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As the demand for human–robot collaboration in manufacturing applications grows, the necessity for collision detection functions in robots becomes increasingly paramount for safety. Hence, this paper aims to improve the existing method to achieve efficient, accurate and sensitive robot collision detection.

The external torque is estimated by momentum observers based on the robot dynamics model. Because the state of the joints is more accessible to distinguish under the action of the suppression operator proposed in this paper, the mutated external torque caused by joint reversal can be accurately attenuated. Finally, time series analysis (TSA) methods can continuously generate dynamic thresholds based on external torques.

Compared with the collision detection method based only on TSA, the invalid time of the proposed method is less during joint reversal. Although the soft-collision detection accuracy of this method is lower than that of the symmetric threshold method, it is superior in terms of detection delay and has a higher hard-collision detection accuracy.

Owing to the mutated external torque caused by joint reversal, which seriously affects the stability of time series models, the collision detection method based only on TSA cannot detect continuously. The consequences are disastrous if the robot collides with people or the environment during joint reversal. After multiple experimental verifications, the proposed method still exhibits detection capabilities during joint reversal and can implement real-time collision detection. Therefore, it is suitable for various engineering applications.

The purpose of this paper is to propose a physically plausible solution based on hybrid bounding volume (BV) hierarchy for real‐time collision detection (CD) and response between a deformable and a rigid object.

Hybrid BV can be used to build BV hierarchy for the deformable object. The overlapping tests based on separating axis theorem (SAT) can be used to deal with CD. The physics conception of restitution coefficient and other important forces can be used to more real collision response.

Many methods focus on a specific application, but none of them gives an approach to physically plausible, real‐time simulation of CD and response up to 10,000 of deforming primitives. The paper finds that hybrid BV AABB‐Sphere for deformable object could increase the efficiency for CD, and restitution coefficient and other important physical concepts could provide more real collision response.

The paper does not deal with all types of CD, such as CD for two deformable objects.

Using AABB‐Sphere hybrid BV to build hierarchical BV tree for deformable object, and OBB‐Sphere hybrid BV for rigid object. Owing to the variety of hybrid BV structures, during different phases of CD, different overlapping tests are used to accelerate CD effectively. Using important physics conceptions provides a good solution to simulate more real collision response.

Virtual maintenance simulation is of great importance to help designers find and avoid design problems. During its simulation phase, besides the high precision requirement, collision detection must be suitable for all irregular objects in a virtual maintenance environment. Therefore, in this paper, a collision detection approach is proposed based on encapsulation for irregular objects in the virtual maintenance environment.

First, virtual maintenance simulation characteristics and several commonly used bounding boxes methods are analyzed, which motivates the application of encapsulation theory. Based on these, three different encapsulation methods are oriented to the needs of simulation, including encapsulation of rigid maintenance objects, flexible maintenance objects and maintenance personnel. In addition, to detecting collisions accurately, this paper divides the detection process into two stages. That is, in the first stage, a rough detection is carried out and then a tiny slice space is constructed to generate corresponding capsule groups, which will be redetected in the secondary stage. At last, several case studies are applied to illustrate the performance of the methodology.

The automatic construction algorithm for bounding boxes can be adapted to all forms of objects. The number of detection primitives are greatly reduced. It introduces the reachable space of the human body in maintainability as the collision search area.

The advantages of virtual maintenance simulation could also be advantageous in the industry with further studies. The paper believes this study is of particular interest to the readers of your journal.

Virtual assembly (VA) based on virtual reality (VR) is a key technique of virtual manufacturing. It provides not only an intuitive and interactive interface for virtual product design, but also an efficient method to analyze or verify assembly performance of these products. Preliminary investigations of constructing a VA system were implemented in this paper. There were three key techniques in constructing a VA system, which were data transformation from CAD system to VA system, collision detection, and virtual manipulation with a virtual hand. These key techniques were analyzed further and their concrete algorithms were given. At last an experimental VA system was set‐up to verify these algorithms. It is proved that the transformed data are sufficient, which can satisfy the VA system's requirement; the collision detection algorithm is efficient as it assures the system to be real time; and the virtual manipulation algorithm guarantees the system's reality and maneuverability.

Haptics can significantly enhance the user's sense of immersion and interactivity. Especially in an assembly task, haptic feedback can help designers to have a better understanding of virtual objects and to increase task efficiency. The purpose of this paper is to investigate the design and implementation of a haptic‐based virtual assembly system (HVAS).

A multi‐thread system structure was designed, an automatic data integration interface was developed to transfer geometry, topology, assembly and physics information from a computer‐aided design system to virtual reality application, and a hierarchical constraint‐based data model and scene graph structure was designed to construct the virtual assembly environment. Unlike traditional virtual assembly systems based on collision detection or geometry constraint only, a physics‐based modeling approach combining with haptic feedback and geometry constraint was undertaken to realize and guide the realistic assembly process. When two parts collide into each other, the force and torque can be computed and provide feedback, and a spring‐mass model is used to prevent penetration and simulate dynamic behaviour. When two parts are close enough to each other and the assembly simulation state is activated, a geometry constraint can be captured, an attractive force can be generated to guide the user to assemble the part along the correct position, and the repulsive force can also be generated to realize the mating process as natural and realistic as in real life.

The implementation details and application examples demonstrate that haptic‐based virtual assembly is a valuable tool for assembly design and process planning.

The paper presents an HVAS.

The purpose of this paper is the research of a novel gesture-based dual-robot collaborative interaction interface, which achieves the gesture recognition when both hands overlap. This paper designs a hybrid-sensor gesture recognition platform to detect the both-hand data for dual-robot control.

This paper uses a combination of Leap Motion and PrimeSense in the vertical direction, which detects both-hand data in real time. When there is occlusion between hands, each hand is detected by one of the sensors, and a quaternion-based algorithm is used to realize the conversion of two sensors corresponding to different coordinate systems. When there is no occlusion, the data are fused by a self-adaptive weight fusion algorithm. Then the collision detection algorithm is used to detect the collision between robots to ensure safety. Finally, the data are transmitted to the dual robots.

This interface is implemented on a dual-robot system consisting of two 6-DOF robots. The dual-robot cooperative experiment indicates that the proposed interface is feasible and effective, and it takes less time to operate and has higher interaction efficiency.

A novel gesture-based dual-robot collaborative interface is proposed. It overcomes the problem of gesture occlusion in two-hand interaction with low computational complexity and low equipment cost. The proposed interface can perform a long-term stable tracking of the two-hand gestures even if there is occlusion between the hands. Meanwhile, it reduces the number of hand reset to reduce the operation time. The proposed interface achieves a natural and safe interaction between the human and the dual robot.

Cables are widely used, and they play a key role in complex electromechanical products such as vehicles, ships, aircraft and satellites. Cable design and assembly significantly impact the development cycle and assembly quality, which is be-coming a key element affecting the function of a product. However, there are various kinds of cables, with complex geo-metric configurations and a narrow assembly space, which can easily result in improper or missed assembly, an unreasonable layout or interference. Traditional serial design methods are inefficient and costly, and they cannot predict problems in installation and use. Based on physical modeling, computer-aided cable design and assembly can effectively solve these problems. This paper aims to address virtual assembly (VA) of flexible cables based on physical modeling.

Much research has focused recently on virtual design and assembly-process planning for cables. This paper systematically reviews the research progress and the current state of mechanical models, virtual design, assembly-process planning, collision detection and geometric configuration and proposes areas for further research.

In the first instance, the main research groups and typical systems are investigated, followed by extensive exploration of the major research issues. The latter can be reviewed from five perspectives: the current state of mechanical models, virtual design, assembly-process planning, collision detection and geometric configuration. Finally, the barriers that prevent successful application of VA are also discussed, and the future research directions are summarized.

This paper presents a comprehensive survey of the topics of VA of flexible cables based on physical modeling and investigates some new ideas and recent advances in the area.

Automobile development needs more and more collaborative work involving geographical dispersed designers, that brings difficulty for model verification, conception review and assembly process evaluation, so a collaborative virtual environment for automobile based on network is required. In this kind of environment, designers can do interactive assembly operations collaboratively, such as grasp, move, release, collision detection (CD), assembly evaluation report generation, etc. Furthermore, automobile structure becomes more complicated, how to process this large real‐time data effectively in real‐time interactive virtual environment is a great challenge. The purpose of this paper is focus on this.

A distributed parallel virtual assembly environment (DPVAE) is developed. In this environment, the mechanism of event synchronization based on high‐level architecture/run‐time infrastructure) is applied to realize multi‐user collaboratively interactive operation. To meet the large data set real‐time processing demand, a creative parallel processing approach supported by a single supercomputer or a parallel processing environment composed of common personal computer in a high‐speed local area network is developed. The technologies such as real‐time CD, multiple interactive operation modals are applied in DPVAE and several auxiliary tools are provide to help achieving whole scheme review, component model verification and assembly evaluation.

This paper finds that DPVAE system is an available and efficient tool to support automobile collaborative assembly design.

Designers can discuss and verify the assembly scheme to realize the previous design scenario in DPVAE, so it is useful for reducing costs, improving quality and shortening the time to market, especially for new type automobile development.

A combination of distributed technology and parallel computing technology is applied in product virtual assembly, solving the problems including collaborative work of multi‐user and large data real‐time processing successfully, that provides a useful tool for automobile development.

Control of manipulator collision avoidance by using computer‐aided potential field method is studied. A repulsive force is artificially created using the distances between the robot links and obstacles, which are generated by a distance computation algorithm. Typical approaches for definition of link coordinate frames and kinematics computations are adopted. Control gains in the potential field control model are selected with respect to the ranges of the angular velocity and angular acceleration of an industrial robot. Results on collision detection and collision avoidance control are presented. Using a high‐speed personal computer, real‐time manipulator control was achieved. From the results, changing repulsive force gain can change the safety distance. This makes the safety zone adjustable and provides greater intelligence for robotic tasks under the ever‐changing environment.

Recent years have seen a technological change, Industry 4.0, in the manufacturing industry. Human–robot cooperation, a new application, is increasing and facilitating collaboration without fences, cages or any kind of separation. The purpose of the paper is to review mainstream academic publications to evaluate the current status of human–robot cooperation and identify potential areas of further research.

A systematic literature review is offered that searches, appraises, synthetizes and analyses relevant works.

The authors report the prevailing status of human–robot collaboration, human factors, complexity/ programming, safety, collision avoidance, instructing the robot system and other aspects of human–robot collaboration.

This paper identifies new directions and potential research in practice of human–robot collaboration, such as measuring the degree of collaboration, integrating human–robot cooperation into teamwork theories, effective functional relocation of the robot and product design for human robot collaboration.

This paper will be useful for three cohorts of readers, namely, the manufacturers who require a baseline for development and deployment of robots; users of robots-seeking manufacturing advantage and researchers looking for new directions for further exploration of human–machine collaboration.