in flexible robotic assembly lines Niki Kousi, Christos Gkournelos , - - PowerPoint PPT Presentation

CIRP CARV Conference 2018

08-10 October 2018 Nantes, France

Digital twin for adaptation of robots’ behavior in flexible robotic assembly lines

Niki Kousi, Christos Gkournelos, Sotiris Aivaliotis, Christos Giannoulis, George Michalos, Sotiris Makris

Laboratory for Manufacturing Systems & Automation (LMS)

• Dept. of Mechanical Engineering & Aeronautics

University of Patras, Greece www.lms.mech.upatras.gr

Laboratory for Manufacturing Systems and Automation (LMS) Department of Mechanical Engineering and Aeronautics, University of Patras, Greece

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Contents

▪ Introduction ▪ Hybrid production paradigm ▪ Digital twin infrastructure

• Resource Manager
• Sensor manager
• 3D Environment constructor

▪ Unified data model ▪ Automotive case study ▪ Conclusions ▪ Acknowledgments

Laboratory for Manufacturing Systems and Automation (LMS) Department of Mechanical Engineering and Aeronautics, University of Patras, Greece

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Introduction

Today – Tradition production Tomorrow – Future production

Production system transition to mass customization

Stationary resources – rigid line structure Fixed control logic of the process High cost – effort to make changes in the line-process Market demand for higher product personalization Need for multi product variants Need for Flexible and reconfigurable production lines

Lead to combined with Lead to Lead to

Laboratory for Manufacturing Systems and Automation (LMS) Department of Mechanical Engineering and Aeronautics, University of Patras, Greece

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Hybrid production paradigm

How to enable the dynamic nature of this production paradigm ?

“Perception & skills to automatically program and execute multiple tasks” “Human-Robot & Robot-Robot collaboration in a safe way”

Mobile Product Platform (MPP) Mobile Robot Platform (MRP)

“Enabling mobility on products and resources”

Product & Process Perception Environment Perception

“Dynamic balancing and redirecting to stations”

Laboratory for Manufacturing Systems and Automation (LMS) Department of Mechanical Engineering and Aeronautics, University of Patras, Greece

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Digital twin infrastructure

Resource Nodes

Resource Manager Sensor Manager Layout Manager 3D environment constructor

Unified Data Model Sensor Nodes 3D Scene reconstruction Arm Motion Planner Platform Path Planner Robot behavior adaption

Digital Twin

CAD files

Execution Coordinator

CAD Sensors

Laboratory for Manufacturing Systems and Automation (LMS) Department of Mechanical Engineering and Aeronautics, University of Patras, Greece

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Resource Manager

ROS Driver Driver

: Resource manager

MRP_1 Status topic MRP_1 Location topic MPP_1 Status topic MPP_1 Location Topic

MPP_1 MRP_1

: Status Monitoring : Location Monitoring : Status Monitoring : Location Monitoring ROS Topic Publisher ROS Topic Publisher ROS Topic Subscriber ROS Topic Subscriber ROS Topic Subscriber ROS Topic Subscriber

• The registration of a new

resource into the production system

• The storage of the appropriate

attributes based on the unified resource model

• Realtime monitoring

❖ Resource location ❖ Resource execution status The responsibilities of resource manager are:

Laboratory for Manufacturing Systems and Automation (LMS) Department of Mechanical Engineering and Aeronautics, University of Patras, Greece

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Sensor Manager

ROS Driver rc_visard 65 Kinect MicroScan3 rc_visard 160 ROS Driver ROS Driver ROS Driver ROS Topic Publisher ROS Topic Publisher ROS Topic Publisher ROS Topic Publisher

: Sensor manager

rc_visard 160 topic MicroScan3 topic Kinect topic rc_visard 65 topic

: 2D-3D Sensor Data combination

Fused data topic ROS Topic Subscriber ROS Topic Subscriber ROS Topic Subscriber ROS Topic Subscriber ROS Topic Subscriber

• The interfacing with the existing’s

sensors’ ROS drivers.

• The storage of the appropriate

configuration files based on the unified sensor model

• Sensor data combination

for merging multiple, sensor data into one topic The responsibilities of sensor manager are:

Laboratory for Manufacturing Systems and Automation (LMS) Department of Mechanical Engineering and Aeronautics, University of Patras, Greece

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Layout Manager

• The storage of the CADs files of

fixtures, parts and products.

• The creation of the .sdf files

containing the collisions and the inertia attributes

• The relative positions between

parts and static fixtures The responsibilities of layout manager are:

Laboratory for Manufacturing Systems and Automation (LMS) Department of Mechanical Engineering and Aeronautics, University of Patras, Greece

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3D Environment Constructor

Generated Tf tree 3D Environment constructor rc_visard URDF file MRP URDF file Product SDF file TF topic tree MPP URDF file Kinect URDF file Laser Scanner URDF file Fixtures SDF file

Sensors Manager Layout s Manager

Resources Manager

Publish tf data

Laboratory for Manufacturing Systems and Automation (LMS) Department of Mechanical Engineering and Aeronautics, University of Patras, Greece

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Unified world data model

Laboratory for Manufacturing Systems and Automation (LMS) Department of Mechanical Engineering and Aeronautics, University of Patras, Greece

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Automotive case study (1/3)

Station Task Resource Duration S1 Pre-assembly of right damper Human 12 secs S1 Load damper on comp. machine Human 5 secs S1 Compression of right damper & Alignment / Nut insertion during the compression Human –

• Comp. mach.

20 secs (human - 8 secs) S1 Load comp. damper on AGV Human 5 secs S2 Pre-assembly of left damper Human 12 secs S2 Load damper on comp. machine Human 5 secs S2 Compression of right left & Alignment / Nut insertion during the compression Human –

• Comp. mach.

20 secs (human - 8 secs) S2 Load comp. damper on AGV Human 5 secs S3 Screwing machine connect each damper with one disk Screwing machine 57 secs S4 Cables / Screws Insertion Human 50 secs

• Assembly of the front suspension of a

passenger vehicle

• Involves handling, cabling insertion and

screwing operations – 4 workstations

• Manual assembly & 1 automated screwing

machine

• Challenges of the current set up

❖ Ergonomy: up to 480 dampers (6 Kg) are lifted by human operators per shift ❖ Flexibility: the automated screwing machine cannot handle all product variants

Laboratory for Manufacturing Systems and Automation (LMS) Department of Mechanical Engineering and Aeronautics, University of Patras, Greece

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Automotive case study (2/3)

Laboratory for Manufacturing Systems and Automation (LMS) Department of Mechanical Engineering and Aeronautics, University of Patras, Greece

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Automotive case study (3/3)

MRP H/W configuration Online robot arm motion planning

3D Octomap

Online robot base path planning

Moving

• bstacle

Integrated software components:

Online robot instruction with gestures

Laboratory for Manufacturing Systems and Automation (LMS) Department of Mechanical Engineering and Aeronautics, University of Patras, Greece

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Conclusions

The benefits of the proposed infrastructure for a production system

✓ Robustness against the real-world uncertainty ✓ Generic enough to be applicable in various use cases ✓ Fast and easy integration of new resources

Future work

➢ Integration with the physical robotic set up ➢ Performance validation in the proposed infrastructure ➢ Integration with a high level decision mechanism for online task re-allocation

Laboratory for Manufacturing Systems and Automation (LMS) Department of Mechanical Engineering and Aeronautics, University of Patras, Greece

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Acknowledgments

THOMAS Mobile dual arm robotic workers with embedded cognition for hybrid and dynamically reconfigurable manufacturing systems

(Grant Agreement: 723616)

http://www.thomas-project.eu

http://www.thomas-project.eu/facebook http://www.thomas-project.eu/youtube http://www.thomas-project.eu/twitter http://www.thomas-project.eu/googleplus http://www.thomas-project.eu/linkedin

CIRP CARV Conference 2018

08-10 October 2018 Nantes, France

THANK YOU!

Laboratory for Manufacturing Systems & Automation (LMS)

• Dept. of Mechanical Engineering & Aeronautics

University of Patras, Greece www.lms.mech.upatras.gr