GM R&D Roland Menassa Human-centered Robotics for Manufacturing Systems Enablers for Advanced Autonomous Robotic Assembly
Dr. Roland Menassa
Mfg Systems Research Lab General Motors
GM R&D Roland Menassa GM R&D History
Central R&D organization for General Motors
Organized in 1920 under Charles F. (“Boss”) Kettering
World‟s first automotive research organization
3 3/3/08 GM R&D Roland Menassa Global R&D Footprint
Sweden Silicon Canada (2005) Russia Valley Mainz- Korea Warren (2002) Kastel (2005) (2007) (1920) China (2004) Honeoye (2007) Israel Falls (2008) HRL (2007) (2000) (2007) India Brazil (2003) (2008) Australia GM Labs Science Offices (2006) Affiliated Lab
GM R&D Roland Menassa KEY DRIVERS AND TECHNOLOGY ENABLERS
KEY DRIVERS AND TECHNOLOGY ENABLERS
KEY DRIVERS AND TECHNOLOGY ENABLERS
AUTO INDUSTRY PROGRESS
• Reduced Emissions by 99% • Improved FE by 180%/90% • Reduced Fatal Crashes by 70% • Improved Affordability by 40% URBAN CHALLENGE: MEGACITIES
¶ By 2030, 60% of the world‟s population will live in urban areas, up from 50% today
¶ Within 20 years, 80% of wealth will be concentrated in cities
¶ As the urban population increases, traffic congestion in large metro areas will become an even bigger issue Energized by Energized by Biofuels, Petroleum Electricity, and Hydrogen
Powered Mechanically by Powered Electrically by Internal Combustion Engine Electric Motors
Controlled Controlled Mechanically Electronically
Stand-alone “Connected”
Totally Dependence Semi/Full Autonomous on the Driver Driving
Vehicle Sized for Max Vehicle Tailored to Use – People and Cargo Specific Use NEW VEHICLE DNA GM Hy-wire Fuel Cell / By-wire Concept Vehicle
Chevrolet Volt Electric Vehicle with Extended Range
EN-V Electric, Networked Urban Mobility Concept TECHNOLOGY DRIVERS FOR THE 2ND CENTURY OF PERSONAL MOBILITY Challenges Stretch Goals ¶ Energy Low-cost renewable energy
¶ Emissions No tailpipe environmental impact
¶ Safety Vehicles that don‟t crash Autonomous driving
¶ Congestion Congestion-free routing Megacity parking
¶ Affordability “A car for every purse and purpose” Industry Trends are Driving Increasing Need for Innovation
•Consumer driven industry with fierce competition – High option content
•Product life about 5 to 6 years with major mid-cycle enhancement every 3 years
•Production volume varies between 20k to 300k per plant per year (10 to 65 JPH)
GM R&D Roland Menassa Creating the Next Paradigm in Automotive Manufacturing
Smart Manufacturing The paradigm beyond (World Wide Web „lean‟ will be driven by Analogy) the availability and exploitation of: Taiichi Ohno: Lean Mfg. (Grocery Business) 1- real-time information across the manufacturing Henry Ford Assembly Line enterprise, (Meat Packaging) 2- the virtual capability to launch the plant “In” Henry Leland Interchangeable Parts and “With” math, and (Gun Industry) 3- Agile - advanced intelligent robotics Craft Manufacturing
GM R&D Roland Menassa Technological Discontinuities in Manufacturing Arena
Pervasive sensing Real
Pervasive communications Time Mfg
Pervasive device intelligence Agile Pervasive servo actuation
Pervasive simulation/visualization Virtual
GM R&D Roland Menassa Smart Manufacturing Space Real Time Mfg
Real-time Optimized Manufacturing (“m” & “M”)
Agile Smart Manufacturing Virtual Flexible Mfg System Virtual Mfg Eng. & Infrastructure: Dexterous Validation: Math and Intelligent Robots Tools & Processes
GM R&D Roland Menassa Typical Vehicle Assembly Plant
Body Shop Paint Shop General Assembly
2.5 – 3.5 million sq feet 400-600 robots 400-600 PLC‟s 20-25 miles of conveyors 800-1200 vehicles in the system 1000-1200 operators/shift 60 vehicles/hour output
GM R&D Roland Menassa “Robot” origin: Capek 1920
Rossum‟s Universal Robots
“robota” = “serf labor” in Czech
New York 1922 production Primus (a robot) Prague 1920 GM R&D Roland Menassa Industrial Robots – 50 years
First industrial robot installation 1961: Unimate robot in GM Turnstedt (die cast unload)
GM R&D Roland Menassa Robots as Assembly Workers
PUMA: Programmable Universal Machine for Assembly
State of the art in 1978 Why are there so few robots in assembly even today?
Lack of sensing
Primitive hands
Lack of mobility
No intelligence • Hard to program complex tasks PUMA 500 • Not safe in close proximity to humans
GM R&D Roland Menassa Definitions (Webster‟s) Android (1727)
An automaton with human form Humanoid (1918)
Having human form or characteristics The “Turk” 1769 Robot (1923) (reproduction)
A machine that looks like a human being and performs various complex acts of a human being An automatic apparatusThe original that concept. performs functions ordinarily ascribed to humans
An apparatus that operates with near human intelligenceWhat most robots are today. A mechanism guided by automatic controls
GM R&D Roland Menassa What is a humanoid? Hollywood Versions
Gort (1951) Robby (1959) C-3PO (1977) NS-5 (2004) The Day the Earth Stood Forbidden Planet Star Wars I, Robot Still
GM R&D Roland Menassa What is a humanoid?
Android/Actroid/Gynoid/Fembot
Hanson Robotics Albert-Hubo & Phillip K. Dick Sanrio DER2
AIST HRP-4C
GM R&D Roland Menassa What is a humanoid? Toys
Mr. Mercury (1963) Robosapien (2003) Mindstorms NXT (2006) Marx WowWee LEGO
GM R&D Roland Menassa Walking Characteristics
Walking „bots
Toyota Partner Honda Robot ASIMO
PAL Robotics REEM-B Boston KAIST Dynamics HUBO Petman
GM R&D Roland Menassa Bipedalism Takes Persistence!
GM R&D Roland Menassa What is a humanoid?
Upper Body „bots (stationary)
Dexter
UMass Amherst MIT Domo DLR Justin
GM R&D Roland Menassa What is a humanoid? Upper Body „bots on wheels
U. Tokyo Willow Garage IRT PR2
UMass Robotic Towel Folding Amherst J. Maitin-Shepard & P. Abbeel Ubot-5 Univ. Calif., Berkeley
GM R&D Roland Menassa Hands: Special Purpose
Toyota Partner Robot Yaskawa/ Motoman 2-arm „bot
GM R&D Roland Menassa Hands: Intrinsic Actuation DLR-HIT Meka H1 Hands I & II
13 & 15 DOF
U. Tokyo IRT
GM R&D Roland Menassa Hands: Extrinsic Actuation
Shadow Robot Co.
18 DOF hand+wrist
GM R&D Roland Menassa Steps Toward Autonomous The Future… Robots Working with People Humans & Robots Working In Harmony Safe Interaction With Humans and Understanding Social Understanding of Knowledge State of an eight year old
Fine Object Manipulation with Tactile and Force Feedback Manual Dexterity of a six year old
Intuitive Human Interaction with a Robot Language Understanding of a four year old
Flexible Perception Object Recognition of a two year old
Adapted from Rodney Brooks The Start… 2008 - Global Production First 50 Years of Robot Fleet: 25,000 Industrial Robotics: Units
1961 - First Production Robot Application
GM R&D Roland Menassa GM R&D Roland Menassa GM NASA Announcement: Day 1
Coverage Snapshot to Date Notable Placements
• As of 5:30 p.m. ET on Feb. 4, there are approximately 139 articles in print, online and blog outlets • Currently, there are 773 Twitter posts reaching an estimated audience of 1,686,785 • Broad outreach included the following media segments: wires, technology/science, regional/local • Tone is straightforward news coverage with positive sentiment on leadership in advanced robotics technology Sample Quotes & Coverage Excerpts
“For all the attention they get, humanoid robots tend to be a “This could be just the right pretty shallow bunch... Which is time for a robot that's also an why the unveiling this morning astronaut. Far fetched? Check of Robonaut2—or R2—a out what NASA and General collaboration between General Motors just created.” Motor and NASA's Johnson Space Center, is such a milestone.” - Chris Woodyard Sample Tweets - Erik Sofge
“This kind of capability also has “Not content to let Honda and utility for GM, as car makers Toyota have all the fun, General plan for the day when cars will Motors has gotten into the be able to drive themselves.” robot game as well.“ - Dan Carney
- Frank Filipponio GM R&D Roland Menassa Why do we need this Technology?
Strategic Automate “Non Traditional” Applications – drive quality Integrated Sensing to Reduce the Need for Peripheral Fixturing and Equipment – humans and robots in harmony – safety & cost System uses the infrastructure and flexible material systems that more traditional manual systems use rather than the expensive outdated automation methods Exploit “Humanoid Dexterity”…….. drive to Robonaut infinite flexibility R2A and R2B
GM R&D Roland Menassa Robonaut 1 History
1998 2003 Subsystem Development R1A Testing Multi Agent EVA Team Testing of Hand Mechanism R1B Segway Integration
1999 2004 Single Arm Integration R1A Autonomous Manipulation Testing with Teleoperator R1B 0g Airbearing Development
2001 2005 Waist and Vision Integration Development of R1C Joints Testing under Autonomous Supervision across Time Delay Control 2006 2002 Integrate R1B with Centaur Base R1A Autonomy Testing Thermal, Vacuum and Vibration Learning R1B Integration Testing of R1C
GM R&D Roland Menassa Robonaut 2 History
2007 R2 Concept Prototype Joints
2008 R2 Single Arm Integration R2A Integrated
2009 R2A Completes First Assembly Task R2B Integrated
2010 February Public Release R2B Launch 11/2010
GM R&D Roland Menassa FLEXIBLE PERCEPTION Enables Dexterous Robot Assembly Cognitive perception in real time and in a dynamic environment From: To: Repeatability Driven Perception Driven Traditional Fixtures & Tooling Similar/Identical to Manual Systems Flexible & Robust Vision Tactile Sensing for Dexterous Hands Proximity Detection for Collision Avoidance Force Sensing & Control with High Bandwidth Fusion of Multiple Sensors for Situational Awareness Cognitive Understanding of Task & Sensor Response Human Detection & Tracking for Safe Interaction
GM R&D Roland Menassa R2 Sensors
Total count 350 sensors
Sensor Types Phalange force/torque load cells Angle sensors at all joints Torque sensors on all arm joints Motor encoders & temperature sensors
Vision Stereo high resolution Cameras Auxiliary sensors Structured light Auxiliary lighting
GM R&D Roland Menassa Intuitive Human Robot Interaction High level human interfaces, which enable a user to specify tasks conveniently and efficiently From: To: Engineering Driven Shop Floor Human Robot Programming Teaching Interface
Learning by Imitation High level Human Machine Interfaces Cognitive Understanding of Task & Assembly Sequence Advanced Controls Architecture
GM R&D Roland Menassa Hand Level Manipulation
Force Torque Control MEMS Phalange Sensing In-Finger A/D Digitization
Joint Control Embedded Hall Sensing In-Finger A/D Digitization
Tendon Control Force Tube Sensing Motor Encoder/Screw Sensor
Hybrid Control Multi-Priority Control Cartesian/Impedance Control
GM R&D Roland Menassa Dexterous Robots Human-like manipulation and assembly of parts in real time and in a dynamic environment
From: To: Dedicated Robotics Tooling and Dexterous Hand Fixtured Parts Manipulation in an Unstructured Environment
Full Human Hand Range Motion Sensory Touch for Proper Part Manipulation Grasp Planning for Part Manipulation Manipulation of Complex & flexible part handling
GM R&D Roland Menassa Finger Level Manipulation
Hand Extrinsic Actuation 14 DOF Tendon Driven Capable of Cutkosky‟s 13 grasps
Thumb 4 DOF Position Control & Tactile Sensing
Primary Fingers 3 DOF Position Control & Tactile Sensing
Secondary Fingers 1 DOF Under Actuated Position Control & Tactile Sensing
GM R&D Roland Menassa Social Interaction A natural interface that employs human- like cues and communication modalities
From: To: Real Time Human Off-Line Computer Driven Driven Interaction Communication
Social human interaction Robot learning capabilities Cognitive behavior & perception Safety and human factors
GM R&D Roland Menassa Arm Level Manipulation
Series Elastic Actuation Rotary Springs Rotary Sensing
Dual Arm Control Impedance Control Torque Saturation
Three Layer Safety layers Joint Force Control Wrist Force Control Shoulder Force Control
Mechanical Safety Smooth Superficial Design Soft Padding
GM R&D Roland Menassa Shuttle Launch Date: Feb 24th Mission: STS-133 Launch Vehicle: Space Shuttle Discovery Launch Site: Kennedy Space Center - Launch Pad 39A Launch Time: 4:50 p.m. EDT STS-133 Description: Space shuttle Discovery will deliver the Express Logistics Carrier 4 (ELC4), a MultiPurpose Logistics Module (MPLM) and critical spare components to the International Space Station.
GM R&D Roland Menassa GM R&D Roland Menassa In Summary
Next generation manufacturing will be enabled by robots with humanoid capability and NOT humanoid robots.
Yes X
GM R&D Roland Menassa Learn More About Our Assembly Processes: http://www.gm.com/experience/education/5GM R&D Roland Menassa -8/making_vehicles/trim.jsp