Vision-Based Solutions for Human-Robot Collaboration in Industrial Workcells

Industrial robots are both versatile and high performant, enabling the flexible automation typical of the modern Smart Factories. For safety reasons, however, they must be relegated inside closed fences and/or virtual safety barriers, to keep them strictly separated from human operators. This can be a limitation in some scenarios in which it is useful to combine the human cognitive skill with the accuracy and repeatability of a robot, or simply to allow a safe coexistence in a shared workspace. Collaborative robots (cobots), on the other hand, are intrinsically limited in speed and power in order to share workspace and tasks with human operators, and feature the very intuitive hand guiding programming method. Cobots, however, cannot compete with industrial robots in terms of performance, and are thus useful only in a limited niche, where they can actually bring an improvement in productivity and/or in the quality of the work thanks to their synergy with human operators. The limitations of both the pure industrial and the collaborative paradigms can be overcome by combining industrial robots with artificial vision. In particular, vision can be exploited for a real-time adjustment of the pre-programmed task-based robot trajectory, by means of the visual tracking of dynamic obstacles (e.g. human operators). This strategy allows the robot to modify its motion only when necessary, thus maintain a high level of productivity but at the same time increasing its versatility. Other than that, vision offers the possibility of more intuitive programming paradigms for the industrial robots as well, such as the programming by demonstration paradigm. These possibilities offered by artificial vision enable, as a matter of fact, an efficacious and promising way of achieving human-robot collaboration, which has the advantage of overcoming the limitations of both the previous paradigms yet keeping their strengths.

Architectures and design patterns for functional design of logic control and diagnostics in industrial automation

Recently in most of the industrial automation process an ever increasing degree of automation has been observed. This increasing is motivated by the higher requirement of systems with great performance in terms of quality of products/services generated, productivity, efficiency and low costs in the design, realization and maintenance. This trend in the growth of complex automation systems is rapidly spreading over automated manufacturing systems (AMS), where the integration of the mechanical and electronic technology, typical of the Mechatronics, is merging with other technologies such as Informatics and the communication networks. An AMS is a very complex system that can be thought constituted by a set of flexible working stations, one or more transportation systems. To understand how this machine are important in our society let considerate that every day most of us use bottles of water or soda, buy product in box like food or cigarets and so on. Another important consideration from its complexity derive from the fact that the the consortium of machine producers has estimated around 350 types of manufacturing machine. A large number of manufacturing machine industry are presented in Italy and notably packaging machine industry,in particular a great concentration of this kind of industry is located in Bologna area; for this reason the Bologna area is called “packaging valley”. Usually, the various parts of the AMS interact among them in a concurrent and asynchronous way, and coordinate the parts of the machine to obtain a desiderated overall behaviour is an hard task. Often, this is the case in large scale systems, organized in a modular and distributed manner. Even if the success of a modern AMS from a functional and behavioural point of view is still to attribute to the design choices operated in the definition of the mechanical structure and electrical electronic architecture, the system that governs the control of the plant is becoming crucial, because of the large number of duties associated to it. Apart from the activity inherent to the automation of themachine cycles, the supervisory system is called to perform other main functions such as: emulating the behaviour of traditional mechanical members thus allowing a drastic constructive simplification of the machine and a crucial functional flexibility; dynamically adapting the control strategies according to the different productive needs and to the different operational scenarios; obtaining a high quality of the final product through the verification of the correctness of the processing; addressing the operator devoted to themachine to promptly and carefully take the actions devoted to establish or restore the optimal operating conditions; managing in real time information on diagnostics, as a support of the maintenance operations of the machine. The kind of facilities that designers can directly find on themarket, in terms of software component libraries provides in fact an adequate support as regard the implementation of either top-level or bottom-level functionalities, typically pertaining to the domains of user-friendly HMIs, closed-loop regulation and motion control, fieldbus-based interconnection of remote smart devices. What is still lacking is a reference framework comprising a comprehensive set of highly reusable logic control components that, focussing on the cross-cutting functionalities characterizing the automation domain, may help the designers in the process of modelling and structuring their applications according to the specific needs. Historically, the design and verification process for complex automated industrial systems is performed in empirical way, without a clear distinction between functional and technological-implementation concepts and without a systematic method to organically deal with the complete system. Traditionally, in the field of analog and digital control design and verification through formal and simulation tools have been adopted since a long time ago, at least for multivariable and/or nonlinear controllers for complex time-driven dynamics as in the fields of vehicles, aircrafts, robots, electric drives and complex power electronics equipments. Moving to the field of logic control, typical for industrial manufacturing automation, the design and verification process is approached in a completely different way, usually very “unstructured”. No clear distinction between functions and implementations, between functional architectures and technological architectures and platforms is considered. Probably this difference is due to the different “dynamical framework”of logic control with respect to analog/digital control. As a matter of facts, in logic control discrete-events dynamics replace time-driven dynamics; hence most of the formal and mathematical tools of analog/digital control cannot be directly migrated to logic control to enlighten the distinction between functions and implementations. In addition, in the common view of application technicians, logic control design is strictly connected to the adopted implementation technology (relays in the past, software nowadays), leading again to a deep confusion among functional view and technological view. In Industrial automation software engineering, concepts as modularity, encapsulation, composability and reusability are strongly emphasized and profitably realized in the so-calledobject-oriented methodologies. Industrial automation is receiving lately this approach, as testified by some IEC standards IEC 611313, IEC 61499 which have been considered in commercial products only recently. On the other hand, in the scientific and technical literature many contributions have been already proposed to establish a suitable modelling framework for industrial automation. During last years it was possible to note a considerable growth in the exploitation of innovative concepts and technologies from ICT world in industrial automation systems. For what concerns the logic control design, Model Based Design (MBD) is being imported in industrial automation from software engineering field. Another key-point in industrial automated systems is the growth of requirements in terms of availability, reliability and safety for technological systems. In other words, the control system should not only deal with the nominal behaviour, but should also deal with other important duties, such as diagnosis and faults isolations, recovery and safety management. Indeed, together with high performance, in complex systems fault occurrences increase. This is a consequence of the fact that, as it typically occurs in reliable mechatronic systems, in complex systems such as AMS, together with reliable mechanical elements, an increasing number of electronic devices are also present, that are more vulnerable by their own nature. The diagnosis problem and the faults isolation in a generic dynamical system consists in the design of an elaboration unit that, appropriately processing the inputs and outputs of the dynamical system, is also capable of detecting incipient faults on the plant devices, reconfiguring the control system so as to guarantee satisfactory performance. The designer should be able to formally verify the product, certifying that, in its final implementation, it will perform itsrequired function guarantying the desired level of reliability and safety; the next step is that of preventing faults and eventually reconfiguring the control system so that faults are tolerated. On this topic an important improvement to formal verification of logic control, fault diagnosis and fault tolerant control results derive from Discrete Event Systems theory. The aimof this work is to define a design pattern and a control architecture to help the designer of control logic in industrial automated systems. The work starts with a brief discussion on main characteristics and description of industrial automated systems on Chapter 1. In Chapter 2 a survey on the state of the software engineering paradigm applied to industrial automation is discussed. Chapter 3 presentes a architecture for industrial automated systems based on the new concept of Generalized Actuator showing its benefits, while in Chapter 4 this architecture is refined using a novel entity, the Generalized Device in order to have a better reusability and modularity of the control logic. In Chapter 5 a new approach will be present based on Discrete Event Systems for the problemof software formal verification and an active fault tolerant control architecture using online diagnostic. Finally conclusive remarks and some ideas on new directions to explore are given. In Appendix A are briefly reported some concepts and results about Discrete Event Systems which should help the reader in understanding some crucial points in chapter 5; while in Appendix B an overview on the experimental testbed of the Laboratory of Automation of University of Bologna, is reported to validated the approach presented in chapter 3, chapter 4 and chapter 5. In Appendix C some components model used in chapter 5 for formal verification are reported.

On-line adaptive visual tracking

Visual tracking is the problem of estimating some variables related to a target given a video sequence depicting the target. Visual tracking is key to the automation of many tasks, such as visual surveillance, robot or vehicle autonomous navigation, automatic video indexing in multimedia databases. Despite many years of research, long term tracking in real world scenarios for generic targets is still unaccomplished. The main contribution of this thesis is the definition of effective algorithms that can foster a general solution to visual tracking by letting the tracker adapt to mutating working conditions. In particular, we propose to adapt two crucial components of visual trackers: the transition model and the appearance model. The less general but widespread case of tracking from a static camera is also considered and a novel change detection algorithm robust to sudden illumination changes is proposed. Based on this, a principled adaptive framework to model the interaction between Bayesian change detection and recursive Bayesian trackers is introduced. Finally, the problem of automatic tracker initialization is considered. In particular, a novel solution for categorization of 3D data is presented. The novel category recognition algorithm is based on a novel 3D descriptors that is shown to achieve state of the art performances in several applications of surface matching.

Nonlinear Control Strategies for Cooperative Control of Multi-Robot Systems

This thesis deals with distributed control strategies for cooperative control of multi-robot systems. Specifically, distributed coordination strategies are presented for groups of mobile robots. The formation control problem is initially solved exploiting artificial potential fields. The purpose of the presented formation control algorithm is to drive a group of mobile robots to create a completely arbitrarily shaped formation. Robots are initially controlled to create a regular polygon formation. A bijective coordinate transformation is then exploited to extend the scope of this strategy, to obtain arbitrarily shaped formations. For this purpose, artificial potential fields are specifically designed, and robots are driven to follow their negative gradient. Artificial potential fields are then subsequently exploited to solve the coordinated path tracking problem, thus making the robots autonomously spread along predefined paths, and move along them in a coordinated way. Formation control problem is then solved exploiting a consensus based approach. Specifically, weighted graphs are used both to define the desired formation, and to implement collision avoidance. As expected for consensus based algorithms, this control strategy is experimentally shown to be robust to the presence of communication delays. The global connectivity maintenance issue is then considered. Specifically, an estimation procedure is introduced to allow each agent to compute its own estimate of the algebraic connectivity of the communication graph, in a distributed manner. This estimate is then exploited to develop a gradient based control strategy that ensures that the communication graph remains connected, as the system evolves. The proposed control strategy is developed initially for single-integrator kinematic agents, and is then extended to Lagrangian dynamical systems.

Distributed Large-scale Mixed-Integer Optimization with Application to Energy and Multi-robot Networks

Several decision and control tasks in cyber-physical networks can be formulated as large- scale optimization problems with coupling constraints. In these "constraint-coupled" problems, each agent is associated to a local decision variable, subject to individual constraints. This thesis explores the use of primal decomposition techniques to develop tailored distributed algorithms for this challenging set-up over graphs. We first develop a distributed scheme for convex problems over random time-varying graphs with non-uniform edge probabilities. The approach is then extended to unknown cost functions estimated online. Subsequently, we consider Mixed-Integer Linear Programs (MILPs), which are of great interest in smart grid control and cooperative robotics. We propose a distributed methodological framework to compute a feasible solution to the original MILP, with guaranteed suboptimality bounds, and extend it to general nonconvex problems. Monte Carlo simulations highlight that the approach represents a substantial breakthrough with respect to the state of the art, thus representing a valuable solution for new toolboxes addressing large-scale MILPs. We then propose a distributed Benders decomposition algorithm for asynchronous unreliable networks. The framework has been then used as starting point to develop distributed methodologies for a microgrid optimal control scenario. We develop an ad-hoc distributed strategy for a stochastic set-up with renewable energy sources, and show a case study with samples generated using Generative Adversarial Networks (GANs). We then introduce a software toolbox named ChoiRbot, based on the novel Robot Operating System 2, and show how it facilitates simulations and experiments in distributed multi-robot scenarios. Finally, we consider a Pickup-and-Delivery Vehicle Routing Problem for which we design a distributed method inspired to the approach of general MILPs, and show the efficacy through simulations and experiments in ChoiRbot with ground and aerial robots.

Safe and Collaborative Navigation & Interaction With Mobile Manipulators in Domestic Appliance Test Labs

Safe collaboration between a robot and human operator forms a critical requirement for deploying a robotic system into a manufacturing and testing environment. In this dissertation, the safety requirement for is developed and implemented for the navigation system of the mobile manipulators. A methodology for human-robot co-existence through a 3d scene analysis is also investigated. The proposed approach exploits the advance in computing capability by relying on graphic processing units (GPU’s) for volumetric predictive human-robot contact checking. Apart from guaranteeing safety of operators, human-robot collaboration is also fundamental when cooperative activities are required, as in appliance test automation floor. To achieve this, a generalized hierarchical task controller scheme for collision avoidance is developed. This allows the robotic arm to safely approach and inspect the interior of the appliance without collision during the testing procedure. The unpredictable presence of the operators also forms dynamic obstacle that changes very fast, thereby requiring a quick reaction from the robot side. In this aspect, a GPU-accelarated distance field is computed to speed up reaction time to avoid collision between human operator and the robot. An automated appliance testing also involves robotized laundry loading and unloading during life cycle testing. This task involves Laundry detection, grasp pose estimation and manipulation in a container, inside the drum and during recovery grasping. A wrinkle and blob detection algorithms for grasp pose estimation are developed and grasp poses are calculated along the wrinkle and blobs to efficiently perform grasping task. By ranking the estimated laundry grasp poses according to a predefined cost function, the robotic arm attempt to grasp poses that are more comfortable from the robot kinematic side as well as collision free on the appliance side. This is achieved through appliance detection and full-model registration and collision free trajectory execution using online collision avoidance.

Towards automation of constellation management with analytical models for collision avoidance

The growing interest for constellation of small, less expensive satellites is bringing space junk and traffic management to the attention of space community. At the same time, the continuous quest for more efficient propulsion systems put the spotlight on electric (low thrust) propulsion as an appealing solution for collision avoidance. Starting with an overview of the current techniques for conjunction assessment and avoidance, we then highlight the possible problems when a low thrust propulsion is used. The need for accurate propagation model shows up from the conducted simulations. Thus, aiming at propagation models with low computational burden, we study the available models from the literature and propose an analytical alternative to improve propagation accuracy. The model is then tested in the particular case of a tangential maneuver. Results show that the proposed solution significantly improve on state of the art methods and is a good candidate to be used in collision avoidance operations. For instance to propagate satellite uncertainty or optimizing avoidance maneuver when conjunction occurs within few (3-4) orbits from measurements time.

Sviluppo di un sistema di Realta Aumentata applicato a un modello 3D della prostata, sviluppato a partire da immagini RM, al fine di facilitare la dissezione del tumore e la conservazione dei fasci neuro vascolari durante l'intervento chirurgico di prostatectomia radicale robot-assistita

La realtà aumentata (AR) è una nuova tecnologia adottata in chirurgia prostatica con l'obiettivo di migliorare la conservazione dei fasci neurovascolari (NVB) ed evitare i margini chirurgici positivi (PSM). Abbiamo arruolato prospetticamente pazienti con diagnosi di cancro alla prostata (PCa) sul base di biopsia di fusione mirata con mpMRI positiva. Prima dell'intervento, i pazienti arruolati sono stati indirizzati a sottoporsi a ricostruzione del modello virtuale 3D basato su mpMRI preoperatoria immagini. Infine, il chirurgo ha eseguito la RARP con l'ausilio del modello 3D proiettato in AR all'interno della console robotica (RARP guidata AR-3D). I pazienti sottoposti a AR RARP sono stati confrontati con quelli sottoposti a "RARP standard" nello stesso periodo. Nel complesso, i tassi di PSM erano comparabili tra i due gruppi; I PSM a livello della lesione indice erano significativamente più bassi nei pazienti riferiti al gruppo AR-3D (5%) rispetto a quelli nel gruppo di controllo (20%; p = 0,01). La nuova tecnica di guida AR-3D per l'analisi IFS può consentono di ridurre i PSM a livello della lesione dell'indice

1° level of automation: the effectiveness of adaptive cruise control on driving and visual behaviour

The research activities have allowed the analysis of the driver assistance systems, called Advanced Driver Assistance Systems (ADAS) in relation to road safety. The study is structured according to several evaluation steps, related to definite on-site tests that have been carried out with different samples of users, according to their driving experience with the ACC. The evaluation steps concern: •The testing mode and the choice of suitable instrumentation to detect the driver’s behaviour in relation to the ACC. •The analysis modes and outputs to be obtained, i.e.: - Distribution of attention and inattention; - Mental workload; - The Perception-Reaction Time (PRT), the Time To Collision (TTC) and the Time Headway (TH). The main purpose is to assess the interaction between vehicle drivers and ADAS, highlighting the inattention and variation of the workloads they induce regarding the driving task. The research project considered the use of a system for monitoring visual behavior (ASL Mobile Eye-XG - ME), a powerful GPS that allowed to record the kinematic data of the vehicle (Racelogic Video V-BOX) and a tool for reading brain activity (Electroencephalographic System - EEG). Just during the analytical phase, a second and important research objective was born: the creation of a graphical interface that would allow exceeding the frame count limit, making faster and more effective the labeling of the driver’s points of view. The results show a complete and exhaustive picture of the vehicle-driver interaction. It has been possible to highlight the main sources of criticalities related to the user and the vehicle, in order to concretely reduce the accident rate. In addition, the use of mathematical-computational methodologies for the analysis of experimental data has allowed the optimization and verification of analytical processes with neural networks that have made an effective comparison between the manual and automatic methodology.

Preventing worker’s musculoskeletal disorders with wearable inertial sensors: ergonomics and modelling of physical human-robot interactions

The most widespread work-related diseases are musculoskeletal disorders (MSD) caused by awkward postures and excessive effort to upper limb muscles during work operations. The use of wearable IMU sensors could monitor the workers constantly to prevent hazardous actions, thus diminishing work injuries. In this thesis, procedures are developed and tested for ergonomic analyses in a working environment, based on a commercial motion capture system (MoCap) made of 17 Inertial Measurement Units (IMUs). An IMU is usually made of a tri-axial gyroscope, a tri-axial accelerometer, and a tri-axial magnetometer that, through sensor fusion algorithms, estimates its attitude. Effective strategies for preventing MSD rely on various aspects: firstly, the accuracy of the IMU, depending on the chosen sensor and its calibration; secondly, the correct identification of the pose of each sensor on the worker’s body; thirdly, the chosen multibody model, which must consider both the accuracy and the computational burden, to provide results in real-time; finally, the model scaling law, which defines the possibility of a fast and accurate personalization of the multibody model geometry. Moreover, the MSD can be diminished using collaborative robots (cobots) as assisted devices for complex or heavy operations to relieve the worker's effort during repetitive tasks. All these aspects are considered to test and show the efficiency and usability of inertial MoCap systems for assessing ergonomics evaluation in real-time and implementing safety control strategies in collaborative robotics. Validation is performed with several experimental tests, both to test the proposed procedures and to compare the results of real-time multibody models developed in this thesis with the results from commercial software. As an additional result, the positive effects of using cobots as assisted devices for reducing human effort in repetitive industrial tasks are also shown, to demonstrate the potential of wearable electronics in on-field ergonomics analyses for industrial applications.

A ROS-based software architecture for a versatile collaborative dual-armed autonomous mobile robot for the manufacturing industry

The industrial context is changing rapidly due to advancements in technology fueled by the Internet and Information Technology. The fourth industrial revolution counts integration, flexibility, and optimization as its fundamental pillars, and, in this context, Human-Robot Collaboration has become a crucial factor for manufacturing sustainability in Europe. Collaborative robots are appealing to many companies due to their low installation and running costs and high degree of flexibility, making them ideal for reshoring production facilities with a short return on investment. The ROSSINI European project aims to implement a true Human-Robot Collaboration by designing, developing, and demonstrating a modular and scalable platform for integrating human-centred robotic technologies in industrial production environments. The project focuses on safety concerns related to introducing a cobot in a shared working area and aims to lay the groundwork for a new working paradigm at the industrial level. The need for a software architecture suitable to the robotic platform employed in one of three use cases selected to deploy and test the new technology was the main trigger of this Thesis. The chosen application consists of the automatic loading and unloading of raw-material reels to an automatic packaging machine through an Autonomous Mobile Robot composed of an Autonomous Guided Vehicle, two collaborative manipulators, and an eye-on-hand vision system for performing tasks in a partially unstructured environment. The results obtained during the ROSSINI use case development were later used in the SENECA project, which addresses the need for robot-driven automatic cleaning of pharmaceutical bins in a very specific industrial context. The inherent versatility of mobile collaborative robots is evident from their deployment in the two projects with few hardware and software adjustments. The positive impact of Human-Robot Collaboration on diverse production lines is a motivation for future investments in research on this increasingly popular field by the industry.