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Article
Publication date: 3 March 2023

Yanbing Ni, Yizhang Cui, Shilei Jia, Chenghao Lu and Wenliang Lu

The purpose of this paper is to propose a method for selecting the position and attitude trajectory of error measurement to improve the kinematic calibration efficiency of a one…

Abstract

Purpose

The purpose of this paper is to propose a method for selecting the position and attitude trajectory of error measurement to improve the kinematic calibration efficiency of a one translational and two rotational (1T2R) parallel power head and to improve the error compensation effect by improving the properties of the error identification matrix.

Design/methodology/approach

First, a general mapping model between the endpoint synthesis error is established and each geometric error source. Second, a model for optimizing the position and attitude trajectory of error measurement based on sensitivity analysis results is proposed, providing a basis for optimizing the error measurement trajectory of the mechanism in the working space. Finally, distance error measurement information and principal component analysis (PCA) ideas are used to construct an error identification matrix. The robustness and compensation effect of the identification algorithm were verified by simulation and through experiments.

Findings

Through sensitivity analysis, it is found that the distribution of the sensitivity coefficient of each error source in the plane of the workspace can approximately represent its distribution in the workspace, and when the end of the mechanism moves in a circle with a large nutation angle, the comprehensive influence coefficient of each sensitivity is the largest. Residual analysis shows that the robustness of the identification algorithm with the idea of PCA is improved. Through experiments, it is found that the compensation effect is improved.

Originality/value

A model for optimizing the position and attitude trajectory of error measurement is proposed, which can effectively improve the error measurement efficiency of the 1T2R parallel mechanism. In addition, the PCA idea is introduced. A least-squares PCA error identification algorithm that improves the robustness of the identification algorithm by improving the property of the identification matrix is proposed, and the compensation effect is improved. This method has been verified by experiments on 1T2R parallel mechanism and can be extended to other similar parallel mechanisms.

Details

Industrial Robot: the international journal of robotics research and application, vol. 50 no. 4
Type: Research Article
ISSN: 0143-991X

Keywords

Article
Publication date: 23 January 2024

Wang Zhang, Lizhe Fan, Yanbin Guo, Weihua Liu and Chao Ding

The purpose of this study is to establish a method for accurately extracting torch and seam features. This will improve the quality of narrow gap welding. An adaptive deflection…

Abstract

Purpose

The purpose of this study is to establish a method for accurately extracting torch and seam features. This will improve the quality of narrow gap welding. An adaptive deflection correction system based on passive light vision sensors was designed using the Halcon software from MVtec Germany as a platform.

Design/methodology/approach

This paper proposes an adaptive correction system for welding guns and seams divided into image calibration and feature extraction. In the image calibration method, the field of view distortion because of the position of the camera is resolved using image calibration techniques. In the feature extraction method, clear features of the weld gun and weld seam are accurately extracted after processing using algorithms such as impact filtering, subpixel (XLD), Gaussian Laplacian and sense region for the weld gun and weld seam. The gun and weld seam centers are accurately fitted using least squares. After calculating the deviation values, the error values are monitored, and error correction is achieved by programmable logic controller (PLC) control. Finally, experimental verification and analysis of the tracking errors are carried out.

Findings

The results show that the system achieves great results in dealing with camera aberrations. Weld gun features can be effectively and accurately identified. The difference between a scratch and a weld is effectively distinguished. The system accurately detects the center features of the torch and weld and controls the correction error to within 0.3mm.

Originality/value

An adaptive correction system based on a passive light vision sensor is designed which corrects the field-of-view distortion caused by the camera’s position deviation. Differences in features between scratches and welds are distinguished, and image features are effectively extracted. The final system weld error is controlled to 0.3 mm.

Details

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

Keywords

Article
Publication date: 15 March 2024

Mohamed Slamani, Hocine Makri, Aissa Boudilmi, Ilian A. Bonev and Jean-Francois Chatelain

This research paper aims to optimize the calibration process for an ABB IRB 120 robot, specifically for robotic orbital milling applications, by introducing and validating the use…

Abstract

Purpose

This research paper aims to optimize the calibration process for an ABB IRB 120 robot, specifically for robotic orbital milling applications, by introducing and validating the use of the observability index and telescopic ballbar for accuracy enhancement.

Design/methodology/approach

The study uses the telescopic ballbar and an observability index for the calibration of an ABB IRB 120 robot, focusing on robotic orbital milling. Comparative simulation analysis selects the O3 index. Experimental tests, both static and dynamic, evaluate the proposed calibration approach within the robot’s workspace.

Findings

The proposed calibration approach significantly reduces circularity errors, particularly in robotic orbital milling, showcasing effectiveness in both static and dynamic modes at various tool center point speeds.

Research limitations/implications

The study focuses on a specific robot model and application (robotic orbital milling), limiting generalizability. Further research could explore diverse robot models and applications.

Practical implications

The findings offer practical benefits by enhancing the accuracy of robotic systems, particularly in precision tasks like orbital milling, providing a valuable calibration method.

Social implications

While primarily technological, improved robotic precision can have social implications, potentially influencing fields where robotic applications are crucial, such as manufacturing and automation.

Originality/value

This study’s distinctiveness lies in advancing the accuracy and precision of industrial robots during circular motions, specifically tailored for orbital milling applications. The innovative approach synergistically uses the observability index and telescopic ballbar to achieve these objectives.

Details

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

Keywords

Article
Publication date: 18 July 2023

Bin Chen, Yuan Wang, Shaoqing Cui, Jiansheng Xiang, John-Paul Latham and Jinlong Fu

Accurate presentation of the rock microstructure is critical to the grain-scale analysis of rock deformation and failure in numerical modelling. 3D granite microstructure…

Abstract

Purpose

Accurate presentation of the rock microstructure is critical to the grain-scale analysis of rock deformation and failure in numerical modelling. 3D granite microstructure modelling has only been used in limited studies with the mineral pattern often remaining poorly constructed. In this study, the authors developed a new approach for generating 2D and 3D granite microstructure models from a 2D image by combining a heterogeneous material reconstruction method (simulated annealing method) with Voronoi tessellation.

Design/methodology/approach

More specifically, the stochastic information in the 2D image is first extracted using the two-point correlation function (TPCF). Then an initial 2D or 3D Voronoi diagram with a random distribution of the minerals is generated and optimised using a simulated annealing method until the corresponding TPCF is consistent with that in the 2D image. The generated microstructure model accurately inherits the stochastic information (e.g. volume fraction and mineral pattern) from the 2D image. Lastly, the authors compared the topological characteristics and mechanical properties of the 2D and 3D reconstructed microstructure models with the model obtained by direct mapping from the 2D image of a real rock sample.

Findings

The good agreements between the mapped and reconstructed models indicate the accuracy of the reconstructed microstructure models on topological characteristics and mechanical properties.

Originality/value

The newly developed reconstruction method successfully transfers the mineral pattern from a granite sample into the 2D and 3D Voronoi-based microstructure models ready for use in grain-scale modelling.

Details

Engineering Computations, vol. 40 no. 6
Type: Research Article
ISSN: 0264-4401

Keywords

Article
Publication date: 28 November 2023

Xindang He, Run Zhou, Zheyuan Liu, Suliang Yang, Ke Chen and Lei Li

The purpose of this paper is to provide a comprehensive review of a non-contact full-field optical measurement technique known as digital image correlation (DIC).

Abstract

Purpose

The purpose of this paper is to provide a comprehensive review of a non-contact full-field optical measurement technique known as digital image correlation (DIC).

Design/methodology/approach

The approach of this review paper is to introduce the research pertaining to DIC. It comprehensively covers crucial facets including its principles, historical development, core challenges, current research status and practical applications. Additionally, it delves into unresolved issues and outlines future research objectives.

Findings

The findings of this review encompass essential aspects of DIC, including core issues like the subpixel registration algorithm, camera calibration, measurement of surface deformation in 3D complex structures and applications in ultra-high-temperature settings. Additionally, the review presents the prevailing strategies for addressing these challenges, the most recent advancements in DIC applications across quasi-static, dynamic, ultra-high-temperature, large-scale and micro-scale engineering domains, along with key directions for future research endeavors.

Originality/value

This review holds a substantial value as it furnishes a comprehensive and in-depth introduction to DIC, while also spotlighting its prospective applications.

Details

Multidiscipline Modeling in Materials and Structures, vol. 20 no. 1
Type: Research Article
ISSN: 1573-6105

Keywords

Article
Publication date: 12 September 2023

Ling Wang, Xiaoliang Wu, Zeng Kang, Yanfeng Gao, Xiai Chen and Binrui Wang

In traditional calibration methods of kinematics parameters of industrial robots, dozens of model parameters are identified together based on an optimization procedure. Due to…

Abstract

Purpose

In traditional calibration methods of kinematics parameters of industrial robots, dozens of model parameters are identified together based on an optimization procedure. Due to different contributions of model parameter errors to the tool center point positioning error of industrial robots, obtaining good results for all model parameters is very difficult. Therefore, the purpose of this paper is to propose a sequential calibration method specifically for transmission ratio parameters, which includes reduction ratios and coupling ratios of industrial robot joints.

Design/methodology/approach

The ABB IRB 1410 industrial robot is considered as an example in this study. The transmission ratios for each joint of the robot are identified using the spatial circle fitting method based on spatial vectors, which fit the center and radius of joint rotation with the least squares optimization algorithm. In addition, a method based on the Rodrigues’ formula is designed and presented for identifying the actual coupling ratio of the robot. Subsequently, an experiment is carried out to verify the proposed sequential calibration method of transmission ratios.

Findings

In this experiment, the actual positions of the linkages before and after joint rotations are measured by a laser tracker. Accurate results of the reduction ratios and the coupling ratios are calculated, and the results are verified experimentally. The results show that by calibrating the reduction ratios and coupling ratios of the ABB robot, the rotation angle errors of the robot joints can be reduced.

Originality/value

The authors propose a sequential calibration method for transmission ratio parameters, including reduction ratios and coupling ratios of industrial robot joints. An experiment is carried out to verify this proposed sequential calibration method. This study may be beneficial for calibrating the kinematic parameters of industrial robots and improving their positioning accuracy.

Details

Industrial Robot: the international journal of robotics research and application, vol. 50 no. 6
Type: Research Article
ISSN: 0143-991X

Keywords

Article
Publication date: 24 November 2022

Murat Kizildag, Jeffrey Thomas Weinland and Ilhan Demirer

The main stance of this paper is to draw an authentic and rigorous outlook in terms of the financial and operational performance of small lodging establishments (SLEs) and put…

Abstract

Purpose

The main stance of this paper is to draw an authentic and rigorous outlook in terms of the financial and operational performance of small lodging establishments (SLEs) and put forth achievable and practical economic solutions that demonstrate the relative effectiveness of the adopted measures. This paper also suggests practical solutions to help minimize SLEs' financial vulnerability to long-term crisis and to boost their resilience with relative measures by applying recovery revival strategies for this particular segment of the lodging industry.

Design/methodology/approach

The authors have picked a locally owned resort hotel in Central Florida area and structured a real-life, case study-based inductive approach that is purposeful and offers rich economic outlook and analysis for the entire lodging industry, especially for the resort-hotel type of accommodation facilities. The main reason for why they only focus on one company is that they can fully understand the financial effects of COVID-19 on resort type of hotels and layout countering strategies. To achieve paper objectives, they have implemented cost–benefit (C–B), break-even (B-E) analyses along with a sensitivity testing approach.

Findings

The most striking result was that during the state-mandated shutdown period in 2020, overhead and overall operational costs associated with room sales and revenues were very high during this period that shrank the contribution margin ratio for rooms CMRw (room) and eventually yielded high sales volumes to be achieved at the B-E points vs lower sales volumes with almost the same average daily rate (ADR) levels needed for the B-E levels.

Research limitations/implications

Future studies should specifically delve further into a portfolio of SLEs in the region or state or nation wise because the units comprising the SLEs might be too small to muster the changes required to bounce forward for the entire lodging industry in the world.

Practical implications

The resort's revenue re-optimization focus should center on financial re-benchmarking and business re-viability stress under different levels of shock scenarios. According to the different scenarios and calibrations for the ADRs, room nights, net present values (NPVs) of cash flows and profit margins derived from our main analyses, minimizing expenses and preserving cash would be the best key strategy for financial recovery during an ongoing COVID-19 pandemic.

Originality/value

It is obvious that the lodging, hospitality and tourism industry are the hardest-hit industries by the harsh and adverse effects of COVID-19. The effects of pandemic are differently shaped on operations in different industries and subsectors. Therefore, the operational and financial evaluation for the SLEs as the core and a catalyst in the entire lodging industry can shed a light on the strategic financial recovery procedures with broadly applicable real-life and endogenous capabilities and reasoning.

Details

Journal of Hospitality and Tourism Insights, vol. 6 no. 5
Type: Research Article
ISSN: 2514-9792

Keywords

Article
Publication date: 29 February 2024

Heng Liu, Yonghua Lu, Haibo Yang, Lihua Zhou and Qiang Feng

In the context of fixed-wing aircraft wing assembly, there is a need for a rapid and precise measurement technique to determine the center distance between two double-hole…

Abstract

Purpose

In the context of fixed-wing aircraft wing assembly, there is a need for a rapid and precise measurement technique to determine the center distance between two double-hole components. This paper aims to propose an optical-based spatial point distance measurement technique using the spatial triangulation method. The purpose of this paper is to design a specialized measurement system, specifically a spherically mounted retroreflector nest (SMR nest), equipped with two laser displacement sensors and a rotary encoder as the core to achieve accurate distance measurements between the double holes.

Design/methodology/approach

To develop an efficient and accurate measurement system, the paper uses a combination of laser displacement sensors and a rotary encoder within the SMR nest. The system is designed, implemented and tested to meet the requirements of precise distance measurement. Software and hardware components have been developed and integrated for validation.

Findings

The optical-based distance measurement system achieves high precision at 0.04 mm and repeatability at 0.02 mm within a range of 412.084 mm to 1,590.591 mm. These results validate its suitability for efficient assembly processes, eliminating repetitive errors in aircraft wing assembly.

Originality/value

This paper proposes an optical-based spatial point distance measurement technique, as well as a unique design of a SMR nest and the introduction of two novel calibration techniques, all of which are validated by the developed software and hardware platform.

Details

Sensor Review, vol. 44 no. 2
Type: Research Article
ISSN: 0260-2288

Keywords

Article
Publication date: 23 November 2022

Chetan Jalendra, B.K. Rout and Amol Marathe

Industrial robots are extensively used in the robotic assembly of rigid objects, whereas the assembly of flexible objects using the same robot becomes cumbersome and challenging…

Abstract

Purpose

Industrial robots are extensively used in the robotic assembly of rigid objects, whereas the assembly of flexible objects using the same robot becomes cumbersome and challenging due to transient disturbance. The transient disturbance causes vibration in the flexible object during robotic manipulation and assembly. This is an important problem as the quick suppression of undesired vibrations reduces the cycle time and increases the efficiency of the assembly process. Thus, this study aims to propose a contactless robot vision-based real-time active vibration suppression approach to handle such a scenario.

Design/methodology/approach

A robot-assisted camera calibration method is developed to determine the extrinsic camera parameters with respect to the robot position. Thereafter, an innovative robot vision method is proposed to identify a flexible beam grasped by the robot gripper using a virtual marker and obtain the dimension, tip deflection as well as velocity of the same. To model the dynamic behaviour of the flexible beam, finite element method (FEM) is used. The measured dimensions, tip deflection and velocity of a flexible beam are fed to the FEM model to predict the maximum deflection. The difference between the maximum deflection and static deflection of the beam is used to compute the maximum error. Subsequently, the maximum error is used in the proposed predictive maximum error-based second-stage controller to send the control signal for vibration suppression. The control signal in form of trajectory is communicated to the industrial robot controller that accommodates various types of delays present in the system.

Findings

The effectiveness and robustness of the proposed controller have been validated using simulation and experimental implementation on an Asea Brown Boveri make IRB 1410 industrial robot with a standard low frame rate camera sensor. In this experiment, two metallic flexible beams of different dimensions with the same material properties have been considered. The robot vision method measures the dimension within an acceptable error limit i.e. ±3%. The controller can suppress vibration amplitude up to approximately 97% in an average time of 4.2 s and reduces the stability time up to approximately 93% while comparing with control and without control suppression time. The vibration suppression performance is also compared with the results of classical control method and some recent results available in literature.

Originality/value

The important contributions of the current work are the following: an innovative robot-assisted camera calibration method is proposed to determine the extrinsic camera parameters that eliminate the need for any reference such as a checkerboard, robotic assembly, vibration suppression, second-stage controller, camera calibration, flexible beam and robot vision; an approach for robot vision method is developed to identify the object using a virtual marker and measure its dimension grasped by the robot gripper accommodating perspective view; the developed robot vision-based controller works along with FEM model of the flexible beam to predict the tip position and helps in handling different dimensions and material types; an approach has been proposed to handle different types of delays that are part of implementation for effective suppression of vibration; proposed method uses a low frame rate and low-cost camera for the second-stage controller and the controller does not interfere with the internal controller of the industrial robot.

Details

Industrial Robot: the international journal of robotics research and application, vol. 50 no. 3
Type: Research Article
ISSN: 0143-991X

Keywords

Article
Publication date: 12 June 2023

Gan Zhan, Zhenyu Zhang, Zhihua Chen, Tianzhen Li, Dong Wang, Jigang Zhan and Zhengang Yan

This paper aims to focus on the spatial docking task of unmanned vehicles under ground conditions. The docking task of military unmanned vehicle application scenarios has strict…

Abstract

Purpose

This paper aims to focus on the spatial docking task of unmanned vehicles under ground conditions. The docking task of military unmanned vehicle application scenarios has strict requirements. Therefore, how to design a docking robot mechanism to achieve accurate docking between vehicles has become a challenge.

Design/methodology/approach

In this paper, first, the docking mechanism system is described, and the inverse kinematics model of the docking robot based on Stewart is established. Second, the genetic algorithm-based optimization method for multiobjective parameters of parallel mechanisms including workspace volume and mechanism flexibility is proposed to solve the problem of multiparameter optimization of parallel mechanism and realize the docking of unmanned vehicle space flexibility. The optimization results verify that the structural parameters meet the design requirements. Besides, the static and dynamic finite element analysis are carried out to verify the structural strength and dynamic performance of the docking robot according to the stiffness, strength, dead load and dynamic performance of the docking robot. Finally, taking the docking robot as the experimental platform, experiments are carried out under different working conditions, and the experimental results verify that the docking robot can achieve accurate docking tasks.

Findings

Experiments on the docking robot that the proposed design and optimization method has a good effect on structural strength and control accuracy. The experimental results verify that the docking robot mechanism can achieve accurate docking tasks, which is expected to provide technical guidance and reference for unmanned vehicles docking technology.

Originality/value

This research can provide technical guidance and reference for spatial docking task of unmanned vehicles under the ground conditions. It can also provide ideas for space docking missions, such as space simulator docking.

Details

Robotic Intelligence and Automation, vol. 43 no. 3
Type: Research Article
ISSN: 2754-6969

Keywords

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