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While teleoperation of technical highly sophisticated systems has already been a wide field of research, especially for space and robotics applications, the automation industry has not yet benefited from its results. Besides the established fields of application, also production lines with industrial robots and the surrounding plant components are in need of being remotely accessible. This is especially critical for maintenance or if an unexpected problem cannot be solved by the local specialists.
Special machine manufacturers, especially robotics companies, sell their technology worldwide. Some factories, for example in emerging economies, lack qualified personnel for repair and maintenance tasks. When a severe failure occurs, an expert of the manufacturer needs to fly there, which leads to long down times of the machine or even the whole production line. With the development of data networks, a huge part of those travels can be omitted, if appropriate teleoperation equipment is provided.
This thesis describes the development of a telemaintenance system, which was established in an active production line for research purposes. The customer production site of Braun in Marktheidenfeld, a factory which belongs to Procter & Gamble, consists of a six-axis cartesian industrial robot by KUKA Industries, a two-component injection molding system and an assembly unit. The plant produces plastic parts for electric toothbrushes.
In the research projects "MainTelRob" and "Bayern.digital", during which this plant was utilised, the Zentrum für Telematik e.V. (ZfT) and its project partners develop novel technical approaches and procedures for modern telemaintenance. The term "telemaintenance" hereby refers to the integration of computer science and communication technologies into the maintenance strategy. It is particularly interesting for high-grade capital-intensive goods like industrial robots. Typical telemaintenance tasks are for example the analysis of a robot failure or difficult repair operations. The service department of KUKA Industries is responsible for the worldwide distributed customers who own more than one robot. Currently such tasks are offered via phone support and service staff which travels abroad. They want to expand their service activities on telemaintenance and struggle with the high demands of teleoperation especially regarding security infrastructure. In addition, the facility in Marktheidenfeld has to keep up with the high international standards of Procter & Gamble and wants to minimize machine downtimes. Like 71.6 % of all German companies, P&G sees a huge potential for early information on their production system, but complains about the insufficient quality and the lack of currentness of data.
The main research focus of this work lies on the human machine interface for all human tasks in a telemaintenance setup. This thesis provides own work in the use of a mobile device in context of maintenance, describes new tools on asynchronous remote analysis and puts all parts together in an integrated telemaintenance infrastructure. With the help of Augmented Reality, the user performance and satisfaction could be raised. A special regard is put upon the situation awareness of the remote expert realized by different camera viewpoints. In detail the work consists of:
- Support of maintenance tasks with a mobile device
- Development and evaluation of a context-aware inspection tool
- Comparison of a new touch-based mobile robot programming device to the former teach pendant
- Study on Augmented Reality support for repair tasks with a mobile device
- Condition monitoring for a specific plant with industrial robot
- Human computer interaction for remote analysis of a single plant cycle
- A big data analysis tool for a multitude of cycles and similar plants
- 3D process visualization for a specific plant cycle with additional virtual information
- Network architecture in hardware, software and network infrastructure
- Mobile device computer supported collaborative work for telemaintenance
- Motor exchange telemaintenance example in running production environment
- Augmented reality supported remote plant visualization for better situation awareness
Imagine a technology that automatically creates a full 3D thermal model of an environment and detects temperature peaks in it. For better orientation in the model it is enhanced with color information. The current state of the art for analyzing temperature related issues is thermal imaging. It is relevant for energy efficiency but also for securing important infrastructure such as power supplies and temperature regulation systems. Monitoring and analysis of the data for a large building is tedious as stable conditions need to be guaranteed for several hours and detailed notes about the pose and the environment conditions for each image must be taken. For some applications repeated measurements are necessary to monitor changes over time. The analysis of the scene is only possible through expertise and experience.
This thesis proposes a robotic system that creates a full 3D model of the environment with color and thermal information by combining thermal imaging with the technology of terrestrial laser scanning. The addition of a color camera facilitates the interpretation of the data and allows for other application areas. The data from all sensors collected at different positions is joined in one common reference frame using calibration and scan matching. The first part of the thesis deals with 3D point cloud processing with the emphasis on accessing point cloud data efficiently, detecting planar structures in the data and registering multiple point clouds into one common coordinate system. The second part covers the autonomous exploration and data acquisition with a mobile robot with the objective to minimize the unseen area in 3D space. Furthermore, the combination of different modalities, color images, thermal images and point cloud data through calibration is elaborated. The last part presents applications for the the collected data. Among these are methods to detect the structure of building interiors for reconstruction purposes and subsequent detection and classification of windows. A system to project the gathered thermal information back into the scene is presented as well as methods to improve the color information and to join separately acquired point clouds and photo series.
A full multi-modal 3D model contains all the relevant geometric information about the recorded scene and enables an expert to fully analyze it off-site. The technology clears the path for automatically detecting points of interest thereby helping the expert to analyze the heat flow as well as localize and identify heat leaks. The concept is modular and neither limited to achieving energy efficiency nor restricted to the use in combination with a mobile platform. It also finds its application in fields such as archaeology and geology and can be extended by further sensors.
The principle of targeted separation or weakening of individual components of the abdominal wall to relieve tension in the median line during major abdominal reconstruction has been known for over 30 years as anterior component separation (aCS) and is an established procedure. In search of alternatives with lower complication rates, posterior component separation (pCS) was developed; transversus abdominis release (TAR) is a nerve-sparing modification of pCS. With the ergonomic resources of robotics (e.g., angled instruments), TAR can be performed in a minimally invasive manner (r-TAR): hernia gaps of up to 14 cm can be closed and a large extraperitoneal mesh implanted. In this video article, the treatment of large incisional hernias using the r‑TAR technique is presented. Exemplary results of a cohort study in 13 consecutive patients are presented. The procedure is challenging, but our own results—as well as reports from the literature—are encouraging. The r‑TAR is becoming the pinnacle procedure for abdominal wall reconstruction.
This work deals with teams in teleoperation scenarios, where one human team partner (supervisor) guides and controls multiple remote entities (either robotic or human) and coordinates their tasks. Such a team needs an appropriate infrastructure for sharing information and commands. The robots need to have a level of autonomy, which matches the assigned task. The humans in the team have to be provided with autonomous support, e.g. for information integration. Design and capabilities of the human-robot interfaces will strongly influence the performance of the team as well as the subjective feeling of the human team partners. Here, it is important to elaborate the information demand as well as how information is presented. Such human-robot systems need to allow the supervisor to gain an understanding of what is going on in the remote environment (situation awareness) by providing the necessary information. This includes achieving fast assessment of the robot´s or remote human´s state. Processing, integration and organization of data as well as suitable autonomous functions support decision making and task allocation and help to decrease the workload in this multi-entity teleoperation task. Interaction between humans and robots is improved by a common world model and a responsive system and robots. The remote human profits from a simplified user interface providing exactly the information needed for the actual task at hand. The topic of this thesis is the investigation of such teleoperation interfaces in human-robot teams, especially for high-risk, time-critical, and dangerous tasks. The aim is to provide a suitable human-robot team structure as well as analyze the demands on the user interfaces. On one side, it will be looked on the theoretical background (model, interactions, and information demand). On the other side, real implementations for system, robots, and user interfaces are presented and evaluated as testbeds for the claimed requirements. Rescue operations, more precisely fire-fighting, was chosen as an exemplary application scenario for this work. The challenges in such scenarios are high (highly dynamic environments, high risk, time criticality etc.) and it can be expected that results can be transferred to other applications, which have less strict requirements. The present work contributes to the introduction of human-robot teams in task-oriented scenarios, such as working in high risk domains, e.g. fire-fighting. It covers the theoretical background of the required system, the analysis of related human factors concepts, as well as discussions on implementation. An emphasis is placed on user interfaces, their design, requirements and user testing, as well as on the used techniques (three-dimensional sensor data representation, mixed reality, and user interface design guidelines). Further, the potential integration of 3D sensor data as well as the visualization on stereo visualization systems is introduced.
Radiation therapy today, on account of improvements in treatment procedures over the last 60 years, allows precise treatment of static tumors inside the human body. However, irradiation of moving tumors is still a challenging task as moving tumors often leave the treatment beam and the radiation dose delivered to the tumor reduces simultaneously increasing that on healthy tissue. This research work aims to push the frontiers of radiation therapy in order to enable precise treatment of moving tumors with focus on research and development of a unique real-time system enabling active motion compensation through robotic means to compensate tumor motion. During treatment, patients lie on a treatment couch which is normally used for static position corrections of patient set-up errors prior to radiation treatment. The treatment couch used, called HexaPOD, is a parallel manipulator with six degrees of freedom which can precisely position heavy loads inside a small region. Despite the HexaPOD not initially built with dynamics in mind, it is used in this work for sustained motion compensation by moving patients such that tumors stay precisely located at the center of the treatment beam during the complete course of treatment. In order to realize real-time tumor motion compensation by means of the HexaPOD, several challanges need to be addressed. Real-time aspects are covered by the adoption of a hard real-time operation system in combination with measurement and estimation of latencies of all physical quantities in the compensation system such as tumor or breathing position measurements. Accurate timing information is respected consistently in the whole system and all software-induced latencies are adaptively compensated for. This requires knowledge of future tumor positions from predictors. Several predictors for breathing and tumor motion predictions are proposed and evaluated in terms of a variety of different performance metrics. Extensions to prediction algorithms are introduced fusing both breathing and tumor position information to allow for predictions without the need of an explicit correlation model. Predictions determine the future motion path of the HexaPOD in order to compensate for tumor motion. Several control schemes are developed to enable reference tracking for the HexaPOD. Based on linear and non-linear dynamic modelling of the HexaPOD with system identification methods, a first controller is derived in the form of a model predictive controller. A second controller is proposed based on an assumption of the working principle of the HexaPOD's internal controller. Finally, a third controller is derived as combination of the first and second one. For each of these controllers, comparative results with real hardware experiments and humans in the loop as well as choices of free parameters are presented and discussed. Apart from precise tracking, emphasis is placed on patient comfort which is of crucial importance for acceptance of the system. It is demonstrated that smooth trajectories can be realized by the controllers to guarantee that patients feel comfortable while their tumor motion is compensated at sub-millimeter accuracies. Overall errors of the system are analyzed by relating them to tracking and prediction errors. By exploiting the properties of different predictors, it is shown that the startup time until tracking is reached can be reduced to only a few seconds, even in the case of an initially at-rest HexaPOD and with no initial knowledge of tumor motion. This makes the system especially suitable for the relatively short-fractionated treatment sessions for lung tumors. The tumor motion compensation system has been developed solely based on standard clinical hardware, found in most treatment rooms. With a simple and flexible design, existing treatment can be updated in a cost-efficient way to introduce motion compensation capabilities. Simultaneously, the system does not impose any constraints on state-of-the-art treatment types such as intensity modulated radiotherapy or volumetric modulated arc therapy. Supporting different compensation modes, the system can be applied to any moving tumor whether its motion is predictable (lung tumors) or unpredictable (prostate tumors). By integration of adequate tumor position determination methods, the system can be easily extended to other tumors as well.
This work focuses on coordination methods and the control of motion in groups of nonholonomic wheeled mobile robots, in particular of the car-like type. These kind of vehicles are particularly restricted in their mobility. In the main part of this work the two problems of formation motion coordination and of rendezvous in distributed multi-vehicle systems are considered. We introduce several enhancements to an existing motion planning approach for formations of nonholonomic mobile robots. Compared to the original method, the extended approach is able to handle time-varying reference speeds as well as adjustments of the formation's shape during reference trajectory segments with continuously differentiable curvature. Additionally, undesired discontinuities in the speed and steering profiles of the vehicles are avoided. Further, the scenario of snow shoveling on an airfield by utilizing multiple formations of autonomous snowplows is discussed. We propose solutions to the subproblems of motion planning for the formations and tracking control for the individual vehicles. While all situations that might occur have been tested in a simulation environment, we also verified the developed tracking controller in real robot hardware experiments. The task of the rendezvous problem in groups of car-like robots is to drive all vehicles to a common position by means of decentralized control laws. Typically there exists no direct interaction link between all of the vehicles. In this work we present decentralized rendezvous control laws for vehicles with free and with bounded steering. The convergence properties of the approaches are analyzed by utilizing Lyapunov based techniques. Furthermore, they are evaluated within various simulation experiments, while the bounded steering case is also verified within laboratory hardware experiments. Finally we introduce a modification to the bounded steering system that increases the convergence speed at the expense of a higher traveled distance of the vehicles.
3D point clouds are a de facto standard for 3D documentation and modelling. The advances in laser scanning technology broadens the usability and access to 3D measurement systems. 3D point clouds are used in many disciplines such as robotics, 3D modelling, archeology and surveying. Scanners are able to acquire up to a million of points per second to represent the environment with a dense point cloud. This represents the captured environment with a very high degree of detail. The combination of laser scanning technology with photography adds color information to the point clouds. Thus the environment is represented more realistically. Full 3D models of environments, without any occlusion, require multiple scans. Merging point clouds is a challenging process. This thesis presents methods for point cloud registration based on the panorama images generated from the scans. Image representation of point clouds introduces 2D image processing methods to 3D point clouds. Several projection methods for the generation of panorama maps of point clouds are presented in this thesis. Additionally, methods for point cloud reduction and compression based on the panorama maps are proposed. Due to the large amounts of data generated from the 3D measurement systems these methods are necessary to improve the point cloud processing, transmission and archiving. This thesis introduces point cloud processing methods as a novel framework for the digitisation of archeological excavations. The framework replaces the conventional documentation methods for excavation sites. It employs point clouds for the generation of the digital documentation of an excavation with the help of an archeologist on-site. The 3D point cloud is used not only for data representation but also for analysis and knowledge generation. Finally, this thesis presents an autonomous indoor mobile mapping system. The mapping system focuses on the sensor placement planning method. Capturing a complete environment requires several scans. The sensor placement planning method solves for the minimum required scans to digitise large environments. Combining this method with a navigation system on a mobile robot platform enables it to acquire data fully autonomously. This thesis introduces a novel hole detection method for point clouds to detect obscured parts of a captured environment. The sensor placement planning method selects the next scan position with the most coverage of the obscured environment. This reduces the required number of scans. The navigation system on the robot platform consist of path planning, path following and obstacle avoidance. This guarantees the safe navigation of the mobile robot platform between the scan positions. The sensor placement planning method is designed as a stand alone process that could be used with a mobile robot platform for autonomous mapping of an environment or as an assistant tool for the surveyor on scanning projects.
Educational robotics is an innovative approach to teaching and learning a variety of different concepts and skills as well as motivating students in the field of Science, Technology, Engineering, and Mathematics (STEM) education. This especially applies to educational robotics competitions such as, for example, the FIRST LEGO League, the RoboCup Junior, or the World Robot Olympiad as out-of-school and goal-oriented approach to educational robotics. These competitions have gained greatly in popularity in recent years and thousands of students participate in these competitions worldwide each year. Moreover, the corresponding technology became more accessible for teachers and students to use it in their classrooms and has arguably a high potential to impact the nature of science education at all levels. One skill, which is said to be benefitting from educational robotics, is problem solving. This thesis understands problem solving skills as engineering design skills (in contrast to scientific inquiry). Problem solving skills count as important skills as demanded by industry leaders and policy makers in the context of 21st century skills, which are relevant for students to be well-prepared for their future working life in today’s world, shaped by an ongoing process of automation, globalization, and digitalization. The overall aim of this thesis is to try to answer the question if educational robotics competitions such as the World Robot Olympiad (WRO) have a positive impact on students’ learning in terms of their problem solving skills (as part of 21st century skills). In detail, this thesis focuses on a) if students can improve their problem solving skills through participation in educational robotics competitions, b) how this skill development is accomplished, and c) the teachers’ support of their students during their learning process in the competition. The corresponding empirical studies were conducted throughout the seasons of 2018 and 2019 of the WRO in Germany. The results show overall positive effects of the participation in the WRO on students’ learning of problem solving skills. They display an increase of students’ problem solving skills, which is not moderated by other variables such as the competition’s category or age group, the students’ gender or experience, or the success of the teams at the competition. Moreover, the results indicate that students develop their problem solving skills by using a systematic engineering design process and sophisticated problem solving strategies. Lastly, the teacher’s role in the educational robotics competitions as manager and guide (in terms of the constructionist learning theory) of the students’ learning process (especially regarding the affective level) is underlined by the results of this thesis. All in all, this thesis contributes to the research gap concerning the lack of systematic evaluation of educational robotics to promote students’ learning by providing more (methodologically) sophisticated research on this topic. Thereby, this thesis follows the call for more rigorous (quantitative) research by the educational robotics community, which is necessary to validate the impact of educational robotics.
With the progress in robotics research the human machine interfaces reach more and more the status of being the major limiting factor for the overall system performance of a system for remote navigation and coordination of robots. In this monograph it is elaborated how mixed reality technologies can be applied for the user interfaces in order to increase the overall system performance. Concepts, technologies, and frameworks are developed and evaluated in user studies which enable for novel user-centered approaches to the design of mixed-reality user interfaces for remote robot operation. Both the technological requirements and the human factors are considered to achieve a consistent system design. Novel technologies like 3D time-of-flight cameras are investigated for the application in the navigation tasks and for the application in the developed concept of a generic mixed reality user interface. In addition it is shown how the network traffic of a video stream can be shaped on application layer in order to reach a stable frame rate in dynamic networks. The elaborated generic mixed reality framework enables an integrated 3D graphical user interface. The realized spatial integration and visualization of available information reduces the demand for mental transformations for the human operator and supports the use of immersive stereo devices. The developed concepts make also use of the fact that local robust autonomy components can be realized and thus can be incorporated as assistance systems for the human operators. A sliding autonomy concept is introduced combining force and visual augmented reality feedback. The force feedback component allows rendering the robot's current navigation intention to the human operator, such that a real sliding autonomy with seamless transitions is achieved. The user-studies prove the significant increase in navigation performance by application of this concept. The generic mixed reality user interface together with robust local autonomy enables a further extension of the teleoperation system to a short-term predictive mixed reality user interface. With the presented concept of operation, it is possible to significantly reduce the visibility of system delays for the human operator. In addition, both advantageous characteristics of a 3D graphical user interface for robot teleoperation- an exocentric view and an augmented reality view – can be combined.
This dissertation presents controller design methodologies for a formation of cooperative mobile robots to perform trajectory tracking and convoy protection tasks. Two major problems related to multi-agent formation control are addressed, namely the time-delay and optimality problems. For the task of trajectory tracking, a leader-follower based system structure is adopted for the controller design, where the selection criteria for controller parameters are derived through analyses of characteristic polynomials. The resulting parameters ensure the stability of the system and overcome the steady-state error as well as the oscillation behavior under time-delay effect. In the convoy protection scenario, a decentralized coordination strategy for balanced deployment of mobile robots is first proposed. Based on this coordination scheme, optimal controller parameters are generated in both centralized and decentralized fashion to achieve dynamic convoy protection in a unified framework, where distributed optimization technique is applied in the decentralized strategy. This unified framework takes into account the motion of the target to be protected, and the desired system performance, for instance, minimal energy to spend, equal inter-vehicle distance to keep, etc.
Both trajectory tracking and convoy protection tasks are demonstrated through simulations and real-world hardware experiments based on the robotic equipment at Department of Computer Science VII, University of Würzburg.
This work is composed of three main parts: remote control of mobile systems via Internet, ad-hoc networks of mobile robots, and remote control of mobile robots via 3G telecommunication technologies. The first part gives a detailed state of the art and a discussion of the problems to be solved in order to teleoperate mobile robots via the Internet. The focus of the application to be realized is set on a distributed tele-laboratory with remote experiments on mobile robots which can be accessed world-wide via the Internet. Therefore, analyses of the communication link are used in order to realize a robust system. The developed and implemented architecture of this distributed tele-laboratory allows for a smooth access also with a variable or low link quality. The second part covers the application of ad-hoc networks for mobile robots. The networking of mobile robots via mobile ad-hoc networks is a very promising approach to realize integrated telematic systems without relying on preexisting communication infrastructure. Relevant civilian application scenarios are for example in the area of search and rescue operations where first responders are supported by multi-robot systems. Here, mobile robots, humans, and also existing stationary sensors can be connected very fast and efficient. Therefore, this work investigates and analyses the performance of different ad-hoc routing protocols for IEEE 802.11 based wireless networks in relevant scenarios. The analysis of the different protocols allows for an optimization of the parameter settings in order to use these ad-hoc routing protocols for mobile robot teleoperation. Also guidelines for the realization of such telematics systems are given. Also traffic shaping mechanisms of application layer are presented which allow for a more efficient use of the communication link. An additional application scenario, the integration of a small size helicopter into an IP based ad-hoc network, is presented. The teleoperation of mobile robots via 3G telecommunication technologies is addressed in the third part of this work. The high availability, high mobility, and the high bandwidth provide a very interesting opportunity to realize scenarios for the teleoperation of mobile robots or industrial remote maintenance. This work analyses important parameters of the UMTS communication link and investigates also the characteristics for different data streams. These analyses are used to give guidelines which are necessary for the realization of or industrial remote maintenance or mobile robot teleoperation scenarios. All the results and guidelines for the design of telematic systems in this work were derived from analyses and experiments with real hardware.