Automatic Color Inspection for Colored Wires in Electric Cables

In this paper, an automatic optical inspection system for checking the sequence of colored wires in electric cable is presented. The system is able to inspect cables with flat connectors differing in the type and number of wires. This variability is managed in an automatic way by means of a self-learning subsystem and does not require manual input from the operator or loading new data to the machine. The system is coupled to a connector crimping machine and once the model of a correct cable is learned, it can automatically inspect each cable assembled by the machine. The main contributions of this paper are: (i) the self-learning system; (ii) a robust segmentation algorithm for extracting wires from images even if they are strongly bent and partially overlapped; (iii) a color recognition algorithm able to cope with highlights and different finishing of the wire insulation. We report the system evaluation over a period of several months during the actual production of large batches of different cables; tests demonstrated a high level of accuracy and the absence of false negatives, which is a key point in order to guarantee defect-free productions

Robust Intrinsic and Extrinsic Calibration of RGB-D Cameras

Color-depth cameras (RGB-D cameras) have become the primary sensors in most robotics systems, from service robotics to industrial robotics applications. Typical consumer-grade RGB-D cameras are provided with a coarse intrinsic and extrinsic calibration that generally does not meet the accuracy requirements needed by many robotics applications (e.g., highly accurate 3D environment reconstruction and mapping, high precision object recognition and localization, ...). In this paper, we propose a human-friendly, reliable and accurate calibration framework that enables to easily estimate both the intrinsic and extrinsic parameters of a general color-depth sensor couple. Our approach is based on a novel two components error model. This model unifies the error sources of RGB-D pairs based on different technologies, such as structured-light 3D cameras and time-of-flight cameras. Our method provides some important advantages compared to other state-of-the-art systems: it is general (i.e., well suited for different types of sensors), based on an easy and stable calibration protocol, provides a greater calibration accuracy, and has been implemented within the ROS robotics framework. We report detailed experimental validations and performance comparisons to support our statements

Autonomous robotic system for thermographic detection of defects in upper layers of carbon fiber reinforced polymers

Carbon Fiber Reinforced Polymers (CFRPs) are composites whose interesting properties, like high strength-to-weight ratio and rigidity, are of interest in many industrial fields. Many defects affecting their production process are due to the wrong distribution of the thermosetting polymer in the upper layers. In this work, they are effectively and efficiently detected by automatically analyzing the thermographic images obtained by Pulsed Phase Thermography (PPT) and comparing them with a defect-free reference. The flash lamp and infrared camera needed by PPT are mounted on an industrial robot so that surfaces of CFRP automotive components, car side blades in our case, can be inspected in a series of static tests. The thermographic image analysis is based on local contrast adjustment via UnSharp Masking (USM) and takes also advantage of the high level of knowledge of the entire system provided by the calibration procedures. This system could replace manual inspection leading to a substantial increase in efficiency

Fast and Robust Detection of Fallen People from a Mobile Robot

This paper deals with the problem of detecting fallen people lying on the floor by means of a mobile robot equipped with a 3D depth sensor. In the proposed algorithm, inspired by semantic segmentation techniques, the 3D scene is over-segmented into small patches. Fallen people are then detected by means of two SVM classifiers: the first one labels each patch, while the second one captures the spatial relations between them. This novel approach showed to be robust and fast. Indeed, thanks to the use of small patches, fallen people in real cluttered scenes with objects side by side are correctly detected. Moreover, the algorithm can be executed on a mobile robot fitted with a standard laptop making it possible to exploit the 2D environmental map built by the robot and the multiple points of view obtained during the robot navigation. Additionally, this algorithm is robust to illumination changes since it does not rely on RGB data but on depth data. All the methods have been thoroughly validated on the IASLAB-RGBD Fallen Person Dataset, which is published online as a further contribution. It consists of several static and dynamic sequences with 15 different people and 2 different environments

Fast human motion prediction for human-robot collaboration with wearable interfaces

In this paper, we aim at improving human motion prediction during human-robot collaboration in industrial facilities by exploiting contributions from both physical and physiological signals. Improved human-machine collaboration could prove useful in several areas, while it is crucial for interacting robots to understand human movement as soon as possible to avoid accidents and injuries. In this perspective, we propose a novel human-robot interface capable to anticipate the user intention while performing reaching movements on a working bench in order to plan the action of a collaborative robot. The proposed interface can find many applications in the Industry 4.0 framework, where autonomous and collaborative robots will be an essential part of innovative facilities. A motion intention prediction and a motion direction prediction levels have been developed to improve detection speed and accuracy. A Gaussian Mixture Model (GMM) has been trained with IMU and EMG data following an evidence accumulation approach to predict reaching direction. Novel dynamic stopping criteria have been proposed to flexibly adjust the trade-off between early anticipation and accuracy according to the application. The output of the two predictors has been used as external inputs to a Finite State Machine (FSM) to control the behaviour of a physical robot according to user's action or inaction. Results show that our system outperforms previous methods, achieving a real-time classification accuracy of $94.3\pm2.9\%$ after $160.0msec\pm80.0msec$ from movement onset

Teaching humanoid robotics by means of human teleoperation through RGB-D sensors

This paper presents a graduate course project on humanoid robotics offered by the University of Padova. The target is to safely lift an object by teleoperating a small humanoid. Students have to map human limbs into robot joints, guarantee the robot stability during the motion, and teleoperate the robot to perform the correct movement. We introduce the following innovative aspects with respect to classical robotic classes: i) the use of humanoid robots as teaching tools; ii) the simplification of the stable locomotion problem by exploiting the potential of teleoperation; iii) the adoption of a Project-Based Learning constructivist approach as teaching methodology. The learning objectives of both course and project are introduced and compared with the students\u2019 background. Design and constraints students have to deal with are reported, together with the amount of time they and their instructors dedicated to solve tasks. A set of evaluation results are provided in order to validate the authors\u2019 purpose, including the students\u2019 personal feedback. A discussion about possible future improvements is reported, hoping to encourage further spread of educational robotics in schools at all levels

Efficient completeness inspection using real-time 3D color reconstruction with a dual-laser triangulation system

In this chapter, we present the final system resulting from the European Project \u201d3DComplete\u201d aimed at creating a low-cost and flexible quality inspection system capable of capturing 2.5D color data for completeness inspection. The system uses a single color camera to capture at the same time 3D data with laser triangulation and color texture with a special projector of a narrow line of white light, which are then combined into a color 2.5D model in real-time. Many examples of completeness inspection tasks are reported which are extremely difficult to analyze with state-of-the-art 2D-based methods. Our system has been integrated into a real production environment, showing that completeness inspection incorporating 3D technology can be readily achieved in a short time at low costs