Adaptive robotic assembly of compliant aero-structure components

The application of robotics to the assembly of large aero-structures has been limited by the large size and inherent compliance of the components involved. The compliance of the components is significant and simple ‘pick and place’ approaches cannot be used due to the inherent dimensional variability between mating parts. The research described in this paper aims to solve this problem by using a non-contact sensing system to measure part deformation and misalignment in real time. The acquired data can then be processed through a mathematical algorithm to calculate the relative component positions required for optimal assembly. The data can also be used to check gross distortion of components and to reject those outside the specification limits. Existing part-to-part holes were used to provide alignment for individual components within the structure. A series of experiments were performed to investigate the feasibility of the method. Results are presented along with a discussion of the problems that may be encountered during robotic assembly. The experimental results show that robots when combined with non-contact metrology can be used for the assembly of compliant aero-structure components within required tolerance limits.     

机器人柔性腕力传感器及其检测系统

介绍了一种集被动柔顺和力传感器于一身的机器人柔性腕力传感器,该传感器采用非接触式的光电检测装置进行位置/姿态变换的检测,检测准确度高,不易受到干扰,通过USB接口与计算机进行数据传输,接口方便。     

Design of a bio-inspired contact-aided compliant wrist

This paper reports about the design of a bio-inspired compliant wrist, whose mobility (i.e. ulnar-radial deviation and flexion-extension) has been realized by employing two pairs of contact-aided Cross-Axis Flexural Pivots (CAFPs), actuated via remotely-placed servo-motors and tendon transmissions. The human wrist behaves differently when deflecting in clockwise or anticlockwise direction, both in terms of maximum angular deflection and passive stiffness. The device proposed hereafter aims at mimicking such natural asymmetry, while withstanding unexpected external loads. In order to fulfill these requirements, two contacts are included: (i) a pure rolling contact (named passive contact), achieved via a cam mechanism guiding the CAFP deflection and ensuring the wrist resistance to compressive loads; (ii) a purposely shaped contact pair (named active contact), acting on one beam of the CAFP so as to increase its stiffness. The design procedures and tools specifically developed for the wrist optimization are described. In the first step, a CAFP shape optimization is performed, followed by the synthesis of the active contact pair. In the second step, the centrodes are computed and then used to generate the passive contact profiles. At last, the third step focuses on the definition of the tendons routing. To prove the validity of the numerical models, a physical prototype of the wrist is produced and tested. Direct comparisons between simulations and experiments confirm the efficacy of the proposed design method.     

Decomposition-based bi-objective optimization for sustainable robotic assembly line balancing problems

Due to the increasing greenhouse gas emissions and the energy crisis, the manufacturing industry which is one of the most energy intensive sector is paying close attention to the improvement of environmental performance efficiency. Therefore, in this paper the automated assembly line is balanced in a sustainable way which aims to optimize a green manufacturing objective (the total energy consumption) and a productivity-related objective (similar working load) simultaneously. A comprehensive total energy consumption of each processing stage was analyzed and modeled. To make the model more practical, a sequence-based changeover time and robots with different efficiencies and energy consuming rates are considered and optimized. To properly solve the problem, the proposed novel optimal solution takes the well-known MOEA/D as a base and incorporates a well-designed coding scheme and a problem-specific local search mechanism. Computational experiments are conducted to evaluated each improving strategies of the algorithm and its superiority over two other high-performing multi-objective optimization methods. The model allows decision makers to select more sustainable assembly operations based on their decision impacts in both productivity and energy-saving.     

Fuzzy inference mechanism for recognition of contact states in intelligent robotic assembly

This paper presents a methodology for generating a fuzzy inference mechanism (FIM) for recognizing contact states within robotic part mating using active compliant motion. In the part mating process, significant uncertainties are inherently present. As a result it is pertinent that contact states recognition systems operating in such environment be able to make decisions on the contact state currently present in the process, based on data full of uncertainties and imprecision. In such conditions, implementation of fuzzy logic and interval inference brings significant robustness to the system. As a starting point for FIM generation, we use a quasi-static model of the mating force between objects. By applying Discrete Wavelet Transform to the signal generated using this model, we extract qualitative and representative features for classification into contact states. Thus, the obtained patterns are optimally classified using support vector machines (SVM). We exploit the equivalence of SVM and Takagi–Sugeno fuzzy rules based systems for generation of FIM for classification into contact states. In this way, crisp granulation of the feature space obtained using SVM is replaced by optimal fuzzy granulation and robustness of the recognition system is significantly increased. The information machine for contact states recognition that is designed using the given methodology simultaneously uses the advantages of creation of machine based on the process model and the advantages of application of FIM. Unlike the common methods, our approach for creating a knowledge base for the inference machine is neither heuristic, intuitive nor empirical. The proposed methodology was elaborated and experimentally tested using an example of a cylindrical peg in hole as a typical benchmark test.     

Fuzzy logic control synthesis without any rule base

A new analytic fuzzy logic control (FLC) system synthesis without any rule base is proposed. For this purpose the following objectives are preferred and reached: 1) an introduction of a new adaptive shape of fuzzy sets and a new adaptive distribution of input fuzzy sets, 2) a determination of an analytic activation function for activation of output fuzzy sets, instead of using of min-max operators, and 3) a definition of a new analytic function that determines the positions of centers of output fuzzy sets in each mapping process, instead of definition of the rule base. A real capability of the proposed FLC synthesis procedures is presented by synthesis of FLC of robot of RRTR-structure.     

Evolutionary optimization of robotic assembly operation sequencing with collision-free paths

Many problems in the lifecycle of product and production development (PPD) can be formulated as optimization problems. But in most of the real-world cases, they are too complex to be solved by analytical models or classical optimization methods. CAx and virtual manufacturing (VM) tools are on the other hand being employed to create virtual representation of products and processes before any physical realization is conducted. Synergy of these two domains is of interest in this paper where planning a process with the minimum cycle-time for assembling a spot welded sheet-metal product is desired. The methodology suggests an extendible virtual manufacturing-based optimization approach using evolutionary algorithms. Accordingly, a novel toolset with integration of evolutionary optimization and a commercial VM environment is developed. More specifically, the latest feature which takes advantage of the collision avoidant segment path planning functionality of the VM tool and integrates it with the sequence optimizer is described.     

Fuzzy rule base systems verification using high-level Petri nets

In this paper, we propose a Petri nets formalism for the verification of rule-based systems. Typical structural errors in a rule-based system are redundancy, inconsistency, incompleteness, and circularity. Since our verification is based on Petri nets and their incidence matrix, we need to transform rules into a Petri nets first, then derive an incidence matrix from the net. In order to let fuzzy rule-based systems detect above the structural errors, we are presenting a Petri-nets-based mechanism. This mechanism consists of three phases: rule normalization, rules transformation, and rule verification. Rules will be first normalized into Horn clauses, then transform the normalized rules into a high-level Petri net, and finally we verify these normalized rules. In addition, we are presenting our approach to simulate the truth conditions which still hold after a transition firing and negation in Petri nets for rule base modeling. In this paper, we refer to fuzzy rules as the rules with certainty factors, the degree of truth is computed in an algebraic form based on state equation which can be implemented in matrix computation in Petri nets. Therefore, the fuzzy reasoning problems can be transformed as the liner equation problems that can be solved in parallel. We have implemented a Petri nets tool to realize the mechanism presented fuzzy rules in this paper.     

稀疏规则库条件下的模糊推理方法

当模糊规则库是稀疏型时,利用Kóczy线性插值推理方法不能保证推理结论的正规性和凸性,为了解决这一问题,石岩曾提出了插值推理方法的推理条件,当满足这些条件时利用Kóczy线性插值推理方法得到的推理结论也满足正规性和凸性;但是这些条件却限制了模糊推理系统的应用,而且如果多次推理中在同一输入点遇到稀疏情况,必须进行相同的计算才能得到正确的推理结果,这样增加了系统的计算量,降低了系统的速度和效率.因此提出了一种新的稀疏模糊推理方法,不仅能够简单的给出正确的推理结果,还能在相应的位置增加规则,提高规则库的紧密程度.     

Adaptive neuro fuzzy controller for adaptive compliant robotic gripper

The requirement for new flexible adaptive grippers is the ability to detect and recognize objects in their environments. It is known that robotic manipulators are highly nonlinear systems, and an accurate mathematical model is difficult to obtain, thus making it difficult то control using conventional techniques. Here, a novel design of an adaptive neuro fuzzy inference strategy (ANFIS) for controlling input displacement of a new adaptive compliant gripper is presented. This design of the gripper has embedded sensors as part of its structure. The use of embedded sensors in a robot gripper gives the control system the ability to control input displacement of the gripper and to recognize particular shapes of the grasping objects. Since the conventional control strategy is a very challenging task, fuzzy logic based controllers are considered as potential candidates for such an application. Fuzzy based controllers develop a control signal which yields on the firing of the rule base. The selection of the proper rule base depending on the situation can be achieved by using an ANFIS controller, which becomes an integrated method of approach for the control purposes. In the designed ANFIS scheme, neural network techniques are used to select a proper rule base, which is achieved using the back propagation algorithm. The simulation results presented in this paper show the effectiveness of the developed method.     

利用MISA多目标优化的置信规则库分类算法

现有基于置信规则库的分类系统的分类准确率和效率受到系统参数设置以及规则库结构合理性的影响。为了寻找到最佳的参数值和最优的规则库结构,本文结合多目标免疫系统算法（multiobjective immune system algorithm, MISA）提出利用MISA多目标优化的置信规则库分类算法。该方法融合特征属性约简思想和差分进化算法思想建立训练模型,采用多目标免疫系统算法对系统复杂度和分类准确率进行多目标优化,从而寻找到分类模型的最优解。在实验分析中,首先将本文提出的置信规则库多目标分类系统MISA-BRM和置信规则库分类系统的实验结果进行对比,从复杂度和准确率两个维度说明本文方法的有效性。同时还将本文方法与现有的其他分类方法进行比较,验证本文方法的可行性和有效性。实验结果表明,本文方法能够有效地对基于置信规则库的分类系统的准确率和复杂度进行多目标优化。     

Multi-objective optimization design for a sand crab-inspired compliant microgripper

A large working travel and a minimal stress are the most critical characteristics of a microgripper but they are conflicted each other. This paper develops a new efficient hybrid algorithm to solve the multi-objective optimization design for a sand bubbler crab-inspired compliant microgripper. The structure of sand bubbler crab-inspired compliant microgripper is inspired from the profile of sand bubbler crab. A surrogate-assisted multi-objective optimization is conducted by developing a hybrid approach of finite element analysis, response surface method, Kigring metamodel and multi-objective genetic algorithm. First, the data are collected by integrating the finite element analysis and response surface method. Subsequently, in the types of common surrogates, Kigring metamodel is adopted as an efficient tool to approximate the objective functions. And then, the Pareto-optimal fronts are found via the multi-objective genetic algorithm. The results indicated that the optimal results are at the displacement of 5999.9 µm and stress of 330.68 MPa. The results revealed that the optimized results are highly consistent with both the validation results. The accuracy of the surrogate models showed that the regression model is a good prediction. The proposed approach is useful tool to solve complex optimization designs.

     

Fuzzy random multi-objective optimization based routing for wireless sensor networks

Wireless sensor networks are deployed in complex and uncertain environments, and multiple objectives of routing algorithms are expected to be optimal. However, routing algorithms based on deterministic single objective optimization may not flexibly meet the above needs of applications. This paper adopts fuzzy random optimization and multi-objective optimization, introduces fuzzy random variables to describe both fuzziness and randomness of link delay, link reliability and nodes’ residual energy, and proposes a routing model based on fuzzy random expected value and standard deviation model. A hybrid routing algorithm based on fuzzy random multi-objective optimization is designed, which embeds fuzzy random simulation into genetic algorithm with Pareto optimal solution. Simulation results show that the presented algorithm, by adjusting the parameters of fuzzy random variables for depicting both fuzziness and randomness, achieves a longer lifetime and wider performances of delay, latency jitter, reliability, communication interference, energy and balanced energy distribution. Therefore, the presented algorithm can meet different application needs of the cluster head network in the two-tiered wireless sensor networks.     

A bio-inspired approach for self-correcting compliant assembly systems

Statistical process monitoring and control has been popularized in manufacturing as well as various other industries interested in improving product quality and reducing costs. Advances in this field have focused primarily on more efficient ways for diagnosing faults, reducing variation, developing robust design techniques, and increasing sensor capabilities. However, statistical process monitoring cannot address the need for instant variation reduction during assembly operations. This paper presents a unique dimensional error-compensation approach for compliant sheet metal assembly processes. The resulting autonomous self-correction system integrates rapidly advancing data mining methods, physical models, assembly modeling techniques, sensor capabilities, and actuator networks to implement part-by-part dimensional error compensation. Inspired by biological systems, the proposed quality control approach utilizes immunological principles as a means of developing the required mathematical framework behind the self-correcting methodology. The resulting assembly system obtained through this bio-mimicking approach will be used for autonomous monitoring, detection, diagnosis, and control of station and system level faults, contrary to traditional systems that largely rely on final product measurements and expert analysis to eliminate process faults.     

Fuzzy rule optimization for online auction frauds detection based on genetic algorithm

Due to the huge amount of users and low entrance cost of online auction, there are a lot of online fraud cases in online auction sites. According to the IC3 reports from 2003 to 2010, we can understand the fraud cases and victims are increasing rapidly year by year. To improve the prevention of online auction frauds, this research will propose a hybrid approach to detect the fraudster accounts to help the users to identify which seller is more dangerous. In this research, we use social network analysis to produce the behavior features and transform these features into fuzzy rules which can represent the detection rules. Then optimize the fuzzy rules by genetic algorithms to build the auction fraud detection model. For implementation, we collect the real auction data from the online auction site http://www.ruten.com.tw which is the most popular auction site in Taiwan. Finally, we use the proposed features and methodologies to detect the fraudster accounts and find out the detection models of them. We hope the result of this research can help the website administrators to detect the possible collusive fraud groups easier in online auction.     

Proposal of a shape adaptive gripper for robotic assembly tasks

This paper proposes a novel robotic gripper used for assembly tasks that can adaptively grasp objects with different shapes. The proposed hand has a combined structure between two kinds of shape adaptive mechanisms where one is the granular jamming and the other is a multi-finger mechanism driven by a single wire. Due to the effect of the two shape adaptive mechanisms, the pose of a grasped object does not change during an assembly operation. The proposed hand has four fingers where two are the active ones and the other two are the passive ones. The pose of the grasped object can be uniquely determined since the passive fingers are used to orient an object placed on a table before the active fingers are closed to grasp it. Assembly experiments of some kinds of parts are shown to validate the effectiveness of our proposed gripper.     

基于变速粒子群优化的置信规则库参数训练方法

针对置信规则库(BRB)中参数优化模型的求解问题,引入群智能算法中的粒子群优化(PSO)算法,提出一种新的参数训练方法。将参数优化模型求解问题转换为带约束条件的非线性优化问题,在迭代寻优时限制粒子在搜索空间中,对失去速度的粒子重新赋予速度,维持种群中粒子多样性,从而实现参数训练。在输油管道检漏问题仿真实验中,训练后系统的平均绝对误差(MAE)为0.166478。实验结果表明,所提方法有理想的收敛精度,可用于置信规则库参数训练。     

Adaptive parameter optimization approach for robotic grinding of weld seam based on laser vision sensor

Automatic robot grinding technology has been widely applied in the modern manufacturing industry. A flexible abrasive belt wheel used to grind the weld can avoid burns on the base material and improve the processing efficiency. However, when the robot grinds a weld seam, the material removal depth does not coincide with the feed depth because of the soft contact and uneven weld height, affecting the weld seam surface uniformity. Given these problems, an adaptive parameter optimization approach for the robotic grinding of a weld seam was proposed based on a laser vision sensor and a material removal model. First, the depth of weld seam removal was obtained by a laser vision sensor based on triangulation in real-time. Then, a macroscopic material removal model considering flexible deformation was established to determine the relationship between the weld height and process parameters, and the model coefficient was experimentally fitted to ensure the accuracy and reliability of the model. In addition, the data of real-time interaction structure between the robot controller and grinding system were obtained and used to unsure that the rotational speed of the belt wheel increased in the convex part and decreased in the concave part, in order to obtain a uniform weld seam surface. Comparative experiments were performed to verify the effectiveness and superiority of the method, and experiments on the surface roughness and weld seam surface height difference were conducted to verify the universality of the method. Experimental results show that the residual height of the weld after grinding can be controlled within 0.2mm, and the maximum removal height difference can be controlled within 0.05mm. The surface roughness Ra of the weld after grinding could reach 0.408 µm.