Robotic Drilling Research Articles

A client–server architecture for the remote sensing and control of a drilling robot

Remote sensing, implemented through virtual instrumentation, is a very important technology for industrial measurements. Moreover, the architecture and methods involved are effective for the teaching and dissemination of measurement technologies. A proper design may yield to cost-effectiveness, reliability and flexibility. Despite that, some traditional domains, like the drilling equipment production, are reluctant to the innovations and in particular are not confident in the electronic reliability. Therefore in this paper we first briefly discuss the architecture and the main properties of distributed systems for remote sensing and control. Then we refer of a research concerning an entirely remote measurement and control system, for an innovative drilling robot, able to move along a micro-tunnel and drill the landfill to insert drainage pipes, in order to definitively remediate them. Due to the working hazardous conditions, all the operations should be executed with a fully remote control and monitoring. The designed drilling machine has been built and tested at the workshop, moreover the machine successfully drilled a 15 m draining pipe in the final test on site.

Control and breakthrough detection of a three-axis robotic bone drilling system

This paper describes a robotic bone drilling system for applications in orthopedic surgery. The goal is to realize a three-axis robotic drilling system which can automatically stop drilling at the moment a drill breaks through bone. The proposed robotic bone drilling system consists of an inner loop fuzzy controller for robot position control, and an outer loop PD controller for feed unit force control. Moreover, breakthrough detection is a function of thrust force threshold information and trends in drill torque and feed rate. The proposed technique has been verified by drilling pig bones, the results for both the bone drilling and bone breakthrough processes are in accord with theoretical model.

Life at the cutting edge

Biologists, planetary scientists and engineers have gathered in southern Spain to test a robotic drill. They hope some day to probe for life beneath the surface of Mars. Jenny Hogan investigates.

Neural networks vs. regression in localized scan correction for robotic drilling applications

Due to inherent inaccuracies in equipment and assembly variation, a method of on-the-fly correction is necessary for processes using robots for assembly purposes. This research explored the goodness of using the back-propagation feedforward neural network to perform scan correction for a robot vision system. The main goal of this research was to propose a robust procedure for comparing performance of the neural network system with the current regression analysis. This paper presents the process used to develop neural networks to calculate necessary scan corrections, train the neural networks, test and validate the networks using a threefold cross-validation process, and compare the results obtained. The results of the network development and the four current regression-based models are evaluated using hypothesis tests and prediction error statistics. In this case, the neural network results were not a significant improvement over the current regression-based analysis.

Harley‐Davidson buff saddlebags

Product quality improved and finishing cost per saddlebag was reduced when robotic routing, drilling and sanding was instituted at Harley‐Davidson, an American motorcycle builder. Careful planning, and smart engineering all helped smooth the commissioning while not displacing workers.

Application of neural networks augmenting Taguchi's orthogonal arrays for simulating kinematics problems of robotics

This research focuses on integrating back propagation with the concepts of Taguchi's orthogonal arrays to map both robot forward kinematics and robot inverse kinematics. Traditionally, end users were required to have some experience with robot kinematics training programs in order to analyse the kinematics and train the robots. When the type of robot changes, end users must again analyse the robot kinematics and solve extensive mathematical equations in order to control the new robot. An alternative approach for developing robot manipulator models is to use the concepts of neural networks to approximate robot kinematics to overcome the drawbacks of the existing methods. Moreover, an additional benefit is derived from the use of Taguchi's orthogonal arrays. This study shows that using orthogonal arrays for data collection can reduce the amount of data required to map robot kinematics, although some accuracy is lost with solving the inverse kinematics problems. The simulations used to verify the model developed have been conducted on the Jumbo Drilling robot.

8:46 AM: Multisensor‐based Navigation of Robotic Drilling at the Lateral Skull Base

8:46 AM: Multisensor‐based Navigation of Robotic Drilling at the Lateral Skull Base

配管内面穿孔ロボットの開発

The study deals with the development of a drilling robot traveling inside a pipeline. Aiming at inexpensive anti-corrosion and repair of underground pipes, a new method was established and has been widely employed, in which the internal wall of the pipes is coated with some pieces of material or resin layers. However, the coating method has a disadvantage of closing the inlets of pipes connected to a coated pipe. Accordingly, the inlets must be opened again from the outside of the pipe by means of excavating works, which cause high cost and a lot of waste time, and so on. Thus, a movable drilling robot is developed to make the inlets again without excavating works. It can move inside the pipe, search the closed inlets to the connected pipes, and drill holes in the closed inlets. The robot consists of a drilling module for machining holes in the closed inlets, a tool positioning. module for searching drilled points, determining the tool position and checking the drilled holes, and a moving module traveling inside a pipe for carrying the above-mentioned modules. From the demonstration experiments, it is found that the robot can move inside the coated pipeline, find the closed inlets, position a tool, machine holes and check the holes.

Micro Robots for Scientific Applications 2 – Development of a Robotic Sampling System

This paper describes design, manufacturing and testing of a small scaled robotic drilling and sampling system called RoSA. This project was launched by ESTEC in order to study the feasibility of a drilling rover in exobiological exploration on planets, especially Mars. RoSA is a tracked, tethered vehicle, which can drive in harsh off-road conditions. The payload of the rover is a drill with dimensions of 110×110×350mm. Despite of its size drill can drill down to 2 meters and sample totally 10 samples during one sample trip. The mission consists of three sample trips up to 15 meters away from the lander. After one trip the 10 samples are brought back to the lander.

Second-Generation Robotic Controlled Drilling System Developed

Technology Update - No abstract available.

A systematic approach to develop a force control system for robotic drilling

As the application range of present day industrial robots is expanded beyond pick‐and‐place operations, spray painting and spot welding, there is an increasing need for the control of contact forces between the manipulator end point and environment. One important force control task is robotic drilling in hazardous environments. This paper addresses the analysis and characterisation of forcecontrolled robotic drilling, generation of a control strategy in the light of specifications obtained from the characterisation of this task, and the completion of a drilling operation with robot manipulator under contact force control. The experimental results demonstrate that a robot manipulator can perform drilling if enough contact thrust‐force is provided between a workpiece and drill, and is controlled properly. It follows that the analysis and characterisation of a task, especially investigation of the dynamic interactions between the tool carried by a manipulator and a workpiece, strategy generation, and controller design proceed simultaneously in order to develop a force control system for a specific task.

Human–robot interaction in an aircraft wing drilling system

This work examines a robot drilling system in the Aerospace Industrial Development Corporation of Taiwan. Work procedures, human errors and robot failures are also assessed. Based on those assessments, countermeasures and feasible recommendations are proposed to enhance the hybrid system's safety and performance. In addition, some of the recommendations are applied toward the system studied herein, along with the implementation results presented as well. Relevance to industry Industrial robot safety and performance can be advanced through the collaborative efforts of ergonomists and practitioners investigating the work environment and the interaction between humans and robots. based on their observation, sound recommendations regarding human factor-related issues can be made. Therefore, this survey provides a valuable reference for human–robot system designers and practitioners.

The rights of Martians

The apparent - though disputed - discovery of past microbial life on Mars gives rise to the ethical and policy questions of how we can be sure of the status of life on the planet before launching potentially destructive missions; and, should life be found, how we will decide what do to. Both robotic drilling missions and human visits could contaminate or extinguish any life that is present (as well as endangering astronauts); it is questionable whether and how far humans have the right to interfere with extraterrestrial organisms. The author argues that an inclusive, international attempt, perhaps via the UN, must be made to consider these issues now, before any mission is finalized. He suggests that moving away from the Western model of exploitation and colonization could be necessary.

Development And Verification Of A Mathematical Model For Robot Force Control Via Measuring An Output/Input Relationship And Force Control Experiments

This paper describes the development and verification of a mathematical model for a force control system consisting of a PUMA 560 manipulator, force sensor, and environment. Its main contribution is to present an argument that explicit open-loop dynamic models of manipulation systems used for force control are of little relevance or use. Identification techniques are used to model the system as a "black box," measuring only an output/input relationship. The explicit dynamics of the mechanical, hardware, and software elements of the manipulator are neglected; they are considered as parts of the measured output/input relationship. P+D (PD) loops are closed around each joint of the manipulator before identification to reduce uncertainties, to overcome nonlinearities, and thus to linearize the system. Close correspondence between the experimental and the simulated Bode plots for frequencies below 30 Hz indicates that the developed model is accurate enough to analyze and design a force control strategy for hard-on-hard contact applications, such as robotic drilling. A force control strategy based on a PI law for a hard-on-hard application is designed and evaluated in terms of the step response and achievable bandwidth to further validate the mathematical model of the force control system during contact. The simulated and experimental closed-loop step responses and Bode plots from the PI law prove that the mathematical model developed reflects the low-frequency features of the force control system accurately enough for design and implementation of a force control strategy for a real task.

Static Friction Effects During Hard-on-Hard Contact Tasks and Their Implications for Manipulator Design

In this article, we present the results and implications of our experimental study into the effects of static, nonlinear, fric tion during hard-on-hard contact tasks where making a stable contact is problematic. Experiments have been conducted with a PUMA 560 manipulator to address the hard-on-hard con tact stability problem and to stress the importance of damping (active-velocity feedback, and passive-nonlinear friction) for hard-on-hard applications typified by robotic drilling. Experi mental results reveal that during hard-art-hard contact, active damping is inoperative because of quantization, leaving only passive damping to stabilize the system. However, passive damping characteristics vary between joints. Most importantly, the last three joints of the manipulator, which are more af fected by contact force disturbances than others. lack sufficient passive damping, which we argue should match their respec tive joint stiffnesses to achieve contact stability. Therefore, we conclude that manipulator joints with low passive damping should have high-resolution encoders for velocity feedback. These are required to stabilize a force control system making a hard-on-hard constrained contact. The lower the joint friction, the higher the resolution required. This constitutes the main contribution of this article to manipulator design.

Forecasting Minor Machine Failure by DDS Spectrum Analysis

Machine failures are either major or minor. The former usually requires the machine to be stopped immediately, while the latter occurs gradually and can be present before the machine fails. This paper describes the development of an automatic diagnostic system to detect minor machine failure before machine breakdown of computer controlled robotic drilling machines. By using the Dynamic Data System approach, a set of discrete time series data taken from the continuous vibration signal of the machine is analyzed to forecast machine failure and then to distinguish failures due to the spindle, gears, bearings, and air motors of the machine drive system. Compared to the real time analyzer (RTA) approach based on the FFT technique, the DDS power spectrum is smoother and less prone to errors; it successfully identifies defects in the robotic drilling machine.

Preemptive Diagnosis of Minor Machine Failure by DDS Spectrum Analysis

A preemptive diagnostic system has been developed to detect minor machine failures before machine breakdown for a computer controlled robotic drilling end-effector. By using the Dynamic Data System (DDS) approach, a set of discrete time series data taken from the continuous vibration signal of the machine is analyzed to detect machine failure and to distinguish failures due to the spindle, gears, air motors, and ball bearings of the machine drive system. Experiments validate that the proposed diagnostic method can identify spindle, air motors, gear, and bearing defects in the Robotic Drilling Unit.

170 Application of self-learning for tool failure diagnosis in robotic drilling system

170 Application of self-learning for tool failure diagnosis in robotic drilling system

Application of Self-Learning for Tool Failure Diagnosis in Robotic Drilling System

The effort in monitoring tool condition for fully automatic drilling processes has resulted in the development of an intelligent drilling machine to work with industrial robots. This computer-controlled drilling machine has five built-in sensors. Based on the pattern recognition of sensor outputs with sets of algorithms, an intelligent diagnostic system has been developed for on-line detection of and pin-pointing of anyone of the nine drill failures: chisel edge wear, margin wear, breakage, flank wear, crater wear, lip height difference, corner wear and chipping at lips. Many inherent factors affecting the criteria for the judgement of drill wear/breakage, such as drill size, drill material, drill geometry, workpiece material, cutting speed, feed rate, material microstructure, hardness distribution, etc. is avoided by implementing, a self-learning system.

Computer-aided analysis of reconfigurable fixtures and sheet metal parts for robotic drilling

This paper presents an automated manufacturing system for drilling sheet metal parts. All stand-alone systems such as the robot, a set of reconfigurable fixtures and the CAD/CAM workstation have been integrated into a flexible manufacturing system. This system analyzes and evaluates a given fixturing layout and assembles the reconfigurable fixtures automatically using a robot manipulator. An optimum fixturing layout and assembly are achieved by examining the workpart from a stress-strain point of view. In addition, issues such as geometric constraints, yielding and buckling, database design, collision detection, fixturing sequential control and the automatic assembly of fixture elements are considered. The computational and analytical concepts for the reconfigurable fixturing and drilling system are also presented in this paper.