Service Robotics: Past-Present

Service Robotics: Past-Present-Future
• From Industrial Robots to Service Robots
• Current Applications and Markets
• Opportunities and Challenges
Martin Hägele
[email protected], +49 711 970 1203
Fraunhofer-Institut
Produktionstechnik und Automatisierung (IPA)
Stuttgart
April 16th, 2004
© Fraunhofer IPA
Slide 1
MECHATRONIC
Apr. 15, 04
Fraunhofer Society
Resources
12.000 Employees
1000 M€ Annual turn-over
58 Research institutes
43 Locations in Germany
Branch-offices in USA (14),
Asia (9), Europe (8)
Foundation in 1949
Headquarter in Munich
Non-profit research organisation
Research Fields
Februar 2003
© Fraunhofer IPA
•
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•
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Microelectronics
Production
Information and communication technologies
Materials and components
Life sciences
Surface technology and photonics
Defence research and technology
Slide 2
MECHATRONIC
Apr. 15, 04
Fraunhofer IPA, Stuttgart
Fraunhofer Institut
Produktionstechnik und Automatisierung
Resources
250 scientists, engineers
Turnover 2003: 32 M€
Industrial funding 57%
Offices: 5.100 m²
Laboratory area: 5.600 m²
Directors
Prof. Dr.-Ing. Dr. h.c. mult. Rolf Dieter Schraft (Speaker)
Prof. Dr.-Ing. Prof. E. h. Dr. h.c. Engelbert Westkämper
Dr.-Ing. Dipl.-Wirtsch.-Ing. Wilfried Sihn (Deputy)
Business Areas
•
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•
•
Februar 2004
© Fraunhofer IPA
Corporate Management
Enterprise Logistics
Automation Systems
Manufacturing Automation
Manufacturing Technologies
Slide 3
MECHATRONIC
Apr. 15, 04
Competences, Services in “Robot Automation” at IPA
Robot Systems
Processes
Market Studies
Potential Analysis
Systems Engineering
Specifications
Joining processes
- mechanical
- hybrid
- micro
3D-shaping and
forming
Cleaning
Hard- und Software
Industrial Robots
ServiceRobots
Assembly
Material Flow
- Palletizing
- Depalletizing
- Warehousing
- Sorting
3D-Machining and
3D-Forming
Personal Care
Cleaning
Transportation
Hazardous
Environments
Inspection/Repair
Rehabilitation
Entertainment
Welding
Realisations and
Implementations
Computer Controls
© Fraunhofer IPA
Sensors
Kinematics
Interfaces
Slide 4
MECHATRONIC
Apr. 15, 04
Fraunhofer IPA, Center of Institutes
© Fraunhofer IPA
Slide 5
MECHATRONIC
Apr. 15, 04
50 Years in Robotics
Installation at Ford, USA, ca. 1964
Patent Claim 1954
© Fraunhofer IPA
Slide 6
MECHATRONIC
Apr. 15, 04
Robotics has Taken Many Forms
Inspection of reactor outer cores Liquid hydrogen refueling
Robot-framing-station
Courier-robot in hospitals
ASIMO (Newsweek 2/02)
Photos: KUKA Schweissanlagen, Ballard, Matsushita, Newsweek, IPA
© Fraunhofer IPA
Slide 7
MECHATRONIC
Apr. 15, 04
Industrial Robots World Wide: Installation and Shipments
Number
of IR
60.000
50.000
Operational stock of industrial robots 2002
Yearly installations of industrial robots 2002
Number
of IR
Total Installationen
2002: 68.566
2006: 91.100 (forecast)
500.000
40.000
400.000
30.000
300.000
20.000
200.000
10.000
100.000
0
2000
2002
2006
0
Total Stock
2002: 769.889
2006: 875.300 (forecast)
2000
Other Countries
2002
USA
2006
European Union
Japan
IR per 10.000
Germany Japan • Assembly, welding, painting: 70 % of IR-stock
workers
• Growth potential: material flow automation
280 • Car industries: still 60 % of IR installations
General 100
Automotive 650
1273 • Applications in SME: less than 20 % of installations
industries
[Source: World Robotics 2003, UN/ECE, IFR]
© Fraunhofer IPA
Slide 8
MECHATRONIC
Apr. 15, 04
Robotics in New Processes and Applications
Drivers
• Decreasing cost of robots
• Growth industries
• Manual working conditions
• Quality assurance
• New processes
Current research objectives
• Rapid workcell deployment
Sausage packaging
• Programming, instruction IMT Nagler
• Integration into existing
environments
• Technical optimisation
(speed, flexibility, useability)
Robots in ware-houses:
Palletising
Postal automation
Siemens Dematic
Brick-Laying
Baggage
handling
© Fraunhofer IPA
Slide 9
MECHATRONIC
Apr. 15, 04
Migration of Technologies into Industrial Automation
Entertainment Electronics
Flat Screens
CD
PC
Industrial Automation
es
i
A
g
W
olo
ind rchit
n
ow ect
Telecommunication
ch
e
T
ure
Computers
s,
D
CE
CC
ted
n
r ie
O
ct ues
e
j
Ob hniq
c
Te
Software
© Fraunhofer IPA
Industrial
Automation
Teleservice
Teleoperation
DECT, GSM
CA
N
sen -Bus
s
swi or
tch
es
Car-Electronics
Slide 10
MECHATRONIC
Apr. 15, 04
Why Robot Assistants?
Unit Costs
1000
Robot
automation
100
Automated transfer line
Manual
Manufacturing
10
1
Manual workplace
Robot Automation
0,1
100
1.000
10.000
Units/Year
100.000 1.000.000
Graphs (left): Hasegawa, Boothroyd
Handbook of Industrial Robots, Wiley, 1984
© Fraunhofer IPA
Slide 11
MECHATRONIC
Apr. 15, 04
Why Robot Assistants?
Unit Costs
Push:
Labour
Compensation
100
80
40
20
100
Robot prices,
not quality adjusted
60
10
Robot prices, quality adjusted
0
1990
1992
1994
1996
Cost
reduction
1
1998
2000
2002
Pull:
• Instant reaction to markets: Uncertain
production volumes, product life times
• Customized products at series prizes; „MC“
• Cost-effective productions close to markets
• Simple and rapid deployment automation
• Managing the age-quake
© Fraunhofer IPA
Te
Pu ch
sh no
lo
gy
120
Index
1990 = 100
A
Pu ppl
ll ica
tio
n
140
1000
Flexibility
increase
Units/Year
0,1
100
1.000
10.000
100.000 1.000.000
Robot helpers Rapidly
at the manual deployable
robot work cells
workplace
Slide 12
MECHATRONIC
Apr. 15, 04
tea m @ work : Robot Without Fences
Characteristics
Reference
targets
collision
measure
• Cooperation of worker
and robots
• Overlapping work spaces
• Variable degree of
automation
• Handling, assembly tasks
Challenges
• Intuitive programming
and instruction
• Safe physical interaction
• Overall work system
productivity and costeffectiveness
© Fraunhofer IPA
Cameras, ceiling light
Conveyer
SCARA-Robot
Cases
Slide 13
MECHATRONIC
Apr. 15, 04
Migration of Technologies out of Industrial Automation
Household
Health Care
Cleaning Systems
Leisure
Industrial
Automation
Construction Machines
© Fraunhofer IPA
Facility Management
Slide 14
MECHATRONIC
Apr. 15, 04
First Service Robots are Developed at the End of 80ies
Repair (Yaskawa Electric Corp., J)
Sewer Maintenance (Hochtief, D) Vacuum cleaner (Panasonic , J)
Floor grinding FLAT-KN (Shimizu Corp., J)
© Fraunhofer IPA
AMR (CASA, ES)
Manus-Arm (Exact Dynamics, NL) FlorBot (GE Plastics, USA) Auto Sweepy (Toshiba, J)
Slide 15
MECHATRONIC
Apr. 15, 04
Definition “Service Robot”
„A robot which operates semi- or fully
autonomously to perform services
useful to the well-being of humans
and equipment, excluding manufacturing operations.“
© Fraunhofer IPA
Slide 16
MECHATRONIC
Apr. 15, 04
Industrial Robots in Service and Entertainment
RoboShop, Reis-Robotics
Automatic Drink Shop; Reis-Robotics
© Fraunhofer IPA
Champaign-Bar
Robo-Coaster, KUKA, LEGO, Billund
Robo-Disc Jockeys (ZKM)
Slide 17
MECHATRONIC
Apr. 15, 04
Examples of ServiceRobots at IPA (1)
© Fraunhofer IPA
HAKO ACRO, 1996
Info-Mobil, 1996
Climbing robot, 1999
Tennis ball collector, 1997
IMP, 1995
Sewer Robot, 1998
Kärcher BR 700, 1996
Slide 18
MECHATRONIC
Apr. 15, 04
Examples of ServiceRobots at IPA (2)
Refuelling by robot, IPA, 1996
Skywash, PMW, 1998
Museum robots, MPK Berlin, 2001
© Fraunhofer IPA
Fire fighting robot, Iveco Magirus
Care-O-bot I, 1998
Surgical robot; URS, 2001
Mona and Lisa of OPEL Zentrum, Berlin, 2003
Slide 19
MECHATRONIC
Apr. 15, 04
Examples of ServiceRobots at IPA (3)
Roof Cleaning, Lehrter Bahnhof, 2003
Kärcher BR 700, 1996
© Fraunhofer IPA
ARSE, 1998
Cleaning robot; Kärcher, 2000 RACCOON; P&G, 2002
DecontJet, Kärcher, 2003
Quirl, 2003
Slide 20
MECHATRONIC
Apr. 15, 04
Examples of ServiceRobots (4)
Rehabilitation-Equipment, Hitachi
CoWorker, iRobot
© Fraunhofer IPA
Prothetics, Otto-Bock
TMSUK/SANYO: Quadruped
MAid, FAW Ulm
LEGO Mindstorms
CMU Nursebot
K-Team, Khepera II
HelpMate, PYXIS Corp
R100, NEC
Slide 21
MECHATRONIC
Apr. 15, 04
Service Robots for Professional and Private Use
Service robots for professional use
Number
of units
Service robots for private use
Number of units
in thousands
10.000
1.600
Stock at end of 2002
projected installations
in 2003-2006
8.000
6.000
1.400
1.200
1.000
Stock at end of 2002
projected installations
in 2003-2006
800
4.000
600
2.000
400
0
0
Domestic
Entertainment
Cl
ea
ni
ng
De
m
o
Un litio
n
de
rw
at
er
Su
rv
M
ei
ed
lla
nc
ica
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l
Se
cu
M
rit
ob
y
Re
ile
fu
Ag
ro
el
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ric
t p ling
ul
tu
la
re
t
an form
d
s
fo
re
st
ry
La
bo
ra
to
ry
al
lo
th
er
200
[Source: UNECE and IFR, 2003]
© Fraunhofer IPA
Slide 22
MECHATRONIC
Apr. 15, 04
An Industry is Being Created
Professional Applications
• Application of industrial robots in nonmanufacturing fields
• Extension of existing machinery by automated
functions
• Development of new robots from scratch for
existing or new services.
Consumer-Products
• Extension of existing product lines by highend
automated products (e.g. robot vacuum
cleaners)
• Development of new products without
predecessors
• Installations by 2002:
18.600 units, 2,625 Mio. US$ in value
• Forecast 2003-2006:
29.780 new installations (3,280 Mio$ value)
• Installations by 2002:
606,840 units, 960 Mio. US$ in value
• Forecast 2003-2006:
2,163,000 new installations (2,750 Mio$ value)
Cyberknife, Accuray
© Fraunhofer IPA
Brokk 330
MOSRO1, Robowatch
Electrolux Trilobite Robox, Bluebotix Roboscience RS-01
Slide 23
MECHATRONIC
Apr. 15, 04
Indoor- and Outdoor Navigation
Scanner
Gyros
GPS
Display
PC
US-Sensors
µ Controler
Steering drive
Control
CAN-Bus
CANtrol
TESS 1998-2000,
Kärcher 2001
Steering
sensor
© Fraunhofer IPA
Throttle
Incremental
weel sensor
Motors
Cleaning
aggregate
Interfaces
Slide 24
MECHATRONIC
Apr. 15, 04
Software Framework for Mobile Robots
Lines of
Code
Anwendung
45000
Robotics
40000
RealFrame
Plattform
35000
30000
25000
20000
15000
10000
5000
0
1A
Robot
Reuse of software
components in %
© Fraunhofer IPA
1B
1C
1A
1B
1C
Museum Guide
Museum Guide
Museum Guide
73,4
78,3
75,6
1
2
1
Care-O-bot
75,7
2
Cleaning Robot
77,4
Slide 25
MECHATRONIC
Apr. 15, 04
Reuse of Software: Design Patterns and Repositories
Localization
Sensorcontrol
Position
control
Robotics-Toolbox
Design patterns
Realtime-Framework
Operating System
OSACA: Open System Architecture for
Controls within Automation systems
http://www.osaca.org/
http://www.orocos.org/
• Real-time motion kernel: K.U.Leuven
• CORBA-inspired communication primitives
for robotics: KTH Stockholm and FAW Ulm.
• Task execution sequencing: LAAS Toulouse
© Fraunhofer IPA
Slide 26
MECHATRONIC
Apr. 15, 04
Functionalities of Care-o-Bot
• Household tasks
• Fetch and carry-tasks
• Mobility support
• Communication and
social integration
• Monitoring and
safety
• Home Management
© Fraunhofer IPA
Slide 27
MECHATRONIC
Apr. 15, 04
R&D in Robot Sytems: The MORPHA Project (1999-2003)
Scenarios
Home- and
Care-Assistant
Cross-Functions
ManufacturingAssistant
Spin-Off's
Demonstrations
- Channels for manmachine communication
- Scene-analysis and
interpretation
- Advising and adaptability
- Motion planning and
co-ordination
- Interactive task
planning
- Fail-safety, maintenance,
diagnosis
Procedures, Methods, Components
MORPHA was funded by the German BMBF
Pictures by Ruhr-UNI Bocum, DaimlerChrysler, IPA
© Fraunhofer IPA
Slide 28
MECHATRONIC
Apr. 15, 04
Hardware
electrical gripper
manipulator
wireless emergency
button
wireless LAN
gyroscope
laser
scanner
platform control
robot control
battery
© Fraunhofer IPA
position
encoder
Slide 29
MECHATRONIC
Apr. 15, 04
Initial Scenario: Assembly of Hydraulic Pumps
Storage of pump shafts
Robot-assisted workbench
assembly with
Workbench assembly
Preassembly of pump shafts
© Fraunhofer IPA
Brueninghaus Hydromatic,
Bosch Rexroth, IPA, 2001
Slide 30
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Apr. 15, 04
Software Architecture
Man-Machine-Interface
Robot System
Symbolic
planner
Goal list
Voice entry
Scene editor
Domain
description
Action list
Command entry
Voice output
Data channel
(CORBA)
Environmental
model
Execution
module
Plan
library
Environmental
data
Skills
Trajectory
planner
2D-Presentation
3D-Presentation
Camera view
State output
© Fraunhofer IPA
Sensors
Actuators
Slide 31
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Apr. 15, 04
User Interface
GUI-Configuration
3D-View
Command inputs
Symbolic map
© Fraunhofer IPA
Slide 32
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Apr. 15, 04
First Experiences with
+
Mechanical
Design
Navigation
• Operation time 12 hrs
• Compact design
• Safe mobility
© Fraunhofer IPA
• Only small payloads possible
• Collision free navigation • Limited mobility in industrial environment
(doorsteps, cables, uneven floor)
• Fast path planning
• Unreliable computer vision (grasping etc.)
Task Planner • Robust and fast
Safety
-
• Computer vision is
promising for future
safety systems
•
•
•
•
Problems if deviation from map - real world
Difficult data acquisition in real situations
Limited reliability of speech
Safety sensors are only suitable for welldefined control volumes (stationary safety)
• Controlled lighting for robust image
processing
Slide 33
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Apr. 15, 04
Limits and Constraints of
Re-Engineering
Possible Applications for Robot Assistants
• Industrial Engineering
• Tests
• Demonstrations
• Feedback & Discussions
Concentration on effective “Task Domains”
• Compact task
• Clear task allocation between worker and robot
• Clear interaction patterns
• Effectiveness in industrial environments reachable within years
© Fraunhofer IPA
Slide 34
MECHATRONIC
Apr. 15, 04
Definition of Constraint Task Domains
“Weld
Mate”
“Drill
Job”
98°
“Mobile
Scanner”
© Fraunhofer IPA
“CoProcessor”
Slide 35
MECHATRONIC
Apr. 15, 04
Scenario: Weld Mate
Video
Goals:
• Intuitive use
• Quality increase: constant welding velocity
• Instruction instead of programming
rob@work
FT-Sensor
Tool Coupler
Approach:
• PDA-User-Interface
• Implementation of
specific welding skills
• Use of tactile information
© Fraunhofer IPA
Welding Torch
Worker hand
Slide 36
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Apr. 15, 04
Example: Manual Velocity Vector Overide
1 Saw tooth pattern
5 cm
D
Ideal welding line
E
Assisted welding line
V
2 Circle
• Cartesian stiffness control
• Support of constant welding feed
- Quality
- Documentation (customers)
© Fraunhofer IPA
Slide 37
MECHATRONIC
Apr. 15, 04
www.care-o-bot.de
Robotic Home Assistants
Household Tasks
- Fetch and carry objects
- Execute everyday jobs
- Control home infrastructure
Mobility Aid
Communication and Social
Integration
- Media and time
management
- Communication with
medical and public facilities
- Supervision of vital
signs and emergency call
InHouse-Video (Juice)
InHouse-Video (Flowers)
Hannover Trade Fair, 2002
© Fraunhofer IPA
Slide 38
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Apr. 15, 04
Features (1)
Safe Manipulation in Human Environments
Problem/Motivation
• Collision-free manipulation
• Instant adaptation to altering positions
of objects and changing environments
Scientific Approach
• 3-D-scanning of environment
• “Rapidly-Exploring Random Trees” for
path planning
Novelty of Approach
• Using UB-trees for environment-model
to increase planning performance
• Global planning and local optimization
Results
• Collision-free 3-D paths within seconds
© Fraunhofer IPA
Slide 39
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Apr. 15, 04
Features (2)
Reactive Navigation of an Intelligent Robotic Walking Aid
Problem/Motivation
• Flexible path planning and modification
while being followed by a user
Scientific Approach
• Model of the robot followed by a user
• Fast Path Planning Algorithm for
non-holonomic vehicles
• Dynamic Path Modification “Elastic Bands”
Novelty of Approach
• Combining Elastic-Bands and “Dubin’s Car”
• Reacting on external forces applied to
walking aid handles
Results
• Time for path planning: 0.1 Sec.
• Smooth obstacle avoidance
© Fraunhofer IPA
Slide 40
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Apr. 15, 04
Features (3)
Interactive Robot Control for Robot Assistants
Novelty of Approach
• Use of Scripting Language
• SQL-queries to reduce domain
Results
• Execution Framework for concurrent tasks and error handling
• Task description language
© Fraunhofer IPA
Symbolic Planner
(„C“)
w
Ne t a
da
Domain World-knowledge
(SQL-database)
Action list
Problemdescription
Facts
Execution Module “GO“
(„Python“)
Execute
Action list
Sensordata
State
Robot Control:
Behaviors („C++“)
Actuators
Sensors
Slide 41
Feedback
Scientific Approach
• Hybrid three-layer control
architecture
User
Goal
Problem/Motivation
• Robustness in carrying out tasks
in altering/un-known environments
• High-level commands
MECHATRONIC
Apr. 15, 04
Beispiel von Humanoiden (Japan)
Humanoid Robot Hadaly-2,
Waseda Universität, Japan
SDR-3X (Sony Corp.)
Human Symbiotic Robot WENDY
(Waseda ENgineering Designed sYmbiont)
© Fraunhofer IPA
Der Honda-ASIMO: Anzeige in „Newsweek“ vom 5. Feb. 2001
Slide 42
MECHATRONIC
Apr. 15, 04
Honda-Humanoid: Anwendungsszenarien
Physical
Interaction
Services in public
environments
Weiterentwicklung
• Gewichtsreduktion
• Kosten
• Sicherheit
• „Social Harmonization“
Anwendungs-“Roadmap“
1. Entertainment (kurzfristig)
2. Attendant (Services)
3. Work Assistant
4. „Robot as a partner“
(langfristig)
© Fraunhofer IPA
Servant
Assistant
(Workplace)
Public
use
Entertainment
Privat
use
Pet
Emotional/social
interaction
T. Fukui: „The Honda Humanoid Robot“, Plenarvortrag Diskussion, ISR, Seoul, 18. April 2
Slide 43
MECHATRONIC
Apr. 15, 04
Conclusion
• For more than 20 years robots have been entering non-manufacturing applications.
• Some 200 product ideas and applications have been collected (by IPA)
• Service robots have established themselves as a new high potential product category
• Service robots still are specialists designed for a specific application.
• The breakthrough of service robots have been depending on smart components
(e.g. scanner for mobile navigation)
• There is a high potential in sharing software components
• Assistive systems emerge as a category for both manufacturing and service automation
• Extensive RTD in system dependability (capabilities and safety)
• Man-machine interaction as a major challenge in service robotics
• But also good product design and engineering
© Fraunhofer IPA
Slide 44
MECHATRONIC
Apr. 15, 04
Safety System
Safety-Sensors:
• Laser scanner
• Image processing surface matching
• Image processing differential image
Result:
• Promising approaches
• Safety conformability
still open
© Fraunhofer IPA
Slide 45
MECHATRONIC
Apr. 15, 04