ROBOTICS FOR NUCLEAR APPLICATIONS NUCLEAR TELEROBOTICS INDUSTRIAL APPLICATIONS IN FRANCE SAILING TO DEXTROUS TELE- « MANIPULATION » PHILIPPE GARREC ERF 2017 – EDIMBURGH 22-24 MARCH 2017 A favorable context in France leading to a steady activity in nuclear robotics • France is producing about 80% of its electricity by nuclear power plants (EDF) • France recycles the nuclear fuel (AREVA) : La Hague plant is the principle user of teleoperation (more than 500 MSM operational) • The dismantling domain is a major field of application for telerobotics • A continuous long term collaboration between CEA and AREVA • Significant companies operating in the field of nuclear robotics: Getinge-La Calhène, ECA, Cybernetix, Comex, Haption.. • R&D CEA activity concerns the whole range of related technologies (rad-hard electronics and sensors, gamma/alpha camera, decontamination processes, real time dose rate estimation, rad-hard communication network • The CEA supports the emergency intervention robotic group GIE INTRA (a partner of the equivalent German group KHG) | 2 THE DEPLOYMENT OF A NEW GENERATION OF FORCE FEEDBACK TELEOPERATORS IN THE FRENCH NUCLEAR INDUSTRY SUSTAINS THE DEVELOPMENT OF ASSISTIVE ROBOTS WORKSHOP ON RANUF IROS 2015 - PHILIPPE GARREC BASIC CONCEPTS OF MASTER-SLAVE TELEOPERATION | 3 UNILATERAL COUPLING Controller MASTER ARM SLAVE ARM End effector vision (direct/indirect) θ lM θ Sd M m θ Sm lS Position control F Operator S T= − K (θ − θ ) Load S SSm S d (weight, contact, etc.) θ= θ Sd M m MASTER & SLAVE ARE 2 INDEPENDENT MECHANICALSYSTEMS | 4 BILATERAL COUPLING EXTENDED SINGLE MECHANICAL Controller SYSTEM SLAVE ARM MASTER ARM FM End effector vision (direct/indirect) lM lS Master position control Slave position control FS = −θ − θ Load T= − K (θ − θ ) TS K SS( S ) M MMm M d m d (weight, contact, etc.) θ= θ θ= θ S M Md S m d m ANALOGY WITH ELASTIC COHESION FORCES IN A ROD | 5 PERFORMANCE IMPROVEMENT 1 STATIC BALANCING Operator ≡ − θ ≡ − θ Load Tg m master g cos master Tg m slave g cos slave master slave (weight, contact, etc.) FS FM mmaster g mslave g | 6 A NON LINEAR FORCE TRANSFER IS COMPROMISING JOINT TORQUE CONTROL : Non linear spring Non linear damper Stick-slip (spatial for a multi-joint manipulator) Detrimental to advanced guiding control (virtual mechanism) F = 0 F= k ∆ P Torque control Torque control EVERYBODY WANTS A LINEAR JOINT TORQUE CONTROL ! | 7 FORCE TRANSFER IN THE ACTUATOR REVERSIBLE MOTORING IRREVERSIBLE τ REGENERATING τ out out ω − i ω − i Transmissive quadrant Dissipative quadrant ρ −1 Dissipative quadrant ρ −1 R i R i ω + ω + η −1 ρ i ρ i R i M M η −1i R η i η i M Low torque zone τ M f (obtained by prolongation of the 0 out characteristics) J τ τ J Transmissive quadrant in in 0 τ 0 τ Transmissive quadrant I f I f 0 in 0 in ω − ω − Dissipative quadrant Transmissive quadrant Dissipative quadrant ω + ω + “Telerobotics research and development at CEA LIST” P. Garrec and F. Geffard and O. David and F-X Russotto and Y. Measson and Y. Perrot ANS EPRRSD - 13th Robotics & remote Systems for Hazardous Environments • 11th Emergency Preparedness & Response - Knoxville, TN, August 7-10, 2011 "Dry friction modeling in dynamic identification for robot manipulators: Theory and experiments," Kammerer, N.; Garrec, P., Mechatronics (ICM), 2013 IEEE International Conference | 8 FORCE TRANSFER LINEARITY ERROR IN ACTUATOR TRANSMISSION ττ≥, ( ρ−1 − ρτ) + 2 τ − + rin rI in I Dr in r 0 in τ− τ Linearity torque error : out out τ≤ ττ ≤ , 2 τ iτ rJin r in rI in r 0 in in max − ττ≤, () ρρτ −1 + 2 τ rin rJ in DI r in r 0 in SERVO MANIPULATOR MA23 TYPICAL INDUSTRIAL MANIPULATOR 1,50 1,50 1,00 1,00 Linearity… 0,50 0,50 Lineari… 0,00 0,00 -1,0 -0,9 -0,8 -0,7 -0,6 -0,5 -0,4 -0,3 -0,2 -0,1 0,0 0,1 0,2 0,3 0,4 0,5 0,6 0,7 0,8 0,9 1,0 -1,0 -0,9 -0,8 -0,7 -0,6 -0,5 -0,4 -0,3 -0,2 -0,1 0,0 0,1 0,2 0,3 0,4 0,5 0,6 0,7 0,8 0,9 1,0 -0,50 -0,50 -1,00 -1,00 -1,50 -1,50 | 9 PERFORMANCE IMPROVEMENT 2 FRICTION COMPENSATION Operator Load C= sign(θ&) f + λθ & (weight, contact, etc.) fslave slave slave slave C= sign(θ&) f + λθ & fmaster master master master FM FS θ &master θ &slave =θ + λθ Tf sign( & master) f master & master T= sign(θ&) f + λθ & master fslave slave slave slave Model based friction compensation (torque linearization) Load (weight, contact, etc.) FS θ Local force feedback &slave Active closed loop friction compensation (torque linearization) | 10 BACKDRIVABILITY VERSUS REVERSIBILITY (MECHANICALPROPERTY) Mechanical type Behaviour (constructive property) Reversible Backdrivable Backdrivable Irreversible Self-locking if assisted (force closed loop) | 11 KEY TECHNOLOGIES FOR NUCLEAR TELEROBOTICS | 12 Full response for targeted systems • In/Out-doors mobile robots • In/Out-doors cranes • Inspection tools • Electric or hydraulic manipulators Validation for radioactive environments • From 1 kGy to 100 kGy • Fault-tolerance On sites since 1992 • Up-grading with recent electronic technologies • Hardening to specific environments (temperature, neutrons) • Adaptation to existing or new equipments (traveling cranes, cutting and soldering tools, ….) | 13 CAMERAS DURCIES • Camera Ermes TRL9 : Sphinx camera Series / VIZA PTZ / VIZA • Couleur • Résolution : 640x480 • Tenue : de 1,5 kGy à 2 MGy suivant modèle • Possibilité d’intégration dosimètre • Montage sur bras robotique ou fixe • Modèle submersible ( 40 m) VZ-5.0E01-1000-C-LA-N-A-IP68(40m) model VZ-2.0E01-1000-B-LB-N-A-IP68(40m) model SX-1.5E02-2002-1005-LA6.0E03-N-IP68(20m)-RD2 model • LHERITIER Alcen : APPOLLON • Tenue : radiations > 100Mrads (1 Mrad/heure) • Immersion (6 bars) | 14 Dismantling Life Cycle : To simulation, from concept up to task completion Preparation Simulation Execution of the mission of the scenario Scenario definition on Scenario qualification Supervision and the digital mock up Operator training operator assistance Accessibility studies, Real-time simulation with haptics, Operator assistance and scenario dose rate evaluat°, task définit° interactive training Execution kinematics optimization Same content, context, and tools | 15 VIRTUAL REALITY & I NTERACTIVE SIMULATION WORKS • Virtual prototyping : accessibility studies, assembly/disassembly on digital mock-up • Ergonomy studies : musculo-skeleton disorders diagnosis, task optimization • Robotics simulation / supervision : intervention scenario, assistance to cobotic solution design • Training of the operators REAL -TIME MULTI -PHYSICS SOFTWARE (EXTENDED DYNAMIC ENGINE ) | 16 NUCLEAR TELEROBOTICS AT CEA LIST: INDUSTRIAL ACHIEVEMENTS AND R&D RESULTS | 17 50 YEARS OF EXPERIENCE IN ROBOTICS • Historical activity : Remote handling for nuclear industry 1970’s 1990’s computer assisted 2000’s Industrial transfer remote handling Daily operations Intervention and Industrial hostile dismantling environment | 18 TAO SOFTWARE CONTROLLER Functions: • Force feedback teleoperation (« true » or proportionnal) • Trajectory controller • Joint or Cartesian control • Tool weight balancing • Virtual mechanisms • Adjustable homothetical speed and force ratios • Gripper tracking by camera • Continuous data recording • Graphic 3D supervision TAO CONTROL XM XM d d POSITION MULTILATERAL POSITION FORCE MASTER/SLAVE FORCE CONTROLLER CONTROLLER CONTROLLER XM XM m m | 19 SUPERVISED CONTROLLER SCORE | 20 ISO - TC85 - SC2 WG 24 - Remote handling devices for radioactive materials Promotion of a standard for telerobotics Examples of up-to-date telerobotics systems « Cold » zone « Hot » zone Emergency stop Emergency Master device(s) control unit Low Low latency link Tuning, … 3D HMI … Slave arm(s) ethernet »Cellule froide »Cellule haute activité Functional scheme XM d XM d CONTRÔLE CONTRÔLE CONTRÔLE BILATERAL POSITION POSITION MAITRE EFFORT EFFORT ESCLAVE XM m XM m | 21 FORCE FEEDBACK MASTER ARMS Virtuose 6D / MAT6D for teleoperation (2001) replacing the MA23 (La Calhène) Virtuose 6D / MAT6D First arm using ball-screw and cable for torque amplification (patented) Used in CEA’s laboratories and at AREVA a Hague plant (RX TAO et MT200 TAO) Virtuose 6D Haptic (2002) Torque amplification by capstan or Harmonic Drive Sold worldwide Used by major industrials All products industrialized and commercialized by HAPTION™ Virtuose 6D Haptic | 22 SHERPA – Hexapod transporter (European TELEMAN program) Based on the hexapod telescopic legged transporter Odex 3 (Odetics, USA) Original tactile feet (CEA patent) Original algorithms for stair climbing and obstacle avoidance using reflex reactions First legged robot to be demonstrated in nuclear plants Transport of 200 kg on stairs in « loose » teleoperation (EDF Chooz-B, France in 1993 and CEA Fontenay-aux-Roses laboratory (early 1993) ENEL Trino in 1994) | 23 EDF- PWR CHOOZ B - 1993 EXTENSIVE FIELD TESTS IN TWO NUCLEAR POWER PLANTS (1993 – 1994) ENEL PWR TRINO - 1994 | 24 SHERPA 2 projet (CEA-EDF- TECHNICATOME) 1994- 1998 A compact hexapod (55cm width) able to transport 300 kg Deployment of a power foldable arm carrier Use of a compact industrial arm as a tool (Mitsubishi PA10) New telescopic leg mechanical design (patents)ouvelle technologie de jambe compacte et modulaire Bras porteur modulaire redondant (contournement des obstacles) Emport d’un outil de manipulation secondaire Technologie en partie exploitée sur le robot de maintenance de la chambre d’expérimentation du LMJ | 25 Long Reach MANIPULATORS • Long reach articulated arm (AIA) • CEA LIST design and developement (since 1995) • First introduction in the TORE SUPRA tokamak achieved in 2008 (restart of the installation the next day without « braking » the vacuum) • Applications forecasted at AREVA’s La Hague recycling plant • Long reach telescopic arm • LMJ (Mega-Joule Laser) maintenance manipulator • Original design by CEA LIST (2004-2008) for the CEA DAM (CEA defense division) based on CEA LIST patents ( Sherpa 2 project) • Industrialization by Cybernetix in collaboration with CEA LIST • Operational (automatic plug-in of protective panels) in 2012 | 26 Long reach articulated arm (AIA) Real field test in the tokamak TORE SUPRA (2008) Operated at 120°C (200°C for degasing) and 10 -5 Pa Applications in tokamak and hot-cells (undergoing) | 27 Long reach telescopic arm for the LMJ (Mega-Joule Laser) 100kg payload 12 m horizontal ext.