Transforming Industrial Manipulators via Kinesthetic Guidance for Automated Inspection of Complex Geometries

Author:

Loukas Charalampos1ORCID,Vasilev Momchil1,Zimmerman Rastislav1,Vithanage Randika K. W.1ORCID,Mohseni Ehsan1,MacLeod Charles N.1,Lines David1ORCID,Pierce Stephen Gareth1,Williams Stewart2,Ding Jialuo2,Burnham Kenneth3,Sibson Jim4,O’Hare Tom5ORCID,Grosser Michael R.6

Affiliation:

1. SEARCH: Sensor Enabled Automation, Robotics & Control Hub, Centre for Ultrasonic Engineering (CUE), Department of Electronic & Electrical Engineering, University of Strathclyde, Royal College Building, 204 George Street, Glasgow G1 1XW, UK

2. Welding Engineering and Laser Processing Centre, University of Cranfield, Cranfield MK43 0AL, UK

3. Digital Factory, NMIS, Industrial Business Park, Renfrew PA4 8BE, UK

4. Babcock International Group PLC, Bristol BS16 1EJ, UK

5. Spirit Aerosystems Belfast, Belfast BT3 9DZ, Northern Ireland, UK

6. Spirit Aerosystems, Wichita, KS 67210, USA

Abstract

The increased demand for cost-efficient manufacturing and metrology inspection solutions for complex-shaped components in High-Value Manufacturing (HVM) sectors requires increased production throughput and precision. This drives the integration of automated robotic solutions. However, the current manipulators utilizing traditional programming approaches demand specialized robotic programming knowledge and make it challenging to generate complex paths and adapt easily to unique specifications per component, resulting in an inflexible and cumbersome teaching process. Therefore, this body of work proposes a novel software system to realize kinesthetic guidance for path planning in real-time intervals at 250 Hz, utilizing an external off-the-shelf force–torque (FT) sensor. The proposed work is demonstrated on a 500 mm2 near-net-shaped Wire–Arc Additive Manufacturing (WAAM) complex component with embedded defects by teaching the inspection path for defect detection with a standard industrial robotic manipulator in a collaborative fashion and adaptively generating the kinematics resulting in the uniform coupling of ultrasound inspection. The utilized method proves superior in performance and speed, accelerating the programming time using online and offline approaches by an estimate of 88% to 98%. The proposed work is a unique development, retrofitting current industrial manipulators into collaborative entities, securing human job resources, and achieving flexible production.

Funder

EPSRC

Publisher

MDPI AG

Subject

Electrical and Electronic Engineering,Biochemistry,Instrumentation,Atomic and Molecular Physics, and Optics,Analytical Chemistry

Reference38 articles.

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2. Pan, Z., Polden, J., Larkin, N., Duin, S.V., and Norrish, J. (2010, January 7–9). Recent Progress on Programming Methods for Industrial Robots. Proceedings of the ISR 2010 (41st International Symposium on Robotics) and ROBOTIK 2010 (6th German Conference on Robotics), Munich, Germany.

3. Heimann, O., and Guhl, J. (2020, January 8–11). Industrial Robot Programming Methods: A Scoping Review. Proceedings of the 2020 25th IEEE International Conference on Emerging Technologies and Factory Automation (ETFA), Vienna, Austria.

4. Robot Technology in the Shipyard Production Environment;Sagatun;J. Ship Prod.,1996

5. Generating a Job Description for Motion Planning;Jacobsen;IFAC Proc. Vol.,2007

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