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Article
Publication date: 20 December 2021

Ruolong Qi and Wenfeng Liang

Nuclear waste tanks need to be cut into pieces before they can be safely disposed of, but the cutting process produces a large amount of aerosols with radiation, which is very…

Abstract

Purpose

Nuclear waste tanks need to be cut into pieces before they can be safely disposed of, but the cutting process produces a large amount of aerosols with radiation, which is very harmful to the health of the operator. The purpose of this paper is to establish an intelligent strategy for an integrated robot designed for measurement and cutting, which can accurately identify and cut unknown nuclear waste tanks and realize autonomous precise processing.

Design/methodology/approach

A robot system integrating point cloud measurement and plasma cutting is designed in this paper. First, accurate calibration methods for the robot, tool and hand-eye system are established. Second, for eliminating the extremely scattered point cloud caused by metal surface refraction, an omnidirectional octree data structure with 26 vectors is proposed to extract the point cloud model more accurately. Then, a minimum bounding box is calculated for limiting the local area to be cut, the local three-dimensional shape of the nuclear tank is fitted within the bounding box, in which the cutting trajectories and normal vectors are planned accurately.

Findings

The cutting precision is verified by changing the tool into a dial indicator in the simulation and the experiment process. The octree data structure with omnidirectional pointing vectors can effectively improve the filtering accuracy of the scattered point cloud. The point cloud filter algorithm combined with the structure calibration methods for the integrated measurement and processing system can ensure the final machining accuracy of the robot.

Originality/value

Aiming at the problems of large measurement noise interference, complex transformations between coordinate systems and difficult accuracy guarantee, this paper proposes structure calibration, point cloud filtering and point cloud-based planning algorithm, which can greatly improve the reliability and accuracy of the system. Simulation and experiment verify the final cutting accuracy of the whole system.

Details

Industrial Robot: the international journal of robotics research and application, vol. 49 no. 4
Type: Research Article
ISSN: 0143-991X

Keywords

Article
Publication date: 17 October 2016

Ruolong Qi, Weijia Zhou, Huijie Zhang, Wei Zhang and Guangxin Yang

The weld joint of large thin-wall metal parts which deforms in manufacturing and clamping processes is very difficult to manufacture for its shape is different from the initial…

Abstract

Purpose

The weld joint of large thin-wall metal parts which deforms in manufacturing and clamping processes is very difficult to manufacture for its shape is different from the initial model; thus, the space normals of the part surface are uncertain.

Design/methodology/approach

In this paper, an effective method is presented to calculate cutter location points and to estimate the space normals by measuring some sparse discrete points of weld joint. First, a contact-type probe fixed in the end of friction stir welding (FSW) robot is used to measure a series of discrete points on the weld joint. Then, a space curve can be got by fitting the series of points with a quintic spline. Second, a least square plane (LSP) of the measured points is obtained by the least square method. Then, normal vectors of the plane curve, which is the projection of the space curve on the LSP, are used to estimate the space normals of the weld joint curve. After path planning, a post-processing method combing with FSW craft is elaborated.

Findings

Simulation and real experiment demonstrate that the proposed strategy, which obtains cutter locations of welding and normals without measuring the entire surface, is feasible and effective for the FSW of large thin-walled complex surface parts.

Originality/value

This paper presents a novel method which makes it possible to accurately weld the large thin-wall complex surface part by the FSW robot. The proposed method might be applied to any multi-axes FSW robot similar to the robot studied in this paper.

Details

Industrial Robot: An International Journal, vol. 43 no. 6
Type: Research Article
ISSN: 0143-991X

Keywords

Article
Publication date: 21 August 2017

Ruolong Qi, Weijia Zhou and Wang Tiejun

Uncertainty can arise for a manipulator because its motion can deviate unpredictably from the assumed dynamical model and because sensors might provide information regarding the…

Abstract

Purpose

Uncertainty can arise for a manipulator because its motion can deviate unpredictably from the assumed dynamical model and because sensors might provide information regarding the system state that is imperfect because of noise and imprecise measurement. This paper aims to propose a method to estimate the probable error ranges of the entire trajectory for a manipulator with motion and sensor uncertainties. The aims are to evaluate whether a manipulator can safely avoid all obstacles under uncertain conditions and to determine the probability that the end effector arrives at its goal area.

Design/methodology/approach

An effective, analytical method is presented to evaluate the trajectory error correctly, and a motion plan was executed using Gaussian models by considering sensor and motion uncertainties. The method used an integrated algorithm that combined a Gaussian error model with an extended Kalman filter and a linear–quadratic regulator. Iterative linearization of the nonlinear dynamics was used around every section of the trajectory to derive all of the prior probability distributions before execution.

Findings

Simulation and experimental results indicate that the proposed trajectory planning method based on the motion and sensor uncertainties is indeed highly convenient and efficient.

Originality/value

The proposed approach is applicable to manipulators with motion and sensor uncertainties. It helps determine the error distribution of the predefined trajectory. Based on the evaluation results, the most appropriate trajectory can be selected among many predefined trajectories according to the error ranges and the probability of arriving at the goal area. The method has been successfully applied to a manipulator operating on the Chinese Space Station.

Details

Industrial Robot: An International Journal, vol. 44 no. 5
Type: Research Article
ISSN: 0143-991X

Keywords

Article
Publication date: 6 January 2021

Ruolong Qi, Yuangui Tang and Ke Zhang

For some special manipulators such as the ones work at the space station, nuclear or some other unmanned environments, the overload, collision, vibration, temperature change or…

Abstract

Purpose

For some special manipulators such as the ones work at the space station, nuclear or some other unmanned environments, the overload, collision, vibration, temperature change or release of the internal stress would affect the structural parameters. And thus the operation precision might constantly decrease in long-term use. In these unmanned environments, the unattended manipulators should calibrate itself when they execute high precision operations or proceed self-maintenances. The purpose of this paper is to propose an automatic visual assistant on-line calibration (AVOC) method based on multi-markers.

Design/methodology/approach

A camera fixed on the end of the manipulator is used to measure one to three identification points, which forms an unstable multi-sensor eye-in-hand system. A Gaussian motion method which combines the linear quadratic regulator control and extended Kalman filter together is proposed to make the manipulator track the planned trajectories when its inaccurate structural parameters form uncertain motion errors. And a Monte-Carlo method is proposed to form a high precision and stable signal acquisition when the visual system has measurement errors and intermittent signal feedback. An automatic sampling process is adopted to select the optimal measurement points basing on their variances.

Findings

Data analysis and experiment results prove the efficiency and feasibility of the method proposed in this paper. With this method, the positioning accuracy is largely promoted from about 2 mm to 0.04–0.05 mm.

Originality/value

Experiments were carried out successfully on a manipulator in a life sciences glove box that will work at the Chinese space station. It is a low cost and efficient manipulator calibration method. The whole autonomic calibration process takes less than 10 min and requires no human intervention. In addition, this method not only can be used in the calibration of other unmanned articulated manipulator that works in deep ocean, nuclear industry or space but also be useful for the maintenance work in modern factories owing a lot of industrial robots.

Details

Industrial Robot: the international journal of robotics research and application, vol. 48 no. 2
Type: Research Article
ISSN: 0143-991X

Keywords

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