and an adaptive wobbling strategy are proposed as means to increase the overall flexibility of a manufacturing plant. The underlying vision algorithm and control architectures are presented; the robustness of the system to poor illumination conditions and variable reflection conditions is also discussed. The developed solution employed two control loops: the first is able to change the robot pose to follow varying trajectories; the second, able to vary the amplitude of circular wobbling as a function of the gap formed in butt-joint welds. Demonstrator cases on butt-joint welds with AISI 301 stainless steel with increased complexity were used to test the efficacy of the solution. The system was successfully tested on 2 mm thick, planar stainless-steel sheets at a maximum welding speed of 25 mm/s and yielded a maximum positioning and yaw-orientation errors of respectively 0.325 mm and 4.5°. Continuous welds could be achieved with up to 1 mm gaps and variable seam position with the developed control method. The acceptable weld quality could be maintained up to 0.6 mm gap in the employed autogenous welding configuration

Validation of an extended approach to multi-robot cell design and motion planning

According to both industrial practice and literature, multi-robot cell design and robot motion planning for vehicle spot welding are two sequential activities, managed by different functional units through different software tools. Due to this sequential computation, the whole process suffers from inherent inefficiency. In this work, a new methodology is proposed, that overcomes the above inefficiency through the simultaneous resolution of design and motion planning problems. Specifically, three mathematical models were introduced that (i) select and positions the resources, (ii) allocate the tasks to the resources and (iii) identify a coordinated robot motion plan. Based on the proposed methodology, we built three ad-hoc cases with the goal to highlight the relations between design, motion planning and environment complexity. These cases could be taken as reference cases so on. Moreover, results on an industrial case are presented

Design methodology of an active back-support exoskeleton with adaptable backbone-based kinematics

Abstract Manual labor is still strongly present in many industrial contexts (such as aerospace industry). Such operations commonly involve onerous tasks requiring to work in non-ergonomic conditions and to manipulate heavy parts. As a result, work-related musculoskeletal disorders are a major problem to tackle in workplace. In particular, back is one of the most affected regions. To solve such issue, many efforts have been made in the design and control of exoskeleton devices, relieving the human from the task load. Besides upper limbs and lower limbs exoskeletons, back-support exoskeletons have been also investigated, proposing both passive and active solutions. While passive solutions cannot empower the human's capabilities, common active devices are rigid, without the possibility to track the human's spine kinematics while executing the task. The here proposed paper describes a methodology to design an active back-support exoskeleton with backbone-based kinematics. On the basis of the (easily implementable) scissor hinge mechanism, a one-degree of freedom device has been designed. In particular, the resulting device allows tracking the motion of a reference vertebra, i.e., the vertebrae in the correspondence of the connection between the scissor hinge mechanism and the back of the operator. Therefore, the proposed device is capable to adapt to the human posture, guaranteeing the support while relieving the person from the task load. In addition, the proposed mechanism can be easily optimized and realized for different subjects, involving a subject-based design procedure, making possible to adapt its kinematics to track the spine motion of the specific user. A prototype of the proposed device has been 3D-printed to show the achieved kinematics. Preliminary tests for discomfort evaluation show the potential of the proposed methodology, foreseeing extensive subjects-based optimization, realization and testing of the device

A Structured methodology for business network design

In the new manufacturing environment, a single enterprise does not often own all resources and skills to offercompetitive solutions. Therefore, such enterprises become part of enterprise networks of independent corecompetencies in order to produce marketable products. Thus, Business Networking is an innovative businessparadigm that can help companies to remain competitive in the market. Nevertheless, its practical implementation isvery complicated because of the several dimensions that it involves, and, especially in network start up phase,because it is often left to the case and not managed with adequate methodologies and tools. The present paperproposes a structured methodology for long term business network design that is based on a network descriptivemodel and that should be applied by a network architect. The proposed methodology has been developed andapplied in the frame of KoBaS project funded through European Commission Program

Kinect V2 Performance Assessment in Daily-Life Gestures: Cohort Study on Healthy Subjects for a Reference Database for Automated Instrumental Evaluations on Neurological Patients

Background. The increase of sanitary costs related to poststroke rehabilitation requires new sustainable and cost-effective strategies for promoting autonomous and dehospitalized motor training. In the Riprendo@Home and Future Home for Future Communities research projects, the promising approach of introducing low-cost technologies that promote home rehabilitation is exploited. In order to provide reliable evaluation of patients, a reference database of healthy people’s performances is required and should consider variability related to healthy people performances. Methods. 78 healthy subjects performed several repetitions of daily-life gestures, the reaching movement (RM) and hand-to-mouth (HtMM) movement with both the dominant and nondominant upper limbs. Movements were recorded with a Kinect V2. A synthetic biomechanical protocol based on kinematical, dynamical, and motor control parameters was used to assess motor performance of the healthy people. The investigation was conducted by clustering participants depending on their limb dominancy (right/left), gender (male/female), and age (young/middle/senior) as sources of variability. Results. Results showed that limb dominancy has minor relevance in affecting RM and HtMM; gender has relevance in affecting the HtMM; age has major effect in affecting RM and HtMM. Conclusions. An investigation of healthy subjects’ upper limb performances during daily-life gestures was performed with the Kinect V2 sensor. Findings will be the basis for a database of normative data for neurological patients’ motor evaluation

Robotic Assistance for Upper Limbs May Induce Slight Changes in Motor Modules Compared With Free Movements in Stroke Survivors: A Cluster-Based Muscle Synergy Analysis

Background: The efficacy of robot-assisted rehabilitation as a technique for achieving motor recovery is still being debated. The effects of robotic assistance are generally measured using standard clinical assessments. Few studies have investigated the value of human-centered instrumental analysis, taking the modular organization of the human neuromotor system into account in assessing how stroke survivors interact with robotic set-ups. In this paper, muscle synergy analysis was coupled with clustering procedures to elucidate the effect of human-robot interaction on the spatial and temporal features, and directional tuning of motor modules during robot-assisted movements.Methods: Twenty-two stroke survivors completed a session comprising a series of hand-to-mouth movements with and without robotic assistance. Patients were assessed instrumentally, recording kinematic, and electromyographic data to extract spatial muscle synergies and their temporal components. Patients' spatial synergies were grouped by means of a cluster analysis, matched pairwise across conditions (free and robot-assisted movement), and compared in terms of their spatial and temporal features, and directional tuning, to examine how robotic assistance altered their motor modules.Results: Motor synergies were successfully extracted for all 22 patients in both conditions. Seven clusters (spatial synergies) could describe the original datasets, in both free and robot-assisted movements. Interacting with the robot slightly altered the spatial synergies' features (to a variable extent), as well as their temporal components and directional tuning.Conclusions: Slight differences were identified in the characteristics of spatial synergies, temporal components and directional tuning of the motor modules of stroke survivors engaging in free and robot-assisted movements. Such effects are worth investigating in the framework of a modular description of the neuromusculoskeletal system to shed more light on human-robot interaction, and the effects of robotic assistance and rehabilitation