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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
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