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Introduction to Robotics

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Introduction to Robotics

Vijay KumarUniversity of Pennsylvania

Philadelphia, PA

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Outline

� What is Robotics

� Why Robotics

� History

� State of the Art

� Current Research

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What is a robot?� Webster

An automatic apparatus or device that performs functions ordinarily ascribed to humans or operates with what appears to be almost human intelligence.

� Robotics Institute of AmericaA robot is a reprogrammable multifunctional manipulator designed to

move material, parts, tools or specialized devices through variable programmed motions for the performance of a variety of tasks.

� Hollywood

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Which is the better definition? � Robotics Institute of America

A robot is a reprogrammable, multifunctional, manipulator designed to move material, parts, tools or specialized devices through variable programmed motions for the performance of a variety of tasks.

� WebsterA robot is an automatic apparatus or device that performs functions ordinarily ascribed to humans or operates with what appears to be almost human intelligence.

� Hollywood

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Human perception and controlVisual system

Posterior parietal cortex

Motor cortex

Motor neurons

Muscles

Limb

Sensors, frame grabbers

Processing, task recognition,

decomposition

Servo controller

Actuators

Mechanical linkage

Planner

VISUO-MOTORGOAL

MOVEMENT GOAL, MOTOR COMMAND

MUSCLE COMMAND, CONTROL SIGNAL

PROPRIO-CEPTIVE

FEEDBACK

VISUALFEEDBACK

POTENTIALS, ELECTRIC CURRENT

FORCES, TORQUES

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Why Robotics?

Automation in � Manufacturing� Service

Why Automation?

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Reasons for AutomationShortage of labor

� The ratio of the number of workers to the number of retirees in the U.S. is expected to be 2 to 1 in 2000. Main reason in Japan.

High cost of labor� Low wages are also accompanied by lower productivity

[U.N. study comparing wages and productivity]� In 1990, hourly wages in Malaysia were approx. 15% of that of the U.S. Hourly

productivity was also comparable.� Labor costs are rising Country 1985 1995

Germany 9.6 31.88Japan 6.34 23.66France 7.52 19.34USA 13.01 17.20UK 6.27 13.17

Malaysia 1.08 1.59South Korea 1.23 7.40

China 0.19 0.25India 0.35 0.25

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Reasons for AutomationIncreased productivity

� value of output per person per hour increases

Lower costs� reduced scrap rate� lower in-process inventory� superior quality� superior quality� shorter (compact) lines

Reducing manufacturing lead time� respond quickly to the consumers’ needs� rapid response to changes in design

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Reasons for AutomationCompetition

� lower prices, better products� better image� better labor relations

Safety

Potential for mass customization

New process technologies require automation

� e.g., robot controlled thermal spray torch for coating engine blocks with atomized steel particles

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Need Automation Even in Low-Wage Countries

Capital intensity is equally high� Fiat plant at Belo Horizonte, Brazil� Carplastic - manufacturer of car plastic components

Ford subsidiary in Monterrey Mexico

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Case study: CARPLASTIC

A wholly-owned Ford subsidiary in Monterrey, MexicoProducts

� headlamps, polycarbonate instrument panels, radiator grill, consolesProduction

� 1800 pieces/day, failures 10-15 parts per million � main process is injection molding

� 200-4000 ton machines (Engel, Cincinnati Milacron, Huskies)� largest product is 6 kg. Expedition instrument panel (shot size 12 kg)� cycle-time 1 min to 1 min 45 secs.

� abrasive water-jet cutting� 200 workers, $1-2/hour

� compare with $17/hour in the US, $6/hour in Brazil)

� reasonably automated� material handling is not automated, main processes are automated (no option)

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Case study: CARPLASTIC

Question:Can highly automated facilities be maintained and upgraded in “low-wage countries”?

� Hi-tech machinery maintenance and repair� Quality control, process control requires sophistication� Material handling costs versus other manufacturing costs

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Robotics

Types of AutomationFixed automation

custom-engineered, special-purpose equipment to automate a fixed sequence of operations� high production rates, inflexible product design

Programmable automationequipment designed to accommodate a specific class of product changes� batch production, medium volume

Flexible automationdesigned to manufacture a variety of products or parts� low production rates, varying product design and demand

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History: Fixed Automation� Eli Whitney, pioneer of mass production

Contracted to make 10,000 muskets in 28 months (1798, factory at New Haven). � Machines for producing interchangeable parts� Reduced skills required of operators, increased production rates� Assembly work was simplified

� Oliver Evans, automated “conveying” (1793)� Automated flour mill

� Elihu RootColt six-shooters (1849)� Divide the work and multiply the output� Assembly was reduced to short and simple unit operations which required very

little worker training and high efficiencies could be obtained.

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Gillette South Boston PlantSensor Excel Cartridges

1.5 to 2 billion cartridges/year100 cartridges/minute/line

� Major processes:� injection molding

� 500 ton, 32 cavity molds ($ 1M) machines, 20 second cycle time� extrusion� others: grinding, stamping, welding, assembly� bottlenecks in assembly: injection molding and part feeding

Time to market: 24 monthsCapital cost: $200 millionEstimated life cycle: 6-8 years

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Flexible Automation

Cars, motor cycles13 months from design to production

Group technology

Drug Discovery

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Reasons for not automating� Labor resistance� Cost of upgraded labor

� Chrysler Detroit plant - 1 million hours of retraining� GM Wilmington assembly plant - $250 hours/person/year

� Initial investment� Management of process improvements

� Intellectual assets versus technological assets� Toyota versus Ford study

� Appropriate use of technology� A systems approach to automation is important� Equipment incompatibilities

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Case study: Toyota versus FordToyota Georgetown Plant �Camry/Avalon�20 models�2 lines, 2 platforms/line�Workforce

� 25% college grads� 50% entered college

�Flexible automation� 20 models, 197,000 cars/year� 39,000 specifications � 23,000 one-of-a-kind specifications

Ford Atlanta Plant�Taurus�2 models�2 lines, 1 platform/line�Workforce

� 50% high school drop outs

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Cost of Flexible AutomationCapital costs per car (1996)

Toyota� 480,000 cars/year, $3960/car

Nissan� 450,000 cars/year, $2670/car

Honda� 610,000 cars/year, $3300/year

Suzuki� 200,000 cars/year, $2150/year

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HistoryOrigin of the word “robot”

� Czech word “robotnik”� 1920 play by Karel Capek � 1940s - Isaac Asimov’s science fiction

History of automation� Industrial revolution (late 18th century)� Mechanical looms

� Jacquard looms � Programmable looms

� Crane with motorized grippers (1892)� Mechanical arm for spray painting (1938)� Telecheric/teleoperators (World War II)� First industrial robot (1961)

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Chinese Drawloom

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Swedish Loom (1872)

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Electronic Numerical Integrator and Computer (1946)

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HistoryAdvent of computers

� First large scale electronic computer (1946)� Eniac (University of Pennsylvania)� Whirlwind (MIT)

� Numerically controlled machine tool (1952)� Robot with playback memory (1954)� First industrial robot (1962)

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History: Industrial Robots

GM and Robotics

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History: ResearchWalking robots

� GE walking machine (1967)� Odetics’ Hexapod (1983)� Adaptive Suspension Vehicle (1985)� Ambler (1993)� Honda Humanoid (1997)

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Adaptive Suspension Vehicle (1987)

� 3500 kgs, 500 kg payload� powered by a 550 cc 75 hp Kawasaki engine� 19 8086-based controllers

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The Honda Humanoid (1997)P3-Clip2

Honda_P3_3.mov

Honda_p3.mov

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State of the artIndustrial robotics

� $ 2 billion industry in the U.S. (1999)� $5.3 billion industry world wide (1997)� 15% growth rate (1997 - )

Robotics is a much bigger industry� entertainment� military/space technology� appliances

70 Industrial robots per human worker entering the US labor force in 2000.

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Service RobotsPutzmeister

Honda

CRASAR/iRobotSearch and Rescue

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Robots for Assistive Technology

Raptor

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Service Robots

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What is a robot?Definition of a robot revisited

� manipulate objects in the physical world� compare this to a PC manipulating data

� sense information about the physical world� make decisions based on available information or ask for additional

information� interface in a “friendly”manner with humans� mimic humans� reprogrammable by humans � safe

� Asimov’s laws of robotics

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ApplicationsApplication in 4D environments� dangerous� dirty� dull� difficult

4A tasks� automation� augmentation� assistance� autonomous

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Challenges

Automation

Aut

onom

y

PARTFEEDER

INDUSTRIALROBOT

LAWNMOWER

AGV

IT has had a greaterimpact on automation than on autonomy

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Applications: 1. Biotechnology

� Sequencing Projects

� Research in gene expression� RNA expression� Protein interaction� Antibody library assays

� Combinatorial chemistry� New compounds

� High throughput screening� Targets that can be “hit”

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Biotechnology: SequencingReduction of time and labor intensive DNA/RNA processing and analysis methods� Automation in cell assays� DNA amplification and purification� Plate management� Electrophoresis and quantitative imaging

Hardware� robotic arms, automated turntables and storage systems � pipettors� chromatography devices� thermal cyclers � imaging and detection systems

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Microarray Techniques

A. 100 glass substratesB. Two multi-well plates and blot padC. Arm to deliver plates and de-lidD. 72 plate hotelE. Printing pinsF. Sonicator bathG. Rinse stationH. Drying station

A

B

CD

E

FG

H

Courtesy: J. Gregg and D. Baldwin

OmniGrid from GeneMachines

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Biotechnology: HTS

Compounds

Number of Targets

O

O

N

NN

O

NN O

OH

O

O O

O

O

O

OO

O O

O

NO

N

NN S

O

N+ O

O

NN

O

>106

20 / month

A+B =AB

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ELISA: Enzyme-Linked Immunosorbent Assay

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Bead-Based Assays

Locator

Bead Mixer

Shakers

Washer/Filtration

384, 96 well plates

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What goes where?Variety of block designs/layoutsVariety of reaction protocolsAnalysis protocols

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007

Robotic Sample Processor

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014

HTS: Sample Handling

MOL BANK™ plate storage unit

Handling samples

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Automated analysis

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Liquid Handling Systems

12.5ul with 384 well plates

384 pin adapters

TekCel PlateServerTM

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Cold Store

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Defrost Oven Feeder

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Liquid Handling Cell

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2. Military applications

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3. Space RoboticsHuman operators on earth can control partially autonomous vehicles and manipulators on distant planets

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Space Robotics

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4. Entertainment IndustryEntertainment robot is more'byte' than bark (CNN)Sony AIBO

Honda ASIMO

Disney Robots

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5. Personal Robots?

http://www.personalrobots.com

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Domestic Companions?

Cog, MIT AI Lab

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True Potential: 4D to 3A4D tasks

� dangerous� dirty� dull� dumb

Just as the personal computer is used for automated information management even in households, robots can be used to execute domestic tasks. � Manipulation of bits of information (PC)� Manipulation of physical objects (PR)

AutomationA

uton

omy

Augmen

tation