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Challenges in human-robot collaborative assembly in shipbuilding and ship maintenance, repair and conversion (SMRC) industry

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Procedia CIRP 2022年 106卷 120-125页

作者： Natalia Zacharaki Nikos Dimitropoulos Sotiris Makris Laboratory for Manufacturing Systems & Automation University of Patras Rion Patras 26504 Greece

In recent years research in manufacturing has been shifting towards flexible and intuitive Human-Robot Collaborative (HRC) solutions, allowing operators to coexist and interact safely with robots of various payloads. Previous research provided proof that HRC systems can improve the quality and cycle time of processes, including welding, grinding, polishing, assembly and picking. Applying such solutions to shipbuilding and ship maintenance, repair and conversion (SMRC) industry though is not straight forward. Lack of 3D-CAD models, variety of processes that have to be performed, manipulation of dissimilar parts, confined spaces, unpredictable external conditions are some of the challenges that arise. Nevertheless, the shipbuilding and SMRC industry is a dynamic and competitive sector, which could highly benefit from leveraging technology advancements, emerged from Industry 4.0 revolution. These advancements can not only improve the work life of the operators, supporting them in dangerous working environments, but also increase the quality of the final product as well as productivity rate. In this direction, this paper aims to present the challenges that derive from the shipbuilding and SMRC industry related with assembly operations, as well as a novel user-centric solution that aspires to overcome these challenges. The solution consists of a reconfigurable HRC cell, involving a high payload collaborative manipulator able to perform lifting and positioning of large heavy parts, while the operator performs the welding task. Intuitive interaction solutions allow precise parts handling by workers. Moreover, multi-layer safety systems allow the monitoring of the workplace and ensure the safety of the operators. Finally, hand guiding, and intuitive offline programming techniques enable the manipulation and programming of the high-payload robot by not experts.

关键词： human robot interaction human robot collaboration reconfigurable assembly lines offline programming intuitive solutions assembly shipbuilding industry

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Auto-calibration of robot workcells via remote laser scanning

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ROBOTICS AND COMPUTER-INTEGRATED MANUFACTURING 2022年第0期78卷

作者： Park, J. W. Min, K. H. Kim, D. Y. Pohang Univ Sci & Technol Dept Ind & Management Engn Cheongam Ro 77 Pohang 37673 Gyeongbuk South Korea

For new robotic products, the rapid generation of robot programs is generally ensured by offline programming (OLP). Nevertheless, robotic calibration of workcells is essential because of the geometric differences between the three-dimensional (3D) model environment and the real world. In contrast with previous robot self calibration methods that use specific sensors, the proposed method requires neither marker settings nor initial positioning of the measurement system. Instead, the geometric feature of interplane relations finds relative differences between the coordinates of the 3D model and those of the real workcell. In addition, an iterative method of estimating world coordinates is introduced to increase the accuracy of the revised robot path. A portable laser scanner acquires 3D point-cloud data, so it can be located near the workcell instead of being prefixed, thereby facilitating its use. Through experimentation, an average distance of 0.0817 mm is found between the OLP-teaching points and the calibrated points of the pointing operation.

关键词： Robot workcell offline programming Calibration Laser scanner Registration

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A Camera-Based Position Correction System for Autonomous Production Line Inspection

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SENSORS 2021年第12期21卷 4071-4071页

作者： Bedaka, Amit Kumar Lee, Shao-Chun Mahmoud, Alaa M. Cheng, Yong-Sheng Lin, Chyi-Yeu Natl Taiwan Univ Sci & Technol Dept Mech Engn Taipei 106 Taiwan Natl Taiwan Univ Sci & Technol Ctr Cyber Phys Syst Innovat Taipei 106 Taiwan Natl Taiwan Univ Sci & Technol Taiwan Bldg Technol Ctr Taipei 106 Taiwan

Visual inspection is an important task in manufacturing industries in order to evaluate the completeness and quality of manufactured products. An autonomous robot-guided inspection system was recently developed based on an offline programming (OLP) and RGB-D model system. This system allows a non-expert automatic optical inspection (AOI) engineer to easily perform inspections using scanned data. However, if there is a positioning error due to displacement or rotation of the object, this system cannot be used on a production line. In this study, we developed an automated position correction module to locate an object's position and correct the robot's pose and position based on the detected error values in terms of displacement or rotation. The proposed module comprised an automatic hand-eye calibration and the PnP algorithm. The automatic hand-eye calibration was performed using a calibration board to reduce manual error. After calibration, the PnP algorithm calculates the object position error using artificial marker images and compensates for the error to a new object on the production line. The position correction module then automatically maps the defined AOI target positions onto a new object, unless the target position changes. We performed experiments that showed that the robot-guided inspection system with the position correction module effectively performed the desired task. This smart innovative system provides a novel advancement by automating the AOI process on a production line to increase productivity.

关键词： automatic optical inspection (AOI) offline programming position correction image processing production line manipulator camera-based system

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Designing Method of Information-Control Systems Realization for Visual programming Robotic Manipulators

Designing Method of Information-Control Systems Realization ...

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International Conference on Industrial Engineering, Applications and Manufacturing (ICIEAM)

作者： Yukhimets, Dmiby Sakhnenko, Andrey Sych, Alexander FEB RAS Lab Robot Syst Inst Automat & Control Proc Vladivostok Russia FEB RAS Inst Marine Technol Problems Lab Intelligent Control Syst Vladivostok Russia Far Eastern Fed Univ Dept Automat & Control Vladivostok Russia

ISBN: (纸本)9781728145907

The paper considers a universal approach to the design and implementation of information control systems (ICS) that use a human-machine interface for interaction with automatic control systems (ACS) of robotic manipulators. The proposed approach allows you to create and edit control program of manipulator's movements, as well as to simulate its execution regardless of the hardware implementation of the control object. It is assumed that the system implemented in accordance with this approach can be implemented in the control of various industrial robotic manipulators and is considered as a highly effective alternative to the common control tools for manipulators and their working tools, thus representing a universal control panel for robotic complexes. Moreover, the use of such a universal remote control can occur autonomously from existing robots, this is significant advantage over popular alternatives. An example and effectiveness of such an implementation are considered.

关键词： industrial manipulator offline programming human-machine interface information-control system trajectory formation system universal robot teach pendant

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Applications of Digital and Computer Technologies for Control and Motion Simulation of Electromechanical Systems 2

Applications of Digital and Computer Technologies for Contro...

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2nd International Congress on Human-Computer Interaction, Optimization and Robotic Applications (HORA)

作者： Zhilevski, Marin Bratovanov, Nikolay Tech Univ Sofia Fac Automat Sofia Bulgaria

ISBN: (纸本)9781728193526

Digital and computer technologies have been playing a significant role in the field of engineering for more than a couple of decades. Utilizing powerful computational systems for design, development, manufacturing, analysis, simulation and optimization purposes, computer technologies have become an irreplaceable component of nowadays industry, contributing to the improved efficiency and productivity of various processes. This paper demonstrates the applicability of digital and computer technologies in the field of motion control and simulation of electromechanical systems such as machine tools and industrial robots. The presented applications are accomplished via the following software - Ise Design Suite for synthesis of CPLD (Complex Programmable Logic Device) and FPGA (Field-Programmable Gate Array) through hardware description languages, and SolidWorks API (Application programming Interface) for the development of custom tools in the field of 3D modeling, design and motion simulation.

关键词： electromechanical systems industrial robotics motion control motion simulation offline programming CPLD FPGA SolidWorks API

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Virtualization for the Purposes of Modeling and Computer Simulation of a Class of Overconstrained Robots 4

Virtualization for the Purposes of Modeling and Computer Sim...

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4th IEEE International Conference on Robotic Computing (IEEE IRC)

作者： Bratovanov, Nikolay Sotirov, Zlatko Tech Univ Sofia Fac Automat Robot Lab Sofia Bulgaria Genmark Automat Fremont CA USA

ISBN: (纸本)9781728152370

the paper presents an approach to modeling, analysis, and simulation of overconstrained parallel manipulators, based on joint virtualization. This novel concept is proposed for the purpose of studying a three-degree-of-freedom closed-loop mechanism, which has found a broad industrial application in the field of semiconductor device manufacturing and fab automation. A distinctive feature of this overconstrained manipulator, known as GPR, is its ability to "use" the inherent elasticity and backlash of its components in order to perform finite small rotations when in the vicinity of a singular configuration, eliminating the need of using additional kinematic joints. This characteristic behavior is exhaustively studied by introducing virtual joints at the GPR's terminal link, allowing the development of precise computational models that facilitate the execution of realistic motion simulations (in 3D SolidWorks environment), as well as in-depth mobility and accuracy analyses, essential for the efficient implementation and optimization of the GPR in terms of both practice and theory.

关键词： overconstrained mechanisms parallel manipulators kinematic modeling computer simulations joint virtualization semiconductor industry automation motion simulations offline programming SolidWorks API

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High-precision assembly of electronic devices with lightweight robots through sensor-guided insertion

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Procedia CIRP 2021年 97卷 337-341页

作者： Maximilian Metzner Sebastian Leurer Andreas Handwerker Engin Karlidag Andreas Blank Florian Hefner Jörg Franke FAU Erlangen-Nuremberg Institute for Factory Automation and Production Systems Egerlandstraße 7-9 91058 Erlangen Germany SIEMENS AG Digital Industries Frauenauracher Straße 80 91058 Erlangen Germany

Through-hole devices still play an important role in power electronics production. Due to a high number of variants in this field, an automated placement by special machines is often not economically feasible. The resulting manual process is characterized by monotony, ergonomic strain and high labor cost. As a result, a partial automation, using lightweight robots in hybrid assembly system, yields high potential. The lower stiffness and resulting accuracy deficiency of lightweight robots compared to common industrial robots, combined with the precision requirements and inherent fragility of the devices, prohibits the deployment of such systems. In this contribution, a scalable setup and strategies for visual and force-torque guided tactile insertion of such devices is presented and evaluated. A library, based on a system for the offline-programming of such tasks, is used to decrease implementation efforts. A performance evaluation of the system on printed circuit boards with multiple different devices is conducted.

关键词： Lightweight robots Peg in Hole offline programming Electronics production

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A simulation-based approach to develop a holonic robotic cell

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INDUSTRIAL ROBOT-THE INTERNATIONAL JOURNAL OF ROBOTICS RESEARCH AND APPLICATION 2019年第1期46卷 128-134页

作者： Steed, Clint Alex Univ Stellenbosch Dept Mech & Mechatron Engn Matieland South Africa

Purpose - This paper aims to present an approach for the simulation of a heterogeneous robotic cell. The simulation enables the cell's developers to conveniently compare the performance of alternative cell configurations. The approach combines the use of multiple available simulation tools, with a custom holonic cell controller. This overcomes the limitation of currently available robot simulation packages by allowing integration of multiple simulation tools including multiple vendor simulation packages. Design/methodology/approach - A feeding cell was developed as a case study representing a typical robotic application. The case study would compare two configurations of the cell, namely, eye-in-hand vision and fixed-camera vision. The authors developed the physical cell in parallel with the simulated cell to validate its performance. Then they used simulation to scale the models (by adding subsystems) and shortlist suitable cell configurations based on initial capital investment and throughput rate per unit cost. The feeding cell consisted of a six-degree of freedom industrial robot (KUKA KR16), two smart cameras (Cognex ism-1100 and DVT Legend 500), an industrial PC (Beckhoff) and custom reconfigurable singulation units. Findings - The approach presented here allows the combination of dissimilar simulation models constructed for the above mentioned case study. Experiments showed the model developed in this approach could reasonably predict various eye-in-hand and fixed-camera systems' performance. Combining the holonic controller with the simulation allows developers to easily compare the performance of a variety of configurations. The use of a common communication platform allowed the communication between multiple simulation packages, allowing multi-vendor simulation, thereby overcoming current limitation in simulation software. Research limitations/implications - The case study developed here is considered a typical feeding and assembly application. This is how

关键词： offline programming Modular automation Simulation Assembly Flexible manufacturing Cellular manufacturing

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Optimised trajectory calculation for the automated layup of wide lightning protection tapes on double-curved fuselage sections

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COMPOSITE STRUCTURES 2019年 210卷 906-913页

作者： Schmidt-Eisenlohr, Clemens Kaufmann, Patrick Sonnenberg, Martin Malecha, Marcin German Aerosp Ctr Ctr Lightweight Prod Technol Technol Zentrum 4 D-86159 Augsburg Germany IVU Traff Technol AG Bundesallee 88 D-12161 Berlin Germany

Lighting strike protection is not intrinsically provided on modern composite built aircraft due to the lower electrical conductivity of composite materials. A highly conductive copper foil is manually applied onto the fuselage in multiple overlapping tapes. Known automation processes are not adequate for wide tapes particularly in the case of large double-curved surfaces. One key technology for enabling an automated process is tape trajectory generation with a focus on automation constraints. We are introducing a new tape application mechanism for a single wide tape. Our algorithm generates geometry induced layup trajectories, taking into account geometric conditions. We experimentally demonstrate a wrinkle-free automated application. Based on the first algorithm, a second algorithm addresses the challenging issue of an optimised surface coverage with multiple tapes for a fuselage section. A tape application fitness criterion is defined and implemented. We point out that a computer-based algorithm is advantageous for determining the proper arrangement of multiple tapes. It is thus now possible to create a multiple tape design that can be applied with an automation process. In addition, the optimisation leads to a reduction of consumed and wasted tape material in the fuselage production process.

关键词： Lightning strike protection material Composite fuselage Automation offline programming Path generation Doubly curved surface

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offline programming for an Arc Welding Robot with Redundant DOF

Offline Programming for an Arc Welding Robot with Redundant ...

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International Conference on Frontiers of Mechanical Engineering and Materials Engineering (MEME 2012)

作者： Chen, Huanming Liu, Zhouping Nanchang Hangkong Univ Sch Aeronaut Mfg Engn Nanchang 330063 Peoples R China

ISBN: (纸本)9783037854419

To raise the programming efficiency of arc welding robots, the offline programming system was developed for a Motoman-UP20 robot with redundant degrees of freedom in VC++ integration environment. The system consists of kinematics analysis, motion simulation, welding trajectory plan, welding parameters plan and job file generating module. It can plan the motion path and posture of welding gun for saddle-shape seams, and display the workpiece on the interface synchronically. Job instructions can be made step by step, or generated automatically. Kinematics simulation module and communication module are integrated together, and job files can be exchanged between PC and robot controller via Ethernet to realize remote control.

关键词： Arc welding robot offline programming Motion simulation Path planning

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