Periodic Reporting for period 1 - ERABID (Enabling Robot Adaptive Behaviours for NDT Inspections in Dynamic Contexts)
Berichtszeitraum: 2020-03-16 bis 2022-03-15
The action explored two main research topics. The first topic concerned the automated inspections to identify defects (both dimensional and volumetric) in industrial elements through non-destructive control methods. The second topic concerned the programming of industrial robots (robotic manipulators), the development of adaptive automatic methods and data management issues for the nascent intelligent industrial paradigms (Industry 4.0).
The scalability of the approaches developed by this project makes them suitable to be used in different scenarios for applications that go beyond automated non-destructive testing. For example, the autonomous geometry mapping of complex parts and the autonomous robotic navigation are suitable for space exploration programs, land mapping through drones, etc. The outcomes of this action can be used to support digital and robotic innovation in Europe and have an impact on apparently distant fields. They contribute to addressing the needs and requirements defined by the European Factory of the Future initiatives (H2020-FOF projects), especially in zero-defect manufacturing.
This action developed a new approach for real-time creating the robot path required to scan a part geometry. It removes manual programming and interaction requirements, adding autonomy to the geometry mapping problem. The approach is suitable for using a wide variety of metrology sensors and scalable to enable the mapping of large and/or complex geometries.
Novel software modules were conceptualised to implement this action's new robotic inspection paradigms. In particular, the algorithms required to enable autonomous geometry mapping and volumetric robotic inspections were thoroughly tested and validated experimentally. These algorithms involved combining several concepts, including robot kinematics, metrology, machine vision, data collection and data analysis. This action demonstrated real-time robot path correction in response to sensor data.
This action involved students of the department of engineering of the University of Palermo. Through a secondment phase, the researcher visited an Austrian research organisation (RECENDT GmbH) and supported their effort to automate laser-ultrasonic non-contact inspections. The research fellow had vibrant training opportunities, increasing his knowledge of advanced aspects concerning the Fourth Industrial Revolution. He delivered an academic course on Non-Destructive Evaluation for Industry 4.0 to the doctoral students of the department of engineering of the University of Palermo.
The scalability of the approaches developed by this project makes them suitable to be used in different scenarios for applications that go beyond automated non-destructive testing. For example, the autonomous geometry mapping of complex parts and the autonomous robotic navigation are suitable for space exploration programs, land mapping through drones, etc. The outcomes of this action can be used to support digital and robotic innovation in Europe and have an impact on apparently distant fields. They contribute to addressing the needs and requirements defined by the European Factory of the Future initiatives (H2020-FOF projects), especially in zero-defect manufacturing.
This action developed a new approach for real-time creating the robot path required to scan a part geometry. It removes manual programming and interaction requirements, adding autonomy to the geometry mapping problem. The approach is suitable for using a wide variety of metrology sensors and scalable to enable the mapping of large and/or complex geometries.
Novel software modules were conceptualised to implement this action's new robotic inspection paradigms. In particular, the algorithms required to enable autonomous geometry mapping and volumetric robotic inspections were thoroughly tested and validated experimentally. These algorithms involved combining several concepts, including robot kinematics, metrology, machine vision, data collection and data analysis. This action demonstrated real-time robot path correction in response to sensor data.
This action involved students of the department of engineering of the University of Palermo. Through a secondment phase, the researcher visited an Austrian research organisation (RECENDT GmbH) and supported their effort to automate laser-ultrasonic non-contact inspections. The research fellow had vibrant training opportunities, increasing his knowledge of advanced aspects concerning the Fourth Industrial Revolution. He delivered an academic course on Non-Destructive Evaluation for Industry 4.0 to the doctoral students of the department of engineering of the University of Palermo.
As far as the research on metrology and surface mapping approaches was regarded, a new robotic arm was procured for the ultrasonic laboratory of the Department of Engineering of the University of Palermo, and an optical metrology system was integrated with it. Thus, a mathematical framework for adaptive and incremental 3D reconstruction of specimens, suitable to be used with robot-manipulated optical 3D scanners, was developed.
This action investigated the requirements for the robotisation of various inspection techniques. A generalised bisection method for optimum ultrasonic ray tracing in multi-layered structures was produced in this context. The performance of different root-finding methods for the solution of ultrasonic ray tracing was investigated. A phase of this action focused on characterising the dependence of signal amplitude from generation source position in laser-based ultrasonic inspections. Furthermore, the sensitivity of an interferometry instrument as a function of the focusing lens and laser-head position was investigated. A complex geometry sample was inspected with different robotised techniques (immersion ultrasonic pulse-echo, through-transmission air-coupled inspection, through-transmission and pulse-echo laser-based inspections).
The action developed software modules for simulation, control, acquisition and data analysis. A novel framework that enables fully autonomous single-pass geometric and volumetric inspection of complex parts using one single robotised sensor was conceptualised and implemented. The developed approach is scalable to different problem sizes, spanning from inspection of relatively small parts (e.g. through industrial robotic arms) to land surface mapping (e.g. through drones). It allows the progressive construction of the digital model of a part surface throughout the inspection process. The framework autonomously confines the inspection into the region of interest, where the part under inspection is detectable.
This action focused on factors that are currently slowing down the establishment of smart manufacturing, with particular emphasis on integrated quality assessment. This work package was proposed as an important collaboration opportunity between the researcher and other researchers in the disciplinary fields. Unfortunately, due to the delays caused by the contingent COVID-19 pandemic, this phase could not be developed to its full extent. Nevertheless, this action reviewed the state-of-the-art, paving the way for future investigations.
This action has generated four peer-reviewed journal publications and six contributions to international conferences. Outreach activities included participation in two European Research nights and public engagement activities for schools.
This action investigated the requirements for the robotisation of various inspection techniques. A generalised bisection method for optimum ultrasonic ray tracing in multi-layered structures was produced in this context. The performance of different root-finding methods for the solution of ultrasonic ray tracing was investigated. A phase of this action focused on characterising the dependence of signal amplitude from generation source position in laser-based ultrasonic inspections. Furthermore, the sensitivity of an interferometry instrument as a function of the focusing lens and laser-head position was investigated. A complex geometry sample was inspected with different robotised techniques (immersion ultrasonic pulse-echo, through-transmission air-coupled inspection, through-transmission and pulse-echo laser-based inspections).
The action developed software modules for simulation, control, acquisition and data analysis. A novel framework that enables fully autonomous single-pass geometric and volumetric inspection of complex parts using one single robotised sensor was conceptualised and implemented. The developed approach is scalable to different problem sizes, spanning from inspection of relatively small parts (e.g. through industrial robotic arms) to land surface mapping (e.g. through drones). It allows the progressive construction of the digital model of a part surface throughout the inspection process. The framework autonomously confines the inspection into the region of interest, where the part under inspection is detectable.
This action focused on factors that are currently slowing down the establishment of smart manufacturing, with particular emphasis on integrated quality assessment. This work package was proposed as an important collaboration opportunity between the researcher and other researchers in the disciplinary fields. Unfortunately, due to the delays caused by the contingent COVID-19 pandemic, this phase could not be developed to its full extent. Nevertheless, this action reviewed the state-of-the-art, paving the way for future investigations.
This action has generated four peer-reviewed journal publications and six contributions to international conferences. Outreach activities included participation in two European Research nights and public engagement activities for schools.
The project enhanced the research fellow's potential and future career prospects, who is continuing his research career at the National Research Council of Italy (CNR), within the High Performances Computing and Networking Institute (ICAR). This action allowed the researcher to transfer his skills and knowledge to the Department of Engineering of the University of Palermo.
It allowed the University of Palermo to activate a new research line, focusing on investigating novel robotic non-destructive testing applications. Thanks to the dissemination of the results, the beneficiary has an increased capacity to attract research funding and innovate.
The scalability of the approaches developed by this action makes them suitable to be used in different scenarios for applications that go beyond automated non-destructive testing. For example, the autonomous geometry mapping of complex parts and the autonomous robotic navigation are suitable for space exploration programs, land mapping through drones, etc. This project outcome can be used to support digital and robotic innovation and can have an impact on apparently distant fields. Although this project did not release new products to the market, the executed trials can easily translate to prototypes and industrial impact.
It allowed the University of Palermo to activate a new research line, focusing on investigating novel robotic non-destructive testing applications. Thanks to the dissemination of the results, the beneficiary has an increased capacity to attract research funding and innovate.
The scalability of the approaches developed by this action makes them suitable to be used in different scenarios for applications that go beyond automated non-destructive testing. For example, the autonomous geometry mapping of complex parts and the autonomous robotic navigation are suitable for space exploration programs, land mapping through drones, etc. This project outcome can be used to support digital and robotic innovation and can have an impact on apparently distant fields. Although this project did not release new products to the market, the executed trials can easily translate to prototypes and industrial impact.