Human-Robot Collaboration Framework Based on Impedance Control in Robotic Assembly

Human–robot(HR)collaboration(HRC)is an emerging research field because of the complementary advantages of humans and robots.An HRC framework for robotic assembly based on impedance control is proposed in this paper.In the HRC framework,the human is the decision maker,the robot acts as the executor,while the assembly environment provides constraints.The robot is the main executor to perform the assembly action,which has the position control,drag and drop,positive impedance control,and negative impedance control modes.To reveal the characteristics of the HRC framework,the switch condition map of different control modes and the stability analysis of the HR coupled system are discussed.In the end,HRC assembly experiments are conducted,where the HRC assembly task can be accomplished when the assembling tolerance is 0.08 mm or with the interference fit.Experiments show that the HRC assembly has the complementary advantages of humans and robots and is efficient in finishing complex assembly tasks.

Bio-inspired Attachment Mechanism of Dynastes Hercules:Vertical Climbing for On-Orbit Assembly Legged Robots

With the increasing size of space facilities,on-orbit assembly requires robots to move on different heights of trusses.This paper proposes a bio-inspired attachment mechanism for robot feet to enable climbing on different heights of trusses.Inspired by the attachment and grasping abilities of Dynastes Hercules,we utilize its foot microstructures,such as microhooks and setae,to achieve efficient contact and firm grip with the surface.The morphology and arrangement of these structures can inspire the design of robot feet to improve their grasping and stability performance.We study the biological structure of Dynastes Hercules,design and optimize the bio-inspired structure,analyze the influence of various factors from theoretical and experimental perspectives,and verify the feasibility of the scheme through simulation.We propose an ideal climbing strategy that provides useful reference for robot applications in practice.Moreover,the influence laws of various factors in this paper can be applied to robot foot design to improve their operation ability and stability performance in the space environment.This bio-inspired mechanism can improve robot working range and efficiency,which is critical for on-orbit assemblyin space.

Error Modeling and Sensitivity Analysis of a Parallel Robot with SCARA(Selective Compliance Assembly Robot Arm) Motions

Parallel robots with SCARA（selective compliance assembly robot arm） motions are utilized widely in the field of high speed pick-and-place manipulation. Error modeling for these robots generally simplifies the parallelogram structures included by the robots as a link. As the established error model fails to reflect the error feature of the parallelogram structures, the effect of accuracy design and kinematic calibration based on the error model come to be undermined. An error modeling methodology is proposed to establish an error model of parallel robots with parallelogram structures. The error model can embody the geometric errors of all joints, including the joints of parallelogram structures. Thus it can contain more exhaustively the factors that reduce the accuracy of the robot. Based on the error model and some sensitivity indices defined in the sense of statistics, sensitivity analysis is carried out. Accordingly, some atlases are depicted to express each geometric error’s influence on the moving platform’s pose errors. From these atlases, the geometric errors that have greater impact on the accuracy of the moving platform are identified, and some sensitive areas where the pose errors of the moving platform are extremely sensitive to the geometric errors are also figured out. By taking into account the error factors which are generally neglected in all existing modeling methods, the proposed modeling method can thoroughly disclose the process of error transmission and enhance the efficacy of accuracy design and calibration.

Accuracy Analysis of Assembly Success Rate with Monte Carlo Simulations

Monte Carlo simulation was applied to Assembly Success Bate (ASK) analyses. ASR of two peg-in-hole robot assemblies was used as an example by taking component parts' sizes, manufacturing tolerances and robot repeatability into account. A statistic arithmetic expression was proposed and deduced in this paper, which offers an alternative method of estimating the accuracy of ASR, without having to repeat the simulations. This statistic method also helps to choose a suitable sample size, if error reduction is desired. Monte Carlo simulation results demonstrated the feasibility of the method.

Design of Drilling and Riveting Multi-functional End Effector for CFRP and Aluminum Components in Robotic Aircraft Assembly

To fulfill the demands for higher quality,efficiency and flexibility in aviation industry,a multi-functional end effector is designed to automate the drilling and riveting processes in assembling carbon fiber reinforced polymer(CFRP)and aluminum components for a robotic aircraft assembly system.To meet the specific functional requirements for blind rivet installation on CFRP and aluminum materials,additional modules are incorporated on the end effector aside of the basic processing modules for drilling.And all of these processing modules allow for a onestep-drilling-countersinking process,hole inspection,automatic rivet feed,rivet geometry check,sealant application,rivet insertion and installation.Besides,to guarantee the better quality of the hole drilled and joints riveted,several online detection and adjustment measures are applied to this end effector,including the reference detection and perpendicular calibration,which could effectively ensure the positioning precision and perpendicular accuracy as demanded.Finally,the test result shows that this end effector is capable of producing each hole to a positioning precision within ±0.5 mm,aperpendicular accuracy within 0.3°,a diameter tolerance of H8,and a countersink depth tolerance of±0.01 mm.Moreover,it could drill and rivet up to three joints per minute,with acceptable shearing and tensile strength.

Fuzzy reasoning model using fuzzy Petri Nets for the monitoring of robotic assembly

This paper presented a fuzzy Petri net model to deal with the monitoring of robotic assembly. Based on the fuzzy Petri net model, an efficient composite reasoning mode was proposed to perform fuzzy reasoning automatiealy. It can determine whether there exists an antecedent-consequence relationship between two contact states. Furthermore, various types of sensor signals can be converted to the same form of real values between zero and one, and the contradiction among large number, high degree of truth and importance of input conditions can be resolved very well by introducing the weight factors and priorities for sensor signals. Finally, a peg- in-the-hole example was given to illustrate the reasonability and feasibility of the proposed model.

Research on Precision Assembly Robot's Joint Torque Control Based on Current Measurement

A set of new current sensing device is used to realize joint torque control based on current measurement in a precision assembly robot's third joint. The output torque's model of the joint's brushless DC motor is founded. Disturbance factors and the compensated effect of the torque's closed loop based on current measurement are analyzed. Related simulations and experiments show that the system has good current tracking and anti-disturbances performance, which improve the force control performance of the robot in assembly.

Error Analysis of Robotic Assembly System Based on Screw Theory

Assembly errors have great influence on assembly quality in robotic assembly systems. Error analysis is directed to the propagations and accumula-tions of various errors and their effect on assembly success.Using the screw coordinates, assembly errors are represented as 'error twist', the extremely compact expression. According to the law of screw composition, relative position and orientation errors of mating parts are computed and the necessary condition of assembly success is concluded. A new simple method for measuring assembly errors is also proposed based on the transformation law of a screw.Because of the compact representation of error, the model presented for error analysis can be applied to various part- mating types and especially useful for error analysis of complexity assembly.

Implementation of a new PC based controller for a PUMA robot

This paper describes the replacement of a controller for a programmable universal machine for assembly (PUMA) 512 robot with a newly designed PC based (open architecture) controller employing a real-time direct control of six joints. The original structure of the PUMA robot is retained. The hardware of the new controller includes such in-house designed parts as pulse width modulation (PWM) amplifiers, digital and analog controllers, I/O cards, signal conditioner cards, and 16-bit A/D and D/A boards. An Intel Pentium IV industrial computer is used as the central controller. The control software is implemented using VC++ programming language. The trajectory tracking performance of all six joints is tested at varying velocities. Experimental results show that it is feasible to implement the suggested open architecture platform for PUMA 500 series robots through the software routines running on a PC. By assembling controller from off-the-shell hardware and software components, the benefits of reduced and improved robustness have been realized.

A policy iteration method for improving robot assembly trajectory efficiency

Bolt assembly by robots is a vital and difficult task for replacing astronauts in extravehicular activities(EVA),but the trajectory efficiency still needs to be improved during the wrench insertion into hex hole of bolt.In this paper,a policy iteration method based on reinforcement learning(RL)is proposed,by which the problem of trajectory efficiency improvement is constructed as an issue of RL-based objective optimization.Firstly,the projection relation between raw data and state-action space is established,and then a policy iteration initialization method is designed based on the projection to provide the initialization policy for iteration.Policy iteration based on the protective policy is applied to continuously evaluating and optimizing the action-value function of all state-action pairs till the convergence is obtained.To verify the feasibility and effectiveness of the proposed method,a noncontact demonstration experiment with human supervision is performed.Experimental results show that the initialization policy and the generated policy can be obtained by the policy iteration method in a limited number of demonstrations.A comparison between the experiments with two different assembly tolerances shows that the convergent generated policy possesses higher trajectory efficiency than the conservative one.In addition,this method can ensure safety during the training process and improve utilization efficiency of demonstration data.

ROBOTIC PASSIVE COMPLIANT WRIST AND ITS OPTIMAL DESIGN

Based on the mechanism of passive compliant assembly, geometric- force models of the assembly are presented, and the stiffness matrix of the laminated circular elastic element is set up. The optimum method of RCC wrist is compiled by way of two ohases, respectively.

A tree-shaped motion strategy for robustly executing robotic assembly tasks

An assembly robot needs to be capable of executing an assembly task robustly under various uncertainties.To attain this goal,we use a task sequence tree model originally proposed for manual assembly.This model regards an assembly task under uncertainties as a transformation of the contact state concept.The concept may contain several contact states with probabilities but these are transformed through a series of task elements into the contact state concept having only the goal state at the end.The transformed contact state concept can be classified according to the terminal condition of each task element.Thus,the whole assembly task can be designed as a tree-shaped contingent strategy called a task sequence tree.This paper proposes a systematic approach for reconfiguring a task sequence tree model for application to a robotic assembly task.In addition,by taking a 2D peg-in-hole insertion task to be performed by a robot equipped with a force sensor as an example,we confirm that the proposed approach can provide a robust motion strategy for the task and that the robot can actually execute the task robustly under bounded uncertainty according to the strategy.

Improved approach to quality function deployment based on Pythagorean fuzzy sets and application to assembly robot design evaluation

Quality function deployment(QFD)is an effective method that helps companies analyze customer requirements(CRs).These CRs are then turned into product or service characteristics,which are translated to other attributes.With the QFD method,companies could design or improve the quality of products or services close to CRs.To increase the effectiveness of QFD,we propose an improved method based on Pythagorean fuzzy sets(PFSs).We apply an extended method to obtain the group consensus evaluation matrix.We then use a combined weight determining method to integrate former weights to objective weights derived from the evaluation matrix.To determine the exact score of each PFS in the evaluation matrix,we develop an improved score function.Lastly,we apply the proposed method to a case study on assembly robot design evaluation.

Calibration of robotic drilling systems with a moving rail

Industrial robots are widely used in aircraft assembly systems such as robotic drilling systems. It is necessary to expand a robot＇s working range with a moving rail. A method for improving the position accuracy of an automated assembly system with an industrial robot mounted on a moving rail is proposed. A multi-station method is used to control the robot in this study. The robot only works at stations which are certain positions defined on the moving rail. The calibration of the robot system is composed by the calibration of the robot and the calibration of the stations.The calibration of the robot is based on error similarity and inverse distance weighted interpolation.The calibration of the stations is based on a magnetic strip and a magnetic sensor. Validation tests were performed in this study, which showed that the accuracy of the robot system gained significant improvement using the proposed method. The absolute position errors were reduced by about 85%to less than 0.3 mm compared with the maximum nearly 2 mm before calibration.