004 Datenverarbeitung; Informatik
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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
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.