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Kensuke Harada

Publications and source records attributed to Kensuke Harada.

At least 73 records · Page 4Linked to original sources

Robotic Imitation of Human Assembly Skills Using Hybrid Trajectory and Force Learning

Robotic assembly tasks involve complex and low-clearance insertion trajectories with varying contact forces at different stages. While the nominal motion trajectory can be easily obtained from human demonstrations through kinesthetic teaching, teleoperation, simulation, among other methods, the force profile is harder to obtain especially when a real robot is unavailable. It is difficult to obtain a realistic force profile in simulation even with physics engines. Such simulated force profiles tend to be unsuitable for the actual robotic assembly due to the reality gap and uncertainty in the assembly process. To address this problem, we present a combined learning-based framework to imitate human assembly skills through hybrid trajectory learning and force learning. The main contribution of this work is the development of a framework that combines hierarchical imitation learning, to learn the nominal motion trajectory, with a reinforcement learning-based force control scheme to learn an optimal force control policy, that can satisfy the nominal trajectory while adapting to the force requirement of the assembly task. To further improve the imitation learning part, we develop a hierarchical architecture, following the idea of goal-conditioned imitation learning, to generate the trajectory learning policy on the \textit{skill} level offline. Through experimental validations, we corroborate that the proposed learning-based framework is robust to uncertainty in the assembly task, can generate high-quality trajectories, and can find suitable force control policies, which adapt to the task's force requirements more efficiently.

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Planning to Repose Long and Heavy Objects Considering a Combination of Regrasp and Constrained Drooping

This paper presents a hierarchical motion planner for planning the manipulation motion to repose long and heavy objects considering external support surfaces. The planner includes a task level layer and a motion level layer. We formulate the manipulation planning problem at the task level by considering grasp poses as nodes and object poses for edges. We consider regrasping and constrained in-hand slip (drooping) during building graphs and find mixed regrasping and drooping sequences by searching the graph. The generated sequences autonomously divide the object weight between the arm and the support surface and avoid configuration obstacles. Cartesian planning is used at the robot motion level to generate motions between adjacent critical grasp poses of the sequence found by the task level layer. Various experiments are carried out to examine the performance of the proposed planner. The results show improved capability of robot arms to manipulate long and heavy objects using the proposed planner. Our contribution is we initially develop a graph-based planning system that reasons both in-hand and regrasp manipulation motion considering external supports. On one hand, the planner integrates regrasping and drooping to realize in-hand manipulation with external support. On the other hand, it switches states by releasing and regrasping objects when the object is in stably placed. The search graphs' nodes could be retrieved from remote cloud servers that provide a large amount of pre-annotated data to implement cyber intelligence.

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A Dual-arm Robot that Autonomously Lifts Up and Tumbles Heavy Plates Using Crane Pulley Blocks

This paper develops a planner that plans the action sequences and motion for a dual-arm robot to lift up and flip heavy plates using crane pulley blocks. The problem is motivated by the low payload of modern collaborative robots. Instead of directly manipulating heavy plates that collaborative robots cannot afford, the paper develops a planner for collaborative robots to operate crane pulley blocks. The planner assumes a target plate is pre-attached to the crane hook. It optimizes dual-arm action sequences and plans the robot's dual-arm motion that pulls the rope of the crane pulley blocks to lift up the plate. The crane pulley blocks reduce the payload that each robotic arm needs to bear. When the plate is lifted up to a satisfying pose, the planner plans a pushing motion for one of the robot arms to tumble over the plate while considering force and moment constraints. The article presents the technical details of the planner and several experiments and analysis carried out using a dual-arm robot made by two Universal Robots UR3 arms. The influence of various parameters and optimization goals are investigated and compared in depth. The results show that the proposed planner is flexible and efficient.

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Selecting and Designing Grippers for an Assembly Task in a Structured Approach

In this paper, we present a structured approach to selecting and designing a set of grippers for an assembly task. Compared to current experience-based gripper design method, our approach accelerates the design process by automatically generating a set of initial design options on gripper type and parameters according to the CAD models of assembly components. We use mesh segmentation techniques to segment the assembly components and fit the segmented parts with shape primitives, according to the predefined correspondence between primitive shape and gripper type, suitable gripper types and parameters can be selected and extracted from the fitted shape primitives. Moreover, we incorporate the assembly constraints in the further evaluation of the initially obtained gripper types and parameters. Considering the affordance of the segmented parts and the collision avoidance between the gripper and the subassemblies, applicable gripper types and parameters can be filtered from the initial options. Among the applicable gripper configurations, we further optimize number of grippers for performing the assembly task, by exploring the gripper that is able to handle multiple assembly components during the assembly. Finally, the feasibility of the designed grippers is experimentally verified by assembling a part of an industrial product.

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Variable Compliance Control for Robotic Peg-in-Hole Assembly: A Deep Reinforcement Learning Approach

Industrial robot manipulators are playing a more significant role in modern manufacturing industries. Though peg-in-hole assembly is a common industrial task which has been extensively researched, safely solving complex high precision assembly in an unstructured environment remains an open problem. Reinforcement Learning (RL) methods have been proven successful in solving manipulation tasks autonomously. However, RL is still not widely adopted on real robotic systems because working with real hardware entails additional challenges, especially when using position-controlled manipulators. The main contribution of this work is a learning-based method to solve peg-in-hole tasks with position uncertainty of the hole. We proposed the use of an off-policy model-free reinforcement learning method and bootstrap the training speed by using several transfer learning techniques (sim2real) and domain randomization. Our proposed learning framework for position-controlled robots was extensively evaluated on contact-rich insertion tasks on a variety of environments.

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Multi-Pen Robust Robotic 3D Drawing Using Closed-Loop Planning

This paper develops a flexible and robust robotic system for autonomous drawing on 3D surfaces. The system takes 2D drawing strokes and a 3D target surface (mesh or point clouds) as input. It maps the 2D strokes onto the 3D surface and generates a robot motion to draw the mapped strokes using visual recognition, grasp pose reasoning, and motion planning. The system is flexible compared to conventional robotic drawing systems as we do not fix drawing tools to the end of a robot arm. Instead, a robot selects drawing tools using a vision system and holds drawing tools for painting using its hand. Meanwhile, with the flexibility, the system has high robustness thanks to the following crafts: First, a high-quality mapping method is developed to minimize deformation in the strokes. Second, visual detection is used to re-estimate the drawing tool's pose before executing each drawing motion. Third, force control is employed to avoid noisy visual detection and calibration, and ensure a firm touch between the pen tip and a target surface. Fourth, error detection and recovery are implemented to deal with unexpected problems. The planning and executions are performed in a closed-loop manner until the strokes are successfully drawn. We evaluate the system and analyze the necessity of the various crafts using different real-word tasks. The results show that the proposed system is flexible and robust to generate a robot motion from picking and placing the pens to successfully drawing 3D strokes on given surfaces.

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Planning a Sequence of Base Positions for a Mobile Manipulator to Perform Multiple Pick-and-Place Tasks

In this paper, we present a planner that plans a sequence of base positions for a mobile manipulator to efficiently and robustly collect objects stored in distinct trays. We achieve high efficiency by exploring the common areas where a mobile manipulator can grasp objects stored in multiple trays simultaneously and move the mobile manipulator to the common areas to reduce the time needed for moving the mobile base. We ensure robustness by optimizing the base position with the best clearance to positioning uncertainty so that a mobile manipulator can complete the task even if there is a certain deviation from the planned base positions. Besides, considering different styles of object placement in the tray, we analyze feasible schemes for dynamically updating the base positions based on either the remaining objects or the target objects to be picked in one round of the tasks. In the experiment part, we examine our planner on various scenarios, including different object placement: (1) Regularly placed toy objects; (2) Randomly placed industrial parts; and different schemes for online execution: (1) Apply globally static base positions; (2) Dynamically update the base positions. The experiment results demonstrate the efficiency, robustness and feasibility of the proposed method.

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Four-Arm Collaboration: Two Dual-Arm Robots Work Together to Maneuver Tethered Tools

In this paper, we present a planner for a master dual-arm robot to manipulate tethered tools with an assistant dual-arm robot's help. The assistant robot provides assistance to the master robot by manipulating the tool cable and avoiding collisions. The provided assistance allows the master robot to perform tool placements on the robot workspace table to regrasp the tool, which would typically fail since the tool cable tension may change the tool positions. It also allows the master robot to perform tool handovers, which would normally cause entanglements or collisions with the cable and the environment without the assistance. Simulations and real-world experiments are performed to validate the proposed planner.

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Learning Force Control for Contact-rich Manipulation Tasks with Rigid Position-controlled Robots

Reinforcement Learning (RL) methods have been proven successful in solving manipulation tasks autonomously. However, RL is still not widely adopted on real robotic systems because working with real hardware entails additional challenges, especially when using rigid position-controlled manipulators. These challenges include the need for a robust controller to avoid undesired behavior, that risk damaging the robot and its environment, and constant supervision from a human operator. The main contributions of this work are, first, we proposed a learning-based force control framework combining RL techniques with traditional force control. Within said control scheme, we implemented two different conventional approaches to achieve force control with position-controlled robots; one is a modified parallel position/force control, and the other is an admittance control. Secondly, we empirically study both control schemes when used as the action space of the RL agent. Thirdly, we developed a fail-safe mechanism for safely training an RL agent on manipulation tasks using a real rigid robot manipulator. The proposed methods are validated on simulation and a real robot, an UR3 e-series robotic arm.

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A Mechanical Screwing Tool for 2-Finger Parallel Grippers -- Design, Optimization, and Manipulation Policies

This paper develops a mechanical tool as well as its manipulation policies for 2-finger parallel robotic grippers. It primarily focuses on a mechanism that converts the gripping motion of 2-finger parallel grippers into a continuous rotation to realize tasks like fastening screws. The essential structure of the tool comprises a Scissor-Like Element (SLE) mechanism and a double-ratchet mechanism. They together convert repeated linear motion into continuous rotating motion. At the joints of the SLE mechanism, elastic elements are attached to provide resisting force for holding the tool as well as for producing torque output when a gripper releases the tool. The tool is entirely mechanical, allowing robots to use the tool without any peripherals and power supply. The paper presents the details of the tool design, optimizes its dimensions and effective stroke lengths, and studies the contacts and forces to achieve stable grasping and screwing. Besides the design, the paper develops manipulation policies for the tool. The policies include visual recognition, picking-up and manipulation, and exchanging tooltips. The developed tool produces clockwise rotation at the front end and counter-clockwise rotation at the back end. Various tooltips can be installed at both two ends. Robots may employ the developed manipulation policies to exchange the tooltips and rotating directions following the needs of specific fastening or loosening tasks. Robots can also reorient the tool using pick-and-place or handover, and move the tool to work poses using the policies. The designed tool, together with the developed manipulation policies, are analyzed and verified in several real-world applications. The tool is small, cordless, convenient, and has good robustness and adaptability.

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Development of a Shape-memorable Adaptive Pin Array Fixture

This paper proposes an adaptive pin-array fixture. The key idea of this research is to use the shape-memorable mechanism of pin array to fix multiple different shaped parts with common pin configuration. The clamping area consists of a matrix of passively slid-able pins that conform themselves to the contour of the target object. Vertical motion of the pins enables the fixture to encase the profile of the object. The shape memorable mechanism is realized by the combination of the rubber bush and fixing mechanism of a pin. Several physical peg-in-hole tasks is conducted to verify the feasibility of the fixture.

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Arranging Test Tubes in Racks Using Combined Task and Motion Planning

The paper develops a robotic manipulation system to treat the pressing needs for handling a large number of test tubes in clinical examination and replace or reduce human labor. It presents the technical details of the system, which separates and arranges test tubes in racks with the help of 3D vision and artificial intelligence (AI) reasoning/planning. The developed system only requires a person to put a rack with mixed and non-arranged tubes in front of a robot. The robot autonomously performs recognition, reasoning, planning, manipulation, etc., and returns a rack with separated and arranged tubes. The system is simple-to-use, and there are no requests for expert knowledge in robotics. We expect such a system to play an important role in helping managing public health and hope similar systems could be extended to other clinical manipulation like handling mixers and pipettes in the future.

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Functionally Divided Manipulation Synergy for Controlling Multi-fingered Hands

Synergy supplies a practical approach for expressing various postures of a multi-fingered hand. However, a conventional synergy defined for reproducing grasping postures cannot perform general-purpose tasks expected for a multi-fingered hand. Locking the position of particular fingers is essential for a multi-fingered hand to manipulate an object. When using conventional synergy based control to manipulate an object, which requires locking some fingers, the coordination of joints is heavily restricted, decreasing the dexterity of the hand. We propose a functionally divided manipulation synergy (FDMS) method, which provides a synergy-based control to achieves both dimensionality reduction and in-hand manipulation. In FDMS, first, we define the function of each finger of the hand as either "manipulation" or "fixed." Then, we apply synergy control only to the fingers having the manipulation function, so that dexterous manipulations can be realized with few control inputs. The effectiveness of our proposed approach is experimentally verified.

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Integrating Combined Task and Motion Planning with Compliant Control

Planning a motion for inserting pegs remains an open problem. The difficulty lies in both the inevitable errors in the grasps of a robotic hand and absolute precision problems in robot joint motors. This paper proposes an integral method to solve the problem. The method uses combined task and motion planning to plan the grasps and motion for a dual-arm robot to pick up the objects and move them to assembly poses. Then, it controls the dual-arm robot using a compliant strategy (a combination of linear search, spiral search, and impedance control) to finish up the insertion. The method is implemented on a dual-arm Universal Robots 3 robot. Six objects, including a connector with fifteen peg-in-hole pairs for detailed analysis and other five objects with different contours of pegs and holes for additional validation, were tested by the robot. Experimental results show reasonable force-torque signal changes and end-effector position changes. The proposed method exhibits high robustness and high fidelity in successfully conducting planned peg-in-hole tasks.

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Planning an Efficient and Robust Base Sequence for a Mobile Manipulator Performing Multiple Pick-and-place Tasks

In this paper, we address efficiently and robustly collecting objects stored in different trays using a mobile manipulator. A resolution complete method, based on precomputed reachability database, is proposed to explore collision-free inverse kinematics (IK) solutions and then a resolution complete set of feasible base positions can be determined. This method approximates a set of representative IK solutions that are especially helpful when solving IK and checking collision are treated separately. For real world applications, we take into account the base positioning uncertainty and plan a sequence of base positions that reduce the number of necessary base movements for collecting the target objects, the base sequence is robust in that the mobile manipulator is able to complete the part-supply task even there is certain deviation from the planned base positions. Our experiments demonstrate both the efficiency compared to regular base sequence and the feasibility in real world applications.

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Team O2AS at the World Robot Summit 2018: An Approach to Robotic Kitting and Assembly Tasks using General Purpose Grippers and Tools

We propose a versatile robotic system for kitting and assembly tasks which uses no jigs or commercial tool changers. Instead of specialized end effectors, it uses its two-finger grippers to grasp and hold tools to perform subtasks such as screwing and suctioning. A third gripper is used as a precision picking and centering tool, and uses in-built passive compliance to compensate for small position errors and uncertainty. A novel grasp point detection for bin picking is described for the kitting task, using a single depth map. Using the proposed system we competed in the Assembly Challenge of the Industrial Robotics Category of the World Robot Challenge at the World Robot Summit 2018, obtaining 4th place and the SICE award for lean design and versatile tool use. We show the effectiveness of our approach through experiments performed during the competition.

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Planning to Build Soma Blocks Using a Dual-arm Robot

This paper presents a planner that can automatically find an optimal assembly sequence for a dual-arm robot to assemble the soma blocks. The planner uses the mesh model of objects and the final state of the assembly to generate all possible assembly sequence and evaluate the optimal assembly sequence by considering the stability, graspability, assemblability, as well as the need for a second arm. Especially, the need for a second arm is considered when supports from worktables and other workpieces are not enough to produce a stable assembly. The planner will refer to an assisting grasp to additionally hold and support the unstable components so that the robot can further assemble new workpieces and finally reach a stable state. The output of the planner is the optimal assembly orders, candidate grasps, assembly directions, and the assisting grasps if any. The output of the planner can be used to guide a dual-arm robot to perform the assembly task. The planner is verified in both simulations and real-world executions.

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Motion Planning through Demonstration to Deal with Complex Motions in Assembly Process

Complex and skillful motions in actual assembly process are challenging for the robot to generate with existing motion planning approaches, because some key poses during the human assembly can be too skillful for the robot to realize automatically. In order to deal with this problem, this paper develops a motion planning method using skillful motions from demonstration, which can be applied to complete robotic assembly process including complex and skillful motions. In order to demonstrate conveniently without redundant third-party devices, we attach augmented reality (AR) markers to the manipulated object to track and capture poses of the object during the human assembly process, which are employed as key poses to execute motion planning by the planner. Derivative of every key pose serves as criterion to determine the priority of use of key poses in order to accelerate the motion planning. The effectiveness of the presented method is verified through some numerical examples and actual robot experiments.

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