Researchers building modular, self-programming robots to improve HRI

Many work processes would be almost unthinkable today without robots. But robots operating in manufacturing facilities have often posed risks to workers because they are not responsive enough to their surroundings.

To make it easier for people and robots to work in close proximity in the future, Prof. Matthias Althoff of the Technical University of Munich (TUM) has developed a new system called (IMPROV) that uses interconnectable modules for self-programming and self-verification.

When companies use robots to produce goods, they generally have to position their automatic helpers in safety cages to reduce the risk of injury to people working nearby. A new system could soon free the robots from their cages and thus transform standard practices in the world of automation.

Althoff has developed a toolbox principle for the simple assembly of safe robots using various components. The modules can be combined in almost any way desired, enabling companies to customize their robots for a wide range of tasks – or simply replace damaged components. Althoff’s system was presented in a paper in the June 2019 issue of Science Robotics.

Built-in chip enables the robot to program itself

Robots that can be configured individually using a set of components have been seen before. However, each new model required expert programming before going into operation. Althoff has equipped each module in his IMPROV robot toolbox with a chip that enables every modular robot to program itself on the basis of its own individual toolkit.

In the Science Robotics paper, the researchers said “self-programming of high-level tasks was not considered in this work. The created models were used for automatically synthesizing model-based controllers, as well as for the following two aspects.”

Self-verification

To account for dynamically changing environments, the robot formally verified, by itself, whether any human could be harmed through its planned actions during its operation. A planned motion was verified as safe if none of the possible future movements of surrounding humans leads to a collision.

Because uncountable possible future motions of surrounding humans exist, Althoff bound the set of possible motions using reachability analysis. Althoff said the inherently safe approach renders robot cages unnecessary in many applications.

Scientist Christina Miller working on the modular robot arm. Credit: A. Heddergott/TUM

Keeping an eye on the people working nearby

“Our modular design will soon make it more cost-effective to build working robots. But the toolbox principle offers an even bigger advantage: With IMPROV, we can develop safe robots that react to and avoid contact with people in their surroundings,” said Althoff.

With the chip installed in each module and the self-programming functionality, the robot is automatically aware of all data on the forces acting within it as well as its own geometry. That enables the robot to predict its own path of movement.

At the same time, the robot’s control center uses input from cameras installed in the room to collect data on the movements of people working nearby. Using this information, a robot programmed with IMPROV can model the potential next moves of all of the nearby workers. As a result, it can stop before coming into contact with a hand, for example – or with other approaching objects.

“With IMPROV we can guarantee that the controls will function correctly. Because the robots are automatically programmed for all possible movements nearby, no human will be able to instruct them to do anything wrong,” says Althoff.

IMPROV shortens cycle times

For their toolbox set, the scientists used standard industrial modules for some parts, complemented by the necessary chips and new components from the 3D printer. In a user study, Althoff and his team showed that IMPROV not only makes working robots cheaper and safer – it also speeds them up: They take 36% less time to complete their tasks than previous solutions that require a permanent safety zone around a robot.

Editor’s Note: This article was republished from the Technical University of Munich.

Hank robot from Cambridge Consultants offers sensitive grip to industrial challenges

Robotics developers have taken a variety of approaches to try to equal human dexterity. Cambridge Consultants today unveiled Hank, a robot with flexible robotic fingers inspired by the human hand. Hank uses a pioneering sensory system embedded in its pneumatic fingers, providing a sophisticated sense of touch and slip. It is intended to emulate the human ability to hold and grip delicate objects using just the right amount of pressure.

Cambridge Consultants stated that Hank could have valuable applications in agriculture and warehouse automation, where the ability to pick small, irregular, and delicate items has been a “grand challenge” for those industries.

Picking under pressure

While warehouse automation has taken great strides in the past decade, today’s robots cannot emulate human dexterity at the point of picking diverse individual items from larger containers, said Cambridge Consultants. E‑commerce giants are under pressure to deliver more quickly and at a cheaper price, but still require human operators for tasks that can be both difficult and tedious.

“The logistics industry relies heavily on human labor to perform warehouse picking and packing and has to deal with issues of staff retention and shortages,” said Bruce Ackman, logistics commercial lead at Cambridge Consultants. “Automation of this part of the logistics chain lags behind the large-scale automation seen elsewhere.”

By giving a robot additional human-like senses, it can feel and orient its grip around an object, applying just enough force, while being able to adjust or abandon if the object slips. Other robots with articulated arms used in warehouse automation tend to require complex grasping algorithms, costly sensing devices, and vision sensors to accurately position the end effector (fingers) and grasp an object.

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Hank uses sensors for a soft touch

Hank uses soft robotic fingers controlled by airflows that can flex the finger and apply force. The fingers are controlled individually in response to the touch sensors. This means that the end effector does not require millimeter-accurate positioning to grasp an object. Like human fingers, they close until they “feel” the object, said Cambridge Consultants.

With the ability to locate an object, adjust overall system position and then to grasp that object, Hank can apply increased force if a slip is detected and generate instant awareness of a mishandled pick if the object is dropped.

Cambridge Consultants claimed that Hank moves a step beyond legacy approaches to this challenge, which tend to rely on pinchers and suction appendages to grasp items, limiting the number and type of objects they can pick and pack.

“Hank’s world-leading sensory system is a game changer for the logistics industry, making actions such as robotic bin picking and end-to-end automated order fulfillment possible,” said Ackman. “Adding a sense of touch and slip, generated by a single, low-cost sensor, means that Hank’s fingers could bring new efficiencies to giant distribution centers.”

Molded from silicone, Hank’s fingers are hollow and its novel sensors are embedded during molding, with an air chamber running up the center. The finger surface is flexible, food-safe, and cleanable. As a low-cost consumable, the fingers can simply be replaced if they become damaged or worn.

With offices in Cambridge in the U.K.; Boston, Mass.; and Singapore, Cambridge Consultants develops breakthrough products, creates and licenses intellectual property, and provides business and technology consulting services for clients worldwide. It is part of Altran, a global leader in engineering and research and development services. For more than 35 years, Altran has provided design expertise in the automotive, aerospace, defense, industrial, and electronics sectors, among others.

Techmetics introduces robot fleet to U.S. hotels and hospitals

Fleets of autonomous mobile robots have been growing in warehouses and the service industry. Singapore-based Techmetics has entered the U.S. market with ambitions to supply multiple markets, which it already does overseas.

The company last month launched two new lines of autonomous mobile robots. The Techi Butler is designed to serve hotel guests or hospital patients by interacting with them via a touchscreen or smartphone. It can deliver packages, room-service orders, and linens and towels.

The Techi Cart is intended to serve back-of-house services such as laundry rooms, kitchens, and housekeeping departments.

“Techmetics serves 10 different applications, including manufacturing, casinos, and small and midsize businesses,” said Mathan Muthupillai, founder and CEO of Techmetics. “We’re starting with just two in the U.S. — hospitality and healthcare.”

Building a base

Muthupillai founded Techmetics in Singapore in 2012. “We spent the first three years on research and development,” he told The Robot Report. “By the end of 2014, we started sending out solutions.”

“The R&D team didn’t just start with product development,” recalled Muthupillai. “We started with finding clients first, identified their pain points and expectations, and got feedback on what they needed.”

“A lot of other companies make a robotic base, but then they have to build a payload solution,” he said. “We started with a good robot base that we found and added our body, software layer, and interfaces. We didn’t want to build autonomous navigation from scratch.”

“Now, we’re just getting components — lasers, sensors, motors — and building everything ourselves,” he explained. “The navigation and flow-management software are created in-house. We’ve created our own proprietary software.”

“We have a range of products, all of which use 2-D SLAM [simultaneous localization and mapping], autonomous navigation, and many safety sensors,” Muthupillai added. “They come with three lasers — two vertical and one horizontal for path planning. We’re working on a 3-D-based navigation solution.”

“Our robots are based on ROS [the Robot Operating System],” said Muthupillai. “We’ve created a unique solution that comes with third-party interfaces.”

Techmetics offers multiple robot models for different industries.

Source: Techmetics

Techmetics payloads vary

The payload capacity of Techmetics’ robots depends on the application and accessories and ranges from 250 to 550 lb. (120 to 250 kg).

“The payload and software are based on the behavior patterns in an industry,” said Muthupillai. “In manufacturing or warehousing, people are used to working around robots, but in the service sector, there are new people all the time. The robot must respond to them — they may stay in its path or try to stop it.”

“When we started this company, there were few mobile robots for the manufacturing industry. They looked industrial and had relatively few safety features because they weren’t near people,” he said. “We changed the form factor for hospitality to be good-looking and safer.”

“When we talk with hotels about the Butler robots, they needed something that could go to multiple rooms,” Muthupillai explained. “Usually, staffers take two to three items in a single trip, so if a robot went to only one room and then returned, that would be a waste of time. Our robots have three compartment levels based on this feedback.”

Elevators posed a challenge for the Techi Butler and Techi Cart — not just for interoperability, but also for human-machine interaction, he said.

“Again, people working with robots didn’t share elevators with robots, but in hospitals and hotels, the robot needs to complete its job alongside people,” Muthupillai said. “After three years, we’re still modifying or adding functionalities, and the robots can take an elevator or go across to different buildings.”

“We’re not currently focusing on the supply chain industry, but we will license and launch the base into the market so that third parties can create their own solutions,” he said.

Techmetics' Techi Cart transports linens

Techi Cart transports linens and towels in a hotel or hospital. Source: Techmetics

Differentiators for Techi Butler and Cart

“We provide 10 robot models for four industries — no single company is a competitor for all our markets,” said Muthupillai. “We have three key differentiators.”

“First, customers can engage one vendor for multiple needs, and all of our robots can interact with one another,” he said. “Second, we talk with our clients and are always open to customization — for example, about compartment size — that other’s can’t do.”

“Third, we work across industries and can share our advantages across them,” Muthupillai claimed. “Since we already work with the healthcare industry, we already comply with safety and other regulations.”

“In hospitals or hotels, it’s not just about delivering a product from one point to another,” he said. “We’re adding camera and voice-recognition capabilities. If a robot sees a person who’s lost, it can help them.”

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Distribution and expansion

Techmetics’ mobile robots are manufactured in Thailand. According to Muthupillai, 80% of its robots are deployed in hotels and hospitals, and 20% are in manufacturing. The company already has distributors in Australia, Taiwan, and Thailand, and it is leveraging existing international clients for its expansion.

“We have many corporate clients in Singapore,” Muthupillai said. “The Las Vegas Sands Singapore has deployed 10 robots, and their headquarters in Las Vegas is considering deploying our products.”

“Also, U.K.-based Yotel has two hotels in Singapore, and its London branch is also interested,” he added. “The Miami Yotel is already using our robots, and soon they will be in San Francisco.”

Techmetics has three models for customers to choose from. The first is outright purchase, and the second is a two- or three-year lease. “The third model is innovative — they can try the robots from three to six months or one year and then buy,” Muthupillai said.

Muthupillai said he has moved to Techmetics’ branch office in the U.S. to manage its expansion. “We’ll be doing direct marketing in California, and we’re in the process of identifying partners, especially on the East Coast.”

“Only the theme, colors, or logos changed. No special modifications were necessary for the U.S. market,” he said. “We followed safety regulations overseas, but they were tied to U.S. regulations.”

“We will target the retail industry with a robot concierge, probably by the end of this year,” said Muthupillai. “We will eventually offer all 10 models in the U.S.”

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