Glazed Panel Construction with Human-Robot Cooperation (SpringerBriefs in Computer Science)

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One receives operational signals from an operator, and the other, positioned between the end effector and the 15 kg weighing object, can detect the contact force from the environment. With the signals that are received by the two sensors, the control signals, the manipulator should follow, are generated [2]. The DSP is used for the force analysis and the impedance control of the manipulator.

The manipulator is controlled using an impedance control with inner motion loop method based on the force control. It assumes that the manipulator follows a commanded force derived by Eq. The sampling time for the force analysis and controlling the manipulator is settled as 1 ms. A mount string was used for the environmental system. The stiffness for an actual environment can be adjusted through replacement of the spring.

An indicator, mounted on an object, automatically moves to the home position from the original position. The operator applies force to the gripper, so that the indicator follows a circle trajectory that is described on an acrylic board. Based on the operational force, the robot follows the circle trajectory through the impedance control in the unconstraint condition. The robot contacts a mount spring an environmental system while following the circle trajectory.

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The contact force, generated at this time, enables the impedance control, and the robot should endow with a behavior, considering the compliance. The robot is to follow a circle trajectory, having a diameter of 0. Experiments are conducted after some practices by a healthy managed 29 years. The experimental contents are as follows: Firstly, the influences of each parameter are to be observed for adjustment of the impedance parameters. Secondly, the performance of the suggested impedance control with inner motion control loop is to be evaluated to reduce the position following error for operation of a robot in an unconstrained condition.

Thirdly, the influences of Fh and Fe, according to change of the force augmentation ratio k of an operator, are to be studied. Finally, the changes of Fh and Fe, according to the changes of the actual environmental stiffness, are to be investigated. The characteristic values according to results of the experiment are described in Figs. The force, used for the two experiments, is 5 N and applied for around 10 s. That is to say, this operation does not require relatively higher stability, but requires prompt response velocity of a robot with small operational force. As the Mpt value rises, a robot has low response velocity with respect to same operational force.

That is to say, this case does not require relatively higher mobility, but requires a precise and stable operation. As the stability is increased, the more demanding force may make an operator feel the minimum moving distance shorter. The two factors are related to mobility and stability, and interact with each other.

Therefore, these two factors should be traded off appropriately so that a robot system can have the maximum mobility in the range of securing the system 16 2 Control Algorithm for Human—Robot Cooperation Fig. The Mpt and Bpt values, used in the experiments, were 50I and I respectively for the mobility-requiring operation unconstraint case , and 15I and I respectively for the stabilityrequiring operation constraint case.

Without the operational force, the constant force, which is input to the controller, makes the robot follow an already-programmed circle trajectory desired. As shown in the graph, it can be recognized that the path tracking accuracy is rather poor during execution of the whole tasks if the stiffness parameter is small. The small stiffness parameter also causes reduction of the contact force in the constraint condition. These results occur due to a larger end effector position error in operation.

The inner motion loop gains in Eq. As indicated in the graph, the robot operation without the inner motion control loop shows inferior desired-position-following performance in an unconstraint condition. By using the inner motion control loop, the high following performance can be obtained as shown in the Fig.

The operator applies force to the gripper so that the indicator, mounted in the object, can follow the circle trajectory that is described on the acrylic board. In the graph, the part A is the area where the object contacts the environment mount spring. The force augmentation ratio k , suggested in Eq. In the experiments, we studied changes of Fh and Fe when the force augmentation ratio k was increased from 3 to 6. As shown in Fig. As k increased to 6 from 3, Fh, required in case of no contact with the environment, was reduced by a half, and Fh for the environment-contacting case was also reduced to 15 N by around a half.

We can see that the force, required by an operator, gets smaller as k increases, but there is no significant change in the force Fe that reflects in the contacting condition. The purpose of this experiment, changing the environmental stiffness, lies on comparison of the reaction force Fe that is felt by an operator according to operational conditions such as a case contact with an obstacle occurs or a case the press fit is required. In case there is contact, however, Fh required is around 40 N and Fe generated is around N. A similar result is shown when k increases from 3 to 6 Fig.

In case there is no contact with the environment, Fh of around 5 N is required to move the object. In case there is contact, however, the required force Fh is around 20 N and the generated force Fe is around N. We could find that there was no change in Fh, for handling the object, in case of no contact with the 22 2 Control Algorithm for Human—Robot Cooperation Fig.

It can be recognized that, as Kpe increases, the force, required by an operator, gets increased and the force Fe , reflecting in the contact condition, also gets increased. Kluwer Academic Publishers, Boston 2. First, considering the environment where the system is used, the required specification about the target building that is to be heavy glazed ceiling panels should be constructed.

Then, the existing construction equipment and construction process for installing heavy glazed ceiling panels are analyzed. According to analysis of the target work and building, the functional requirements for implementing a glazed ceiling panel construction robot are deduced. Last, a conceptual design was produced for the proposed robot. Buildings are made of many kinds of materials and each material may be a different shape. A glazed ceiling panel is one type of building material for interior finishing.

The demand for larger glazed ceiling panel has been increasing along with the number of high-rise buildings and the increased interest in interior design. To introduce robotic technology for installing glazed ceiling panel on construction site, we should be considered some problems. Glazed ceiling panel construction robots are receiving special attention because of the difficulties of transporting the panel to high installation positions and handling the fragile S. In order to address these conditions, the form of a glazed ceiling panel construction robot is different from other construction robots.

The existing ceiling panel construction process, which is complicated and hazardous, relies on scaffolding or aerial lift and human labor as shown in Fig. This process exposes operators to falling accidents or vehicle rollovers. In addition, inappropriate working posture is a major element that increases the frequency of accidents by causing various musculo—skeletal disorders and decreasing concentration.

That is to say, it becomes a direct cause of decreasing productivity and safety in construction. Before the conceptual design, considering the environment where a construction robot is used, the required specification about the target building that is to be heavy glazed ceiling panels should be constructed.

The building size is 32 9 22 m and the installation position of the glazed ceiling panel is 15 m above the ground. The glazed ceiling panel measures 3, 9 1, mm the maximum size and weighs max. That is to say, it becomes a direct cause of decreasing productivity and safety in construction Fig.

It can be divided into the two aspects 3. In the side of hardware, the solution includes the aerial work platform to reach the height of the workplace, the multi-Degree of Freedom DOF manipulator to replace the workforce, and lastly the human—robot interfacing device to make a human cooperate with a robot interactively which includes the end-effector to handling the slippery surface of glazed panels.

In the side of software, the human—robot cooperative system which follows the command from the skillful worker and assists the labor with the amplified robotic force and complies with the external environment like a contact force is applied to the entire control algorithm.

The glazed ceiling panel construction robot must be able to lift heavy glazed ceiling panels, an operator, and the installation equipment. It requires engines, batteries, or motors to lift the weight. The glazed ceiling panel construction robot must be able to handle heavy and fragile glazed ceiling panels. It requires sophisticated force and position control including human—robot cooperative control. That is to say, the operator must be able to perceive external information that is received by the robot. The glass ceiling installation robot must be devised to help operators, not to replace them.

The robot must share the work space with an operator. The glass ceiling installation robot must belong in the working process. According to analysis of the upper functional requirements, a conceptual design was generated as below, which will influence the suggested robot i. An aerial work platform is needed that can support heavy glazed ceiling panels, an operator, and the installation equipment with enough work space to reach about 15 m above the ground. A multi-DOF manipulator is required to install heavy glazed ceiling panels, which replaces a large amount of human labor.

The manipulator has to be chosen according to work space and payload. This robot is a semi-automated system to cope with a constantly changing work environment. Thus, the robot works and coexists with operators in atypical work conditions. The operator uses the multi-DOF manipulator from the deck of an aerial lift. The gripper is based on vacuum and mechanical devices, while the glazed ceiling panel gripping is performed manually. After gripping the glazed ceiling panel, the manipulator is operated by an operator.

An operator supplies external force containing an operational command on the HRI device. Therefore, the manipulator can be controlled by an intuitive installation method that can reflect the dexterity of a technical operator. The control strategy of the suggested robot is a combination of the force applied and the robot. From the above approach, the conceptual diagram can be drawn as Figs. The details advances to realize the construction robot by selecting the appropriate multi-DOF manipulator, applying the human—robot interface system HRIs based on the advanced research, adopting the aerial work platform with modifications for our application, and making the control system to cover the entire system.

Taking the HRIs into account, the required payload is approximately kg. The human—robot interface system connects a labor to robotic system physically. The impedance controller with position control is chosen to improve the traceability while the robot works on the unconstrained case no contact between the robot and the environment. After generating the conceptual design, the specifications to satisfy the construction robot to be developed are derived as shown in Table 3.

First of all, the customized construction equipment is necessary to replace the existing constructing manpower to handle and install the heavy weighed panels safely. Also, the construction method with robotic process should reflect the same quality as the existing method does which ensure the stabilized construction quality.

In addition, to improve the productivity, the measures based on the process design of optimized installing procedure, the simulation, and the mock-up test should be taken prior to the application in real field. Chapter 4 Prototype for Glazed Panel Construction Robot Abstract The prototype system of human—robot cooperative manipulation presented in this chapter combines a mobile platform and a manipulator standardized in modular form to compose its basic system. The suggested prototype can execute particular operations in various areas such as construction, national defense and rescue by changing these additional modules.

However, it is possible to change the elements of the basic system according to load specifications. This robot is a special case manipulator where the centers of the last three axes meet in the center of the robot wrist. The kinematic analysis in such form of manipulator can S. The forward kinematics of the manipulator is defined by the question of solving for the position and direction of the end-effector according to each degree of the joints.

That is, it is the problem of solving the position vector and rotational matrix of the end-effector. The kinematic analysis of the manipulator can be executed with any coordinate system but the most typical one is Denavit-Hartenberg Notation noted as D-H notation below. The unknown kinematics values of a series manipulator can be solved by multiplying the homogeneous matrix defined in the following Eq.

The position of the end-effector can be calculated by substituting a given parameter into the D-H transformation matrix in Eq. Analysis of the inverse kinematics of this manipulator is done by separating the information of the first link chain from that of the second link chain using the center position of the wrist P.

Generally, dynamic modeling of a manipulator can be derived like Eq. Also, sei shows the power and moment from the outside affected when the end-effector contacts the surrounding environment. Friction from the joints is a simplified model and only viscous friction is considered. This mobile platform largely consists of caterpillar tread, a top plate and a controller as shown in Fig. The caterpillar tread is powered by two DC motors with a reduction gear. Also, perpendicular movement of the top plate is achieved through a hydraulic cylinder. Through such movement mechanisms, 3DOF movement of forward and backward Ty , left and right rotation Rz and perpendicular movement of the top plate is realized with the central axis Z of the mobile platform as the base.

It is possible to control movement through both wired and wireless controllers and traveling speed can be controlled through an internal controller. The details of specification are shown in Table 4. Robot controller to control motion 2. End-effector to grip glazed panels into the robot 3. Other devices necessary for construction work First, the robot controller needs to be able to implement DOF for a mobile platform and a 6DOF manipulator.

The first robot controller Human—Robot Interfacing device is shown in Fig. It is important to note that external force transmitted through sensor B and that transmitted to sensor A should operate separately from each other. In addition, the switch attached to the HRI device should be able to control the manipulator and mobile platform separately. That is, it plays a role of determining whether external force being inputted is a control signal for the manipulator or that for the mobile platform.

In this prototype, the operator can select between two communication 4. The wireless control system is used to carry materials long distances or to move a robot to places that are difficult for an operator to reach. The wired control system is used in an emergency. For the wireless communication system, it is then possible to choose between the mobile platform control system and the manipulator control system.

In other words, it is possible to control a mobile platform and a manipulator with one wireless controller Fig. Each control signal is transmitted to the controller of a manipulator and a mobile platform through a main controller via a RF communication module and a converter. For the wired communication system, it is again possible to choose between the cooperation-based control system and the emergency control system. Unlike the wireless communication system, the wired communication system uses a separate control unit. The cooperation-based control system operates through main controllers including industrial computers and sensors, and the first robot controller HRI device.

The emergency control system can operate through the teach pendant of a manipulator and a mobile platform in emergency situations, as seen in Fig. The end-effector of a construction robot varies according to the properties of the construction materials. Since this study aims at installing construction materials with relatively smooth surfaces, such as curtain wall and glazed panels, a vacuum pad is used as the end-effector. If a vacuum pad located between the HRI device and object makes the contact surface vacuous through a DC motor, the load and end-effector are strongly attached to each other.

Finally, an outrigger to prevent a robot from tumbling, additional safety devices for the operator, and an alarm device to alert neighboring operators of robot operation are necessary, with consideration for the operation environments and characteristics of construction sites. In this prototype, remote control, human—robot cooperation-based control, and emergency control are proposed as methods to control a robot system.

The operator can select between two communication methods: The wired control system is used to install construction materials by cooperation or in an emergency. Installing of glazed panels by the human—robot cooperation-based control system can be largely divided as below. Process of transporting panels to an installing site 2. Process of inserting them into the correct position or doing press fits, depending on the environment In Chap. Free space motion needs rapid movement with relatively low precision while the operation in constrained case needs precise motion with relatively low motion velocity.

According to modeling of the interactions among the operator, robot and environment, we designed an impedance controller for the human—robot cooperation Fig. When an operator judges that the position X to which a robot carries materials fails to agree with the position Xd to which he or she wants to carry them, his or her force is transmitted to sensor A. In particular, external force Fh measured by sensor A can be used by operators from various age groups through the force augmentation ratio a. That is, all people, regardless of muscular strength, can operate a robot by the force augmentation ratio.

In other words, the current deviation is inputted into a servo controller, which causes a manipulator to pursue the target position value. Relatively rapid and precise motions can be implemented by controlling these parameters. The test is implemented indoors with an operation environment similar to that of an actual construction site. An experimental system to implement press pits after inserting construction materials into the correct position was designed as in Fig. Inserting glazed panels between the supporting board and the L-board is substituted for actual installation operation.

As the gap is narrower than the thickness of glazed panels, they are moved 4. If the supporting board is pressed, it means that contact force occurred; if the length of compression exceeds a certain range i. In this experiment, a glazed panel was limited to 60 N and below as shown in Table 4. Once a glazed panel is completely gripped to a robot through a vacuum pad at a loading site, the robot is moved relatively rapidly to the vicinity of the installation site through a wireless controller.

Precise positioning is performed by human—robot cooperation with a HRI device as Fig. In installing glazed panels, an operator is encouraged to collect information on the operation in real time in order to cope with changing environments. As seen in the graph, about 50 N of a glazed panel is carried by about 7 N of force supplied by an operator.

The force augmentation ratio is about 7, which is necessary to access the supporting board of the experimental system. Contact with the environment experimental system begins to occur, generating a maximum of 70 N of contact force Fe. In the end of section, about 2 N of force is generated by the correlation between the external force provided and the impedance parameters of the experimental system. This value is used to press a spring connected to a supporting board into a position with compliance.

A glazed panel is carried horizontally to be inserted between the supporting board and the L-board.

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A glazed panel is inserted; about 7 N of force is provided by an operator to make press pits, generating about 25 N of contact force. Inserted horizontally, a glazed panel is then inserted vertically. Chapter 5 Glazed Ceiling Panel Construction Robot Abstract The glazed ceiling panel construction robot presented in this chapter combines an aerial work platform and a multi-DOF manipulator.

One of the advantages of the proposed robot is the glazed ceiling panel installing by human— robot cooperative manipulation. Designing of a robotized construction process and field test using the robot is applied on a construction site. A basic system is also composed of series-type multi-DOF manipulator and an aerial work platform similar to prototype system.

However, it is possible to change the elements of not only the basic system also the additional modules according to load specification of building materials. The manipulator is chosen to help the operators, not to replace them. The manipulator has to be chosen according to the work space and payload. The payload and the weight of any additional devices vacuum suction device, HRI device etc.

In order to control the motion of the manipulator, kinematic and dynamic analysis is required. In this study, the aerial work platform raises the selected manipulator, a glazed ceiling panel, and an operator up to 15 m. A discussion follows concerning the selection of the aerial work platform and the design of the work deck. In selecting a suitable work platform, diverse aspects were considered including mobility, reachable distance, and payload.

The work platform must have adjustable movement within a constantly changing work environment. Therefore, considering mobility, a wheel type of work platform was selected, which is mounted on the truck with a telescopic boom. Considering the reachable distance and payload, it is necessary to expand the selection criteria to include not only specific properties but also safety 50 5 Glazed Ceiling Panel Construction Robot Fig.

In order to implement automated lifting, the kinematic analysis of the aerial work platform RRPRR type manipulator must be considered, as shown in Fig. If an operator puts the force containing an operational command on a handle of the HRI Fig. Here, if the manipulator comes in contact with an environment i. It is important to note that the force transmitted through environmental sensor and that transmitted to operational sensor should operate separately from each other. Also, it allows operators to promptly respond to work environments, changing in real time, through the force reflection in the environmental contacting conditions especially during operations such as press-fit work or peg-in-hole.

Moreover, the deck shape must be optimized to increase operation dexterity, in order to avoid obstacles and allow for a smooth approach to the target position. Two cases were proposed concerning the position of the glazed panels on the deck, as shown in Fig. Therefore, case 1 was selected, in which the glazed ceiling panel is positioned in front of the manipulator on the deck, as shown in Fig. Since this study aims at constructing building materials with relatively smooth surfaces, such as glass panels, a vacuum pad is used as the endeffector.

The design of a vacuum suction device includes the position of the vacuum suction pads, available payload, and the weight of itself. A position of the vacuum pads should be designed in accordance with the width of the smallest glass ceiling. Four vacuum pads were used as shown in Fig. The vacuum pads are positioned in a quadrilateral formation so that an operator can easily put the device on the center of a glazed ceiling panel.

The construction procedure of installing glazed ceiling panels with the robot can be classified into two processes: The second one is to follow the optimal path making an operator install the glazed ceiling panel with assistance by the robotic system through the human—robot interface. Once the workspace to be deployed is guaranteed, the kinematical method can provide the appropriate position of the deck as shown in Fig. The DSP is used for the force analysis and the impedance control of the manipulator. The manipulator is controlled using an impedance control with inner motion loop method based on the force control.

It assumes that the manipulator follows a commanded force derived by Eq. The sampling time for the force analysis and controlling the manipulator is settled as 1 ms. A mount string was used for the environmental system. The stiffness for an actual environment can be adjusted through replacement of the spring. An indicator, mounted on an object, automatically moves to the home position from the original position. The operator applies force to the gripper, so that the indicator follows a circle trajectory that is described on an acrylic board. Based on the operational force, the robot follows the circle trajectory through the impedance control in the unconstraint condition.

The robot contacts a mount spring an environmental system while following the circle trajectory. The contact force, generated at this time, enables the impedance control, and the robot should endow with a behavior, considering the compliance. The robot is to follow a circle trajectory, having a diameter of 0. Experiments are conducted after some practices by a healthy managed 29 years. The experimental contents are as follows: Firstly, the influences of each parameter are to be observed for adjustment of the impedance parameters.

Secondly, the performance of the suggested impedance control with inner motion control loop is to be evaluated to reduce the position following error for operation of a robot in an unconstrained condition. Thirdly, the influences of Fh and Fe, according to change of the force augmentation ratio k of an operator, are to be studied.

Finally, the changes of Fh and Fe, according to the changes of the actual environmental stiffness, are to be investigated. The characteristic values according to results of the experiment are described in Figs. The force, used for the two experiments, is 5 N and applied for around 10 s. That is to say, this operation does not require relatively higher stability, but requires prompt response velocity of a robot with small operational force. As the Mpt value rises, a robot has low response velocity with respect to same operational force.

That is to say, this case does not require relatively higher mobility, but requires a precise and stable operation. As the stability is increased, the more demanding force may make an operator feel the minimum moving distance shorter. The two factors are related to mobility and stability, and interact with each other.

Therefore, these two factors should be traded off appropriately so that a robot system can have the maximum mobility in the range of securing the system 16 2 Control Algorithm for Human—Robot Cooperation Fig. The Mpt and Bpt values, used in the experiments, were 50I and I respectively for the mobility-requiring operation unconstraint case , and 15I and I respectively for the stabilityrequiring operation constraint case. Without the operational force, the constant force, which is input to the controller, makes the robot follow an already-programmed circle trajectory desired.

As shown in the graph, it can be recognized that the path tracking accuracy is rather poor during execution of the whole tasks if the stiffness parameter is small. The small stiffness parameter also causes reduction of the contact force in the constraint condition. These results occur due to a larger end effector position error in operation. The inner motion loop gains in Eq. As indicated in the graph, the robot operation without the inner motion control loop shows inferior desired-position-following performance in an unconstraint condition.

By using the inner motion control loop, the high following performance can be obtained as shown in the Fig. The operator applies force to the gripper so that the indicator, mounted in the object, can follow the circle trajectory that is described on the acrylic board. In the graph, the part A is the area where the object contacts the environment mount spring. The force augmentation ratio k , suggested in Eq.

In the experiments, we studied changes of Fh and Fe when the force augmentation ratio k was increased from 3 to 6. As shown in Fig. As k increased to 6 from 3, Fh, required in case of no contact with the environment, was reduced by a half, and Fh for the environment-contacting case was also reduced to 15 N by around a half. We can see that the force, required by an operator, gets smaller as k increases, but there is no significant change in the force Fe that reflects in the contacting condition. The purpose of this experiment, changing the environmental stiffness, lies on comparison of the reaction force Fe that is felt by an operator according to operational conditions such as a case contact with an obstacle occurs or a case the press fit is required.

In case there is contact, however, Fh required is around 40 N and Fe generated is around N. A similar result is shown when k increases from 3 to 6 Fig. In case there is no contact with the environment, Fh of around 5 N is required to move the object. In case there is contact, however, the required force Fh is around 20 N and the generated force Fe is around N.

We could find that there was no change in Fh, for handling the object, in case of no contact with the 22 2 Control Algorithm for Human—Robot Cooperation Fig. It can be recognized that, as Kpe increases, the force, required by an operator, gets increased and the force Fe , reflecting in the contact condition, also gets increased. Kluwer Academic Publishers, Boston 2. First, considering the environment where the system is used, the required specification about the target building that is to be heavy glazed ceiling panels should be constructed. Then, the existing construction equipment and construction process for installing heavy glazed ceiling panels are analyzed.

According to analysis of the target work and building, the functional requirements for implementing a glazed ceiling panel construction robot are deduced. Last, a conceptual design was produced for the proposed robot. Buildings are made of many kinds of materials and each material may be a different shape. A glazed ceiling panel is one type of building material for interior finishing. The demand for larger glazed ceiling panel has been increasing along with the number of high-rise buildings and the increased interest in interior design.

To introduce robotic technology for installing glazed ceiling panel on construction site, we should be considered some problems. Glazed ceiling panel construction robots are receiving special attention because of the difficulties of transporting the panel to high installation positions and handling the fragile S. In order to address these conditions, the form of a glazed ceiling panel construction robot is different from other construction robots.

The existing ceiling panel construction process, which is complicated and hazardous, relies on scaffolding or aerial lift and human labor as shown in Fig. This process exposes operators to falling accidents or vehicle rollovers. In addition, inappropriate working posture is a major element that increases the frequency of accidents by causing various musculo—skeletal disorders and decreasing concentration. That is to say, it becomes a direct cause of decreasing productivity and safety in construction. Before the conceptual design, considering the environment where a construction robot is used, the required specification about the target building that is to be heavy glazed ceiling panels should be constructed.

The building size is 32 9 22 m and the installation position of the glazed ceiling panel is 15 m above the ground. The glazed ceiling panel measures 3, 9 1, mm the maximum size and weighs max. That is to say, it becomes a direct cause of decreasing productivity and safety in construction Fig. It can be divided into the two aspects 3.

In the side of hardware, the solution includes the aerial work platform to reach the height of the workplace, the multi-Degree of Freedom DOF manipulator to replace the workforce, and lastly the human—robot interfacing device to make a human cooperate with a robot interactively which includes the end-effector to handling the slippery surface of glazed panels. In the side of software, the human—robot cooperative system which follows the command from the skillful worker and assists the labor with the amplified robotic force and complies with the external environment like a contact force is applied to the entire control algorithm.

The glazed ceiling panel construction robot must be able to lift heavy glazed ceiling panels, an operator, and the installation equipment. It requires engines, batteries, or motors to lift the weight. The glazed ceiling panel construction robot must be able to handle heavy and fragile glazed ceiling panels. It requires sophisticated force and position control including human—robot cooperative control. That is to say, the operator must be able to perceive external information that is received by the robot. The glass ceiling installation robot must be devised to help operators, not to replace them.

The robot must share the work space with an operator. The glass ceiling installation robot must belong in the working process. According to analysis of the upper functional requirements, a conceptual design was generated as below, which will influence the suggested robot i. An aerial work platform is needed that can support heavy glazed ceiling panels, an operator, and the installation equipment with enough work space to reach about 15 m above the ground. A multi-DOF manipulator is required to install heavy glazed ceiling panels, which replaces a large amount of human labor.

The manipulator has to be chosen according to work space and payload. This robot is a semi-automated system to cope with a constantly changing work environment. Thus, the robot works and coexists with operators in atypical work conditions. The operator uses the multi-DOF manipulator from the deck of an aerial lift. The gripper is based on vacuum and mechanical devices, while the glazed ceiling panel gripping is performed manually.

After gripping the glazed ceiling panel, the manipulator is operated by an operator. An operator supplies external force containing an operational command on the HRI device. Therefore, the manipulator can be controlled by an intuitive installation method that can reflect the dexterity of a technical operator.

The control strategy of the suggested robot is a combination of the force applied and the robot. From the above approach, the conceptual diagram can be drawn as Figs. The details advances to realize the construction robot by selecting the appropriate multi-DOF manipulator, applying the human—robot interface system HRIs based on the advanced research, adopting the aerial work platform with modifications for our application, and making the control system to cover the entire system.

Taking the HRIs into account, the required payload is approximately kg. The human—robot interface system connects a labor to robotic system physically. The impedance controller with position control is chosen to improve the traceability while the robot works on the unconstrained case no contact between the robot and the environment. After generating the conceptual design, the specifications to satisfy the construction robot to be developed are derived as shown in Table 3. First of all, the customized construction equipment is necessary to replace the existing constructing manpower to handle and install the heavy weighed panels safely.

Also, the construction method with robotic process should reflect the same quality as the existing method does which ensure the stabilized construction quality. In addition, to improve the productivity, the measures based on the process design of optimized installing procedure, the simulation, and the mock-up test should be taken prior to the application in real field. Chapter 4 Prototype for Glazed Panel Construction Robot Abstract The prototype system of human—robot cooperative manipulation presented in this chapter combines a mobile platform and a manipulator standardized in modular form to compose its basic system.

The suggested prototype can execute particular operations in various areas such as construction, national defense and rescue by changing these additional modules. However, it is possible to change the elements of the basic system according to load specifications. This robot is a special case manipulator where the centers of the last three axes meet in the center of the robot wrist.

The kinematic analysis in such form of manipulator can S. The forward kinematics of the manipulator is defined by the question of solving for the position and direction of the end-effector according to each degree of the joints. That is, it is the problem of solving the position vector and rotational matrix of the end-effector. The kinematic analysis of the manipulator can be executed with any coordinate system but the most typical one is Denavit-Hartenberg Notation noted as D-H notation below.

The unknown kinematics values of a series manipulator can be solved by multiplying the homogeneous matrix defined in the following Eq. The position of the end-effector can be calculated by substituting a given parameter into the D-H transformation matrix in Eq. Analysis of the inverse kinematics of this manipulator is done by separating the information of the first link chain from that of the second link chain using the center position of the wrist P.

Generally, dynamic modeling of a manipulator can be derived like Eq. Also, sei shows the power and moment from the outside affected when the end-effector contacts the surrounding environment. Friction from the joints is a simplified model and only viscous friction is considered. This mobile platform largely consists of caterpillar tread, a top plate and a controller as shown in Fig.

The caterpillar tread is powered by two DC motors with a reduction gear. Also, perpendicular movement of the top plate is achieved through a hydraulic cylinder. Through such movement mechanisms, 3DOF movement of forward and backward Ty , left and right rotation Rz and perpendicular movement of the top plate is realized with the central axis Z of the mobile platform as the base. It is possible to control movement through both wired and wireless controllers and traveling speed can be controlled through an internal controller. The details of specification are shown in Table 4.

Robot controller to control motion 2. End-effector to grip glazed panels into the robot 3. Other devices necessary for construction work First, the robot controller needs to be able to implement DOF for a mobile platform and a 6DOF manipulator. The first robot controller Human—Robot Interfacing device is shown in Fig. It is important to note that external force transmitted through sensor B and that transmitted to sensor A should operate separately from each other.

In addition, the switch attached to the HRI device should be able to control the manipulator and mobile platform separately. That is, it plays a role of determining whether external force being inputted is a control signal for the manipulator or that for the mobile platform. In this prototype, the operator can select between two communication 4. The wireless control system is used to carry materials long distances or to move a robot to places that are difficult for an operator to reach.

The wired control system is used in an emergency. For the wireless communication system, it is then possible to choose between the mobile platform control system and the manipulator control system. In other words, it is possible to control a mobile platform and a manipulator with one wireless controller Fig. Each control signal is transmitted to the controller of a manipulator and a mobile platform through a main controller via a RF communication module and a converter.

For the wired communication system, it is again possible to choose between the cooperation-based control system and the emergency control system. Unlike the wireless communication system, the wired communication system uses a separate control unit. The cooperation-based control system operates through main controllers including industrial computers and sensors, and the first robot controller HRI device. The emergency control system can operate through the teach pendant of a manipulator and a mobile platform in emergency situations, as seen in Fig.

The end-effector of a construction robot varies according to the properties of the construction materials. Since this study aims at installing construction materials with relatively smooth surfaces, such as curtain wall and glazed panels, a vacuum pad is used as the end-effector. If a vacuum pad located between the HRI device and object makes the contact surface vacuous through a DC motor, the load and end-effector are strongly attached to each other.

Finally, an outrigger to prevent a robot from tumbling, additional safety devices for the operator, and an alarm device to alert neighboring operators of robot operation are necessary, with consideration for the operation environments and characteristics of construction sites. In this prototype, remote control, human—robot cooperation-based control, and emergency control are proposed as methods to control a robot system. The operator can select between two communication methods: The wired control system is used to install construction materials by cooperation or in an emergency.

Installing of glazed panels by the human—robot cooperation-based control system can be largely divided as below. Process of transporting panels to an installing site 2. Process of inserting them into the correct position or doing press fits, depending on the environment In Chap. Free space motion needs rapid movement with relatively low precision while the operation in constrained case needs precise motion with relatively low motion velocity.

According to modeling of the interactions among the operator, robot and environment, we designed an impedance controller for the human—robot cooperation Fig. When an operator judges that the position X to which a robot carries materials fails to agree with the position Xd to which he or she wants to carry them, his or her force is transmitted to sensor A. In particular, external force Fh measured by sensor A can be used by operators from various age groups through the force augmentation ratio a.

That is, all people, regardless of muscular strength, can operate a robot by the force augmentation ratio. In other words, the current deviation is inputted into a servo controller, which causes a manipulator to pursue the target position value. Relatively rapid and precise motions can be implemented by controlling these parameters. The test is implemented indoors with an operation environment similar to that of an actual construction site.

An experimental system to implement press pits after inserting construction materials into the correct position was designed as in Fig. Inserting glazed panels between the supporting board and the L-board is substituted for actual installation operation. As the gap is narrower than the thickness of glazed panels, they are moved 4.

If the supporting board is pressed, it means that contact force occurred; if the length of compression exceeds a certain range i. In this experiment, a glazed panel was limited to 60 N and below as shown in Table 4. Once a glazed panel is completely gripped to a robot through a vacuum pad at a loading site, the robot is moved relatively rapidly to the vicinity of the installation site through a wireless controller.

Precise positioning is performed by human—robot cooperation with a HRI device as Fig. In installing glazed panels, an operator is encouraged to collect information on the operation in real time in order to cope with changing environments. As seen in the graph, about 50 N of a glazed panel is carried by about 7 N of force supplied by an operator.

The force augmentation ratio is about 7, which is necessary to access the supporting board of the experimental system. Contact with the environment experimental system begins to occur, generating a maximum of 70 N of contact force Fe. In the end of section, about 2 N of force is generated by the correlation between the external force provided and the impedance parameters of the experimental system.

This value is used to press a spring connected to a supporting board into a position with compliance.

Glazed Panel Construction with Human-Robot Cooperation

A glazed panel is carried horizontally to be inserted between the supporting board and the L-board. A glazed panel is inserted; about 7 N of force is provided by an operator to make press pits, generating about 25 N of contact force. Inserted horizontally, a glazed panel is then inserted vertically. Chapter 5 Glazed Ceiling Panel Construction Robot Abstract The glazed ceiling panel construction robot presented in this chapter combines an aerial work platform and a multi-DOF manipulator.

One of the advantages of the proposed robot is the glazed ceiling panel installing by human— robot cooperative manipulation. Designing of a robotized construction process and field test using the robot is applied on a construction site. A basic system is also composed of series-type multi-DOF manipulator and an aerial work platform similar to prototype system. However, it is possible to change the elements of not only the basic system also the additional modules according to load specification of building materials. The manipulator is chosen to help the operators, not to replace them.

The manipulator has to be chosen according to the work space and payload. The payload and the weight of any additional devices vacuum suction device, HRI device etc. In order to control the motion of the manipulator, kinematic and dynamic analysis is required. In this study, the aerial work platform raises the selected manipulator, a glazed ceiling panel, and an operator up to 15 m. A discussion follows concerning the selection of the aerial work platform and the design of the work deck.

In selecting a suitable work platform, diverse aspects were considered including mobility, reachable distance, and payload. The work platform must have adjustable movement within a constantly changing work environment. Therefore, considering mobility, a wheel type of work platform was selected, which is mounted on the truck with a telescopic boom. Considering the reachable distance and payload, it is necessary to expand the selection criteria to include not only specific properties but also safety 50 5 Glazed Ceiling Panel Construction Robot Fig.

In order to implement automated lifting, the kinematic analysis of the aerial work platform RRPRR type manipulator must be considered, as shown in Fig. If an operator puts the force containing an operational command on a handle of the HRI Fig. Here, if the manipulator comes in contact with an environment i. It is important to note that the force transmitted through environmental sensor and that transmitted to operational sensor should operate separately from each other. Also, it allows operators to promptly respond to work environments, changing in real time, through the force reflection in the environmental contacting conditions especially during operations such as press-fit work or peg-in-hole.

Moreover, the deck shape must be optimized to increase operation dexterity, in order to avoid obstacles and allow for a smooth approach to the target position. Two cases were proposed concerning the position of the glazed panels on the deck, as shown in Fig. Therefore, case 1 was selected, in which the glazed ceiling panel is positioned in front of the manipulator on the deck, as shown in Fig.

Since this study aims at constructing building materials with relatively smooth surfaces, such as glass panels, a vacuum pad is used as the endeffector. The design of a vacuum suction device includes the position of the vacuum suction pads, available payload, and the weight of itself.

A position of the vacuum pads should be designed in accordance with the width of the smallest glass ceiling. Four vacuum pads were used as shown in Fig. The vacuum pads are positioned in a quadrilateral formation so that an operator can easily put the device on the center of a glazed ceiling panel. The construction procedure of installing glazed ceiling panels with the robot can be classified into two processes: The second one is to follow the optimal path making an operator install the glazed ceiling panel with assistance by the robotic system through the human—robot interface.

Once the workspace to be deployed is guaranteed, the kinematical method can provide the appropriate position of the deck as shown in Fig. After the kinematic analysis of the aerial work platform about each panel number, the robotized construction plan can be established as shown in Table 5. This construction plan is only related to the deployment of the aerial work platform with a deck.

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