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FourByThree proposes the development of a new generation of modular industrial robotic solutions that are suitable for efficient task execution in collaboration with humans in a safe way and are easy to use and program by the factory workers.

The project was active for three years, December 2014-2017.

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Workhop at IROS 2015: recap and lessons learned

The FourByThree project has the ambitious aim of combining different modalities and innovations achieved within the context of safe human-robot interaction in the latest worldwide robotics research and providing a unified solution for industrial applications. The proposed robotic solution will be a modular system that can be easily customised to fit the end-user’s particular needs, it will be easy to programme and intuitive to use and most importantly, it will be safe. To achieve such goals, partners across 6 European countries, coming from SMEs, research institutions and academia have joined hands and brought forward their own expertise. However, an essential necessity for such a project is to stay in contact with the latest research and to constantly update our goals and expectation based on the latest endeavours of our colleagues in the scientific community.

With this aim in mind, a workshop was organised at the 2015 IEEE/RSJ International Conference on Intelligent Robots and Systems (IROS 2015). IROS is one of the top robotics conferences attended by more than 3000 researchers from all around the world. Selecting this conference as the venue for our workshop provided the opportunity of having top researchers in the field be present at the workshop and get involved in it through speeches, posters and discussions. The workshop was titled “Safety for Human-Robot Interaction in Industrial Settings” and was organised by King’s College London, Tekniker and DFKI – all partners in the FourByThree project. The workshop featured speakers active in industry, robotics safety standards and academic research. A call for papers was also announced with 6 papers finally being included in the workshop. The authors presented their work in the form of a poster preceded by a 3-minute teaser presentation.

programme
Figure 1: The workshop programme

Initial talks were given by project partners, Iñaki Maurtua and Jose de Gea Fernandez. Iñaki gave an interesting insight into how human workers perceive the robots closely cooperating with them and whether they find it easy to trust the robots or to communicate with them as they would with a human. Jose on the other hand provided a context for the workshop by describing his previous projects and the needs of the industry within the topic area.

Thomas Krüger, our guest from the Volkswagen group talked about motivations for human-robot collaboration in industry along with application within the Volkswagen group with possible future extensions. It was noted that worldwide increase of average age has resulted in an increasing percentage of employees with physical impairments. Hence requirements for improved ergonomics and age-appropriate working environments becomes more prominent. HRC could be viewed as a new approach between manual labour and full automation. With 44,000 robots globally in use at Volkswagen, the highest potential for HRC was deemed to be in assembly and logistics processes. It was observed that reliable operation of HRC systems requires perceiving robots as a support measure, and most importantly, the human worker should define the cycle time, not the robot.

It was Thomas’s assessment that aside from the promising aspects of HRC in assembly and logistics, new challenges have also emerged, which necessitate new concepts and approaches for the planning of work stations. He concluded that for HRC competence, planning work stations need to consider three main aspects: tasks and employees, robots and automation technology technical capabilities, and the overall design of the work station and product.

Our partner in the FourByThree project, Thomas Pilz, discussed steps to safe collaborative robotic systems according to the ISO TS 15066 standard. Risk assessment was highlighted to be the most important part of a safe collaborative system, considering robot related or application related hazards. It was noted that for traditional robot systems, risk reduction is typically achieved through safeguards that separate the operator from the robot system, whereas for collaborative operation, the risk reduction is primarily addressed by the design and application of the robot system and of the collaborative workspace.

Thomas mentioned that safety function requirements look into considerations for the collaborative workspace, as well as the transitions between non-collaborative operations and collaborative ones. These shall be designed such that the robot system does not pose unacceptable risks to the operator during the transition. In addition considerations for the collaborative operations were discussed, which may include safety-rated monitored stop, hand guiding, speed and separation monitoring or power and force limitations. Finally, Thomas stated that for verification and validation, the risk assessment(s) should be reviewed to assess if all reasonably foreseeable hazards have been identified and corrective actions taken.

Jose Saenz, our partner from Fraunhofer IFF continued the discussion by presenting their experiences from the VALERI project. VALERI involved the creation of a mobile manipulation platform based on the KUKA lightweight robot for aerospace production tasks. Jose presented IFF’s approach to applying safety standards to this platform through a systematic approach of defining applications and roles, identifying hazard sources, mitigating them and finally verifying their solutions. Novel safety technologies were created for VALERI, in particular, laser scanners for proximity and tactile sensors for contact detection. Other methods involved the use of torque sensing in joints for collision detection as well as optical workspace monitoring. IFF took special care during their design process to follow the relevant ISO and DIN standards particularly in limiting forces (ISO TS 15066 and DIN1525).

After the teaser and poster sessions by the researchers who had submitted their work to the workshop, we moved on to our academic speakers to provide a description of the latest research and innovations in the field. Two of the speakers were collaborators of the SAPHARI Project; an EU funded project completed in 2014 which dealt with safe physical human-aware robot interaction. The first speaker was our colleague, Alessandro de Luca, Professor of Robotics at Sapeinza Universita di Roma. Alessandro is an IEEE Fellow and has published numerous works on physical human-robot interaction and collaboration. His talk in our workshop was regarding sensing, monitoring and control issues in physical human-robot collaboration.

Alessandro spoke about different issues that need to be taken into account during the design of a safe human-robot environment, such as how the robot detects and reacts to collisions, how the workspace or environment is monitored and how intentional and accidental human movements are distinguished. He divided these into three main working modalities. The first being the classical solution of robot safety, such as placing the robot in a cage or to stop its movement when the human is close. The second possibility is coexistence, a robot’s ability to share working environments with humans. The last step is collaboration, an ability to perform complex tasks closely with human interaction and coordination.

Alessandro also emphasized the importance of collision detection without the use of external or contact sensors. One way to do this is by analysing the actuator currents on the robot. The robot’s workspace or environment can be mapped using external sensing such as a camera, RGB-Depth, or laser. Using the information from these sensors, the obstacles around the robot can be localised and avoided. Another important requirement is to distinguish hard contacts from accidental collision and soft or intentional contacts. Alessandro proposed a unique solution without the use of contact sensors, relying on analysing the motor currents using high-pass and low-pass filtering processes. Aside from safety, which is indeed the most important factor, the robot is still expected to perform a task! This requires contact force estimation. Once the force can be estimated, the control scheme can be applied to control the force and perform a desired task. Further details on this can be found on Alessandro’s presentation.

Our second academic speaker was our colleague Sami Haddadin, a Professor at the Institute of Automatic Control, Leibniz Universitat Hannover. Sami was also involved on the SAPHARI project with Alessandro in the past. His doctoral thesis on robotic safety was also published by Springer as a book entitled “Towards Safe Robots: Approaching Asimov’s 1st Law”. In his presentation, Sami delivered a talk on robot motion planning and its relation to injury and pain. Sami emphasised the importance of safe real-time motion planning for the robot to collaborate with a human. He described several techniques to achieve this, such as optimisation-based planning which relies on generating movement by minimising a specific cost function.

To ensure fast calculation and thus real-time performance, he proposed several techniques. The basis for his techniques are the artificial potential fields proposed by Prof. Oussama Khatib in 1986. In this technique, obstacles act as a repulsive surface for the robots while a goal configuration to be reached produces attractive field for the end effector. Sami also presented work which combines this collision avoidance strategy with dynamic movement primitives, which stands for a set of previously defined movements that represent a task or manipulation configuration. The last technique Sami described was a circular field, inspired from the magnetic field in Physics. Sami then concluded his talk by emphasising the importance of connecting injury data with robot motion planning and that more data on how injuries are inflicted and what types of collision will lead to more severe injuries can help in optimising robot motion planning and control.

sami haddadinFigure 2: Sami Haddadin delivering his talk to a full room

The academic talks created a lot of excitement in the mostly academic audience of the IROS conference. The speeches were followed by round table discussion where the audience got the change to freely ask their questions and discuss their thoughts with the speakers from the different areas. An interesting discussion was formed between the audience; Sami as an academic and Thomas Pilz and Federico Vicentini as those experienced in safety standard committees. The consensus was that while safety and its standardisation are indeed important for the continued commercialisation and use of robotic solutions for industry and close collaboration with humans, they should not be what guides the researchers in the field. It should in fact be vice versa, wherein researchers are left free to explore their ideas and innovations to achieve new methods for safety and standard committees should be the ones catching up and updating their standards as necessary.

The workshop concluded after this, with many of the attendants commenting on how useful it had been for them and looking for ways to getting access to the presentations. Smaller discussion groups continued on even after the workshop was officially terminated. This workshop allowed for a very interesting exchange of ideas between different sectors of an area with large implication on the future of robotics, economics and society in general. True collaboration of a human and robot will only be possible through cooperation of us researchers. Workshops like this will need to be followed up and repeated at future conferences. The ideas presented during the academic section of the workshop, combined with the vision put forward by industry experts at the workshop and realised within the scope of the safety standards described by our standardisation representatives can result in working real-life solutions for close physical human robot interaction.

fourbythree workshop iros 2015Figure 3: Workshop organizers and some of the speakers

This guest post has been contributed by Kaspar Althoefer, Professor of Robotics and Intelligent Systems and Head of the Centre for Robotics Research (CoRe) at King’s College London, with the support of colleagues Ali Shafti, Ali Shiva and Ahmad Ataka.

FourByThree in Magdeburg, Germany

Last week, october 13-15, members of the FourByThree consortium traveled to Magdeburg, Germany, for a plenary meeting. This time the meeting took place at Fraunhofer-IFF’s impressive headquarters, near Otto von Guericke University. The meeting was attended by EU expert Sasha Jevtic, appointed by the European Commission to monitor the project and offer his advice.

One of the highlights in the visit was the tour to Fraunhofer-IFF’s facilities. All the members of the consortium had the chance to experience firsthand some of the projects where the institute has been working in the last few years, many of them within the field of robotics and, specifically, safe human-robot collaboration. Projection-based interaction and safeguarding is one IFF’s main fields of research, and FourByThree offers a new opportunity to take this technology even further.

During the meeting there was time to carry out technical discussions and workshops on architecture and control. The analysis of the industrial scenarios was also shared, and progress on each work package was discussed. A video update on the meeting in Magdeburg will soon be published.

Discussing trends in human-robot collaboration

The upcoming week, on Friday the 2nd of October, FourByThree will be hosting a workshop on human-robot interaction at IROS 2015, which will be held at Congress Center Hamburg (CCH). Our workshop will focus on safety for human-robot collaboration and some renowned experts will present their reserach and experiments. You can already check the final agenda at fourbythree.eu/iros2015/

The workshop will be an excelent occasion to discuss issues such as existing safety standards and the best technologies to achieve safe robots. These issues are becoming more and more relevant because of the increase in the use of robots in industrial scenarios. They have even made headlines recently, because of unfortunate incidents like a deadly accident in a German plant.

Beyond the media buzz, experts agree on some important trends in the field. In this article, Frank Tobe highlights four main ideas: the broad recognition of the value of robotics within the business world, the impact of China’s massive incorporation of robots on production and sales, the success of vision-enhanced robotic systems, and the growing interest on human-robot collaboration.

What do you think? Which are, in you view, the most important trends in human-robot interaction? Join the conversation on October 2nd!

(Photo credit: Fraunhofer Institute for Factory Operation and Automation, IFF)

Technology watch

Optimizing Robots While They Sleep (RobDREAM Project)

Source: KUKA Laboratories

At Automatica 2016 KUKA Corporate Research presented the initial results of the RobDREAM project, which is part of the larger SPARC European robotics partnership. The RobDREAM research seeks to optimize robotic operation by analyzing data and improving processes during “inactive” periods (such as during an off-shift in the evening) – much like animals do during sleep. One of the main goals was to speed up the programming and optimization of robots so that small and medium-sized enterprises don’t have to invest so much time and resources into that portion of robotic integration.

How Collaborative Robots Are Impacting Education

Source: Amtek Company (Rick Sykes)

A few weeks ago I was sitting in the waiting room at the hospital receiving an update from one of the surgeons on staff. My wife’s surgery had gone well. It only lasted 45 minutes (as opposed to two hours) and she only lost a teaspoon of blood. I felt a wave of relief.

What had made her surgery so successful was the collaborative robot the surgeon used to perform the procedure. I’ve worked with collaborative robots for some time now, but to experience the benefits in my personal life has given me a new perspective.

Collaborative robots have grown in popularity across several industries over the past several years, especially manufacturing and healthcare. How? Let’s start at the beginning.

A collaborative robot is essentially a robot that works with a human to produce or accomplish something. There are a few different types of collaborative robots:

Hand Guiding Robots

This type of collaboration uses regular industrial robots with an added device – most commonly a Force Torque Sensor. The device reads the forces applied on the robot tool. This type of collaboration only applies to the robot while it is performing this particular function, which means that while the robot is functioning in its other modes, the robot still needs to have safeguarding in place.

Speed and Separation Monitoring Robots

Speed and Separation Monitoring robots are designed for occupational safety and are most commonly used in manufacturing environments. They work collaboratively with workers, but have safety precautions built in to keep workers safe.

  • A Safety Monitored Stop is when the robot stops because someone or something gets too close. The robot must wait until the worker gives a signal before it can resume operations.
  • A Separation Monitoring robot will continually work within its designated safety zones. Each zone is gradated so that the robot produces different reactions according to the location of the worker within each zone. The robot can also enlist a Safety Monitored Stop when a worker gets too close to it.

Imagine a manufacturing environment in which a worker is completing multiple tasks and may need a specific tool for only a few minutes within the day. A collaborative robot could deliver this tool safely, slowing down as it enters the worker’s space, arriving just at the time the worker needs it. The robot helps to speed up the manufacturing process and ensure a safe working environment.

Or imagine a manufacturing plant with a heavy sheet metal press, and there is a pinch point where a worker could easily cut their finger. This is where a collaborative robot could step in and handle the dangerous tasks while workers can handle the next steps in the process.

Power and Force Limiting Robots

This is the robot you think of when you hear the term “collaborative robot.” It can work side-by-side with a worker on a specific task without any additional safety devices. It is designed to detect abnormal forces in its path and will stop when it reads an overload.

In the instance of my wife’s surgery, the surgeon used the most widely known medical robot – the da Vinci Surgical System. This system essentially brings superhuman precision to surgical procedures. You can see for yourself in this video.

The cameras on the robot arms can zoom in on microscopic tissues better than a surgeon’s eyes. The result for my wife was a shorter surgery that minimized the effects of anesthesia, shortened her recovery time, and minimized her blood loss.

Collaborative Robots in Education

We’re seeing collaborative robots used in two distinct ways within education.

Universities are studying how to unleash the ultimate potential of collaborative robots across several different industries. They are uncovering new uses and applications, improving existing applications, enhancing robot efficiency, and studying robots’ effects on health and occupational safety in the workplace.

Several universities around the world are studying the use of KUKA’s lightweight, collaborative robot for various medical procedures. The KUKA LBR iiwa is designed to be inherently safe out of the box, without the need for elaborate safety fencing common to many industrial robots. This allows them to work in close proximity with their human operators.

Universities and community colleges also deploy robots, like Universal Robots, to teach students about the up and coming skills and technologies they’ll need to know to enter the workforce. Schools like Johns Hopkins, The University of Maryland, Virginia Tech, Marshall University, and others have collaborative robot education centers that expose students to the robots of the future and offer robotics research opportunities.

Collaborative robots are ushering in the new era of Industry 4.0 and students need to understand the workplace of the future and be prepared to meet the challenges of the coming decades.

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