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
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, 2 University of Patras, Greece
Introduction Production system transition to mass customization Tomorrow – Future production Today – Tradition production Stationary resources – rigid line Market demand for higher product personalization structure combined with Lead to Fixed control logic of the process Need for multi product variants Lead to Lead to Need for Flexible and High cost – effort to make reconfigurable production lines changes in the line-process Laboratory for Manufacturing Systems and Automation (LMS) Department of Mechanical Engineering and Aeronautics, 3 University of Patras, Greece
Hybrid production paradigm “Dynamic balancing and Environment Perception redirecting to stations” “Enabling mobility on products and resources” Mobile Product Mobile Robot Platform (MPP) Platform (MRP) “ Human-Robot & Robot-Robot “Perception & skills to collaboration in a safe Product & Process automatically program and Perception way” execute multiple tasks” How to enable the dynamic nature of this production paradigm ? Laboratory for Manufacturing Systems and Automation (LMS) Department of Mechanical Engineering and Aeronautics, 4 University of Patras, Greece
Digital twin infrastructure Execution Coordinator Robot behavior Resource Nodes adaption Digital Twin Arm Motion 3D Scene reconstruction Planner Resource Manager Sensor Nodes Sensor 3D environment CAD Manager constructor Platform Path Planner Layout Manager CAD files Unified Sensors Data Model Laboratory for Manufacturing Systems and Automation (LMS) Department of Mechanical Engineering and Aeronautics, 5 University of Patras, Greece
Resource Manager The responsibilities of resource MRP_1 MPP_1 manager are: • The registration of a new resource into the production system ROS Driver Driver • The storage of the appropriate ROS Topic ROS Topic attributes based on the unified Publisher Publisher resource model : Resource manager • Realtime monitoring MRP_1 Status MRP_1 MPP_1 Status MPP_1 ❖ Resource location topic Location topic topic Location Topic ROS Topic ROS Topic ROS Topic ROS Topic Subscriber Subscriber Subscriber Subscriber ❖ Resource execution status : Status : Location : Status : Location Monitoring Monitoring Monitoring Monitoring Laboratory for Manufacturing Systems and Automation (LMS) Department of Mechanical Engineering and Aeronautics, 6 University of Patras, Greece
Sensor Manager The responsibilities of sensor rc_visard 65 rc_visard 160 MicroScan3 Kinect manager are: • The interfacing with the existing’s ROS ROS ROS ROS Driver Driver Driver Driver sensors’ ROS drivers. ROS Topic ROS Topic ROS Topic ROS Topic Publisher Publisher Publisher Publisher • The storage of the appropriate configuration files based on the unified sensor model : Sensor manager • rc_visard MicroScan3 rc_visard Sensor data combination Kinect topic 160 topic topic 65 topic for merging multiple, sensor data : 2D-3D into one topic Sensor Data combination Fused data topic ROS Topic ROS Topic ROS Topic ROS Topic ROS Topic Subscriber Subscriber Subscriber Subscriber Subscriber Laboratory for Manufacturing Systems and Automation (LMS) Department of Mechanical Engineering and Aeronautics, 7 University of Patras, Greece
Layout Manager The responsibilities of layout manager are: • 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 Laboratory for Manufacturing Systems and Automation (LMS) Department of Mechanical Engineering and Aeronautics, 8 University of Patras, Greece
3D Environment Constructor Sensors Manager Kinect URDF file Laser Scanner URDF file rc_visard URDF file MRP URDF file Resources Manager TF topic tree 3D Environment constructor Publish tf data MPP URDF file Generated Tf tree Fixtures SDF file Product SDF file Layout s Manager Laboratory for Manufacturing Systems and Automation (LMS) Department of Mechanical Engineering and Aeronautics, 9 University of Patras, Greece
Unified world data model Laboratory for Manufacturing Systems and Automation (LMS) Department of Mechanical Engineering and Aeronautics, 10 University of Patras, Greece
Automotive case study (1/3) Station Task Resource Duration • Assembly of the front suspension of a Pre-assembly of right damper Human 12 secs S1 passenger vehicle Load damper on comp. machine Human 5 secs S1 Compression of right damper & Human – 20 secs Alignment / Nut insertion during Comp. mach. (human - • Involves handling, cabling insertion and S1 the compression 8 secs) screwing operations – 4 workstations Load comp. damper on AGV Human 5 secs S1 S2 Pre-assembly of left damper Human 12 secs • Manual assembly & 1 automated screwing S2 Load damper on comp. machine Human 5 secs machine S2 Compression of right left & Human – 20 secs Alignment / Nut insertion during Comp. mach. (human - the compression 8 secs) • Challenges of the current set up S2 Load comp. damper on AGV Human 5 secs S3 Screwing machine connect each Screwing 57 secs ❖ Ergonomy: up to 480 dampers (6 Kg) damper with one disk machine S4 Cables / Screws Insertion Human 50 secs 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, 11 University of Patras, Greece
Automotive case study (2/3) Laboratory for Manufacturing Systems and Automation (LMS) Department of Mechanical Engineering and Aeronautics, 12 University of Patras, Greece
Automotive case study (3/3) Integrated software components: MRP H/W configuration Online robot arm motion planning Online robot base path planning Moving 3D Octomap obstacle Online robot instruction with gestures Laboratory for Manufacturing Systems and Automation (LMS) Department of Mechanical Engineering and Aeronautics, 13 University of Patras, Greece
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, 14 University of Patras, Greece
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/googleplus http://www.thomas-project.eu/youtube http://www.thomas-project.eu/linkedin http://www.thomas-project.eu/twitter Laboratory for Manufacturing Systems and Automation (LMS) Department of Mechanical Engineering and Aeronautics, 15 University of Patras, Greece
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
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