Autonomous Robotic Assembly: From Part Singulation to Precise Assembly

Imagine a robot that can assemble a functional product from the individual parts presented in any configuration to the robot. Designing such a robotic system is a complex problem which presents several open challenges. To bypass these challenges, the current generation of assembly systems is built with a lot of system integration effort to provide the structure and precision necessary for assembly. These systems are mostly responsible for part singulation, part kitting, and part detection, which is accomplished by intelligent system design. In this paper, we present autonomous assembly of a gear box with minimum requirements on structure. The assembly parts are randomly placed in a two-dimensional work environment for the robot. The proposed system makes use of several different manipulation skills such as sliding for grasping, in-hand manipulation, and insertion to assemble the gear box. All these tasks are run in a closed-loop fashion using vision, tactile, and Force-Torque (F/T) sensors. We perform extensive hardware experiments to show the robustness of the proposed methods as well as the overall system. See supplementary video at https://www.youtube.com/watch?v=cZ9M1DQ23OI.

iPolicy: Incremental Policy Algorithms for Feedback Motion Planning

This paper presents policy-based motion planning for robotic systems. The motion planning literature has been mostly focused on open-loop trajectory planning which is followed by tracking online. In contrast, we solve the problem of path planning and controller synthesis simultaneously by solving the related feedback control problem. We present a novel incremental policy (iPolicy) algorithm for motion planning, which integrates sampling-based methods and set-valued optimal control methods to compute feedback controllers for the robotic system. In particular, we use sampling to incrementally construct the state space of the system. Asynchronous value iterations are performed on the sampled state space to synthesize the incremental policy feedback controller. We show the convergence of the estimates to the optimal value function in continuous state space. Numerical results with various different dynamical systems (including nonholonomic systems) verify the optimality and effectiveness of iPolicy.

Multi-level Reasoning for Robotic Assembly: From Sequence Inference to Contact Selection

Automating the assembly of objects from their parts is a complex problem with innumerable applications in manufacturing, maintenance, and recycling. Unlike existing research, which is limited to target segmentation, pose regression, or using fixed target blueprints, our work presents a holistic multi-level framework for part assembly planning consisting of part assembly sequence inference, part motion planning, and robot contact optimization. We present the Part Assembly Sequence Transformer (PAST) -- a sequence-to-sequence neural network -- to infer assembly sequences recursively from a target blueprint. We then use a motion planner and optimization to generate part movements and contacts. To train PAST, we introduce D4PAS: a large-scale Dataset for Part Assembly Sequences (D4PAS) consisting of physically valid sequences for industrial objects. Experimental results show that our approach generalizes better than prior methods while needing significantly less computational time for inference.

Interactive Planning Using Large Language Models for Partially Observable Robotics Tasks

Designing robotic agents to perform open vocabulary tasks has been the long-standing goal in robotics and AI. Recently, Large Language Models (LLMs) have achieved impressive results in creating robotic agents for performing open vocabulary tasks. However, planning for these tasks in the presence of uncertainties is challenging as it requires \enquote{chain-of-thought} reasoning, aggregating information from the environment, updating state estimates, and generating actions based on the updated state estimates. In this paper, we present an interactive planning technique for partially observable tasks using LLMs. In the proposed method, an LLM is used to collect missing information from the environment using a robot and infer the state of the underlying problem from collected observations while guiding the robot to perform the required actions. We also use a fine-tuned Llama 2 model via self-instruct and compare its performance against a pre-trained LLM like GPT-4. Results are demonstrated on several tasks in simulation as well as real-world environments. A video describing our work along with some results could be found here.

Tactile Estimation of Extrinsic Contact Patch for Stable Placement

Precise perception of contact interactions is essential for the fine-grained manipulation skills for robots. In this paper, we present the design of feedback skills for robots that must learn to stack complex-shaped objects on top of each other. To design such a system, a robot should be able to reason about the stability of placement from very gentle contact interactions. Our results demonstrate that it is possible to infer the stability of object placement based on tactile readings during contact formation between the object and its environment. In particular, we estimate the contact patch between a grasped object and its environment using force and tactile observations to estimate the stability of the object during a contact formation. The contact patch could be used to estimate the stability of the object upon the release of the grasp. The proposed method is demonstrated on various pairs of objects that are used in a very popular board game.

Simultaneous Trajectory Optimization and Contact Selection for Multi-Modal Manipulation Planning

Complex dexterous manipulations require switching between prehensile and non-prehensile grasps, and sliding and pivoting the object against the environment. This paper presents a manipulation planner that is able to reason about diverse changes of contacts to discover such plans. It implements a hybrid approach that performs contact-implicit trajectory optimization for pivoting and sliding manipulation primitives and sampling-based planning to change between manipulation primitives and target object poses. The optimization method, simultaneous trajectory optimization and contact selection (STOCS), introduces an infinite programming framework to dynamically select from contact points and support forces between the object and environment during a manipulation primitive. To sequence manipulation primitives, a sampling-based tree-growing planner uses STOCS to construct a manipulation tree. We show that by using a powerful trajectory optimizer, the proposed planner can discover multi-modal manipulation trajectories involving grasping, sliding, and pivoting within a few dozen samples. The resulting trajectories are verified to enable a 6 DoF manipulator to manipulate physical objects successfully.

A Virtual Reality Teleoperation Interface for Industrial Robot Manipulators

We address the problem of teleoperating an industrial robot manipulator via a commercially available Virtual Reality (VR) interface. Previous works on VR teleoperation for robot manipulators focus primarily on collaborative or research robot platforms (whose dynamics and constraints differ from industrial robot arms), or only address tasks where the robot's dynamics are not as important (e.g: pick and place tasks). We investigate the usage of commercially available VR interfaces for effectively teleoeprating industrial robot manipulators in a variety of contact-rich manipulation tasks. We find that applying standard practices for VR control of robot arms is challenging for industrial platforms because torque and velocity control is not exposed, and position control is mediated through a black-box controller. To mitigate these problems, we propose a simplified filtering approach to process command signals to enable operators to effectively teleoperate industrial robot arms with VR interfaces in dexterous manipulation tasks. We hope our findings will help robot practitioners implement and setup effective VR teleoperation interfaces for robot manipulators. The proposed method is demonstrated on a variety of contact-rich manipulation tasks which can also involve very precise movement of the robot during execution (videos can be found at https://www.youtube.com/watch?v=OhkCB9mOaBc)

Covariance Steering for Uncertain Contact-rich Systems

Planning and control for uncertain contact systems is challenging as it is not clear how to propagate uncertainty for planning. Contact-rich tasks can be modeled efficiently using complementarity constraints among other techniques. In this paper, we present a stochastic optimization technique with chance constraints for systems with stochastic complementarity constraints. We use a particle filter-based approach to propagate moments for stochastic complementarity system. To circumvent the issues of open-loop chance constrained planning, we propose a contact-aware controller for covariance steering of the complementarity system. Our optimization problem is formulated as Non-Linear Programming (NLP) using bilevel optimization. We present an important-particle algorithm for numerical efficiency for the underlying control problem. We verify that our contact-aware closed-loop controller is able to steer the covariance of the states under stochastic contact-rich tasks.

Robust Pivoting Manipulation using Contact Implicit Bilevel Optimization

Generalizable manipulation requires that robots be able to interact with novel objects and environment. This requirement makes manipulation extremely challenging as a robot has to reason about complex frictional interactions with uncertainty in physical properties of the object and the environment. In this paper, we study robust optimization for planning of pivoting manipulation in the presence of uncertainties. We present insights about how friction can be exploited to compensate for inaccuracies in the estimates of the physical properties during manipulation. Under certain assumptions, we derive analytical expressions for stability margin provided by friction during pivoting manipulation. This margin is then used in a Contact Implicit Bilevel Optimization (CIBO) framework to optimize a trajectory that maximizes this stability margin to provide robustness against uncertainty in several physical parameters of the object. We present analysis of the stability margin with respect to several parameters involved in the underlying bilevel optimization problem. We demonstrate our proposed method using a 6 DoF manipulator for manipulating several different objects.

Tactile-Filter: Interactive Tactile Perception for Part Mating

Humans rely on touch and tactile sensing for a lot of dexterous manipulation tasks. Our tactile sensing provides us with a lot of information regarding contact formations as well as geometric information about objects during any interaction. With this motivation, vision-based tactile sensors are being widely used for various robotic perception and control tasks. In this paper, we present a method for interactive perception using vision-based tactile sensors for multi-object assembly. In particular, we are interested in tactile perception during part mating, where a robot can use tactile sensors and a feedback mechanism using particle filter to incrementally improve its estimate of objects that fit together for assembly. To do this, we first train a deep neural network that makes use of tactile images to predict the probabilistic correspondence between arbitrarily shaped objects that fit together. The trained model is used to design a particle filter which is used twofold. First, given one partial (or non-unique) observation of the hole, it incrementally improves the estimate of the correct peg by sampling more tactile observations. Second, it selects the next action for the robot to sample the next touch (and thus image) which results in maximum uncertainty reduction to minimize the number of interactions during the perception task. We evaluate our method on several part-mating tasks for assembly using a robot equipped with a vision-based tactile sensor. We also show the efficiency of the proposed action selection method against a naive method. See supplementary video at https://www.youtube.com/watch?v=jMVBg_e3gLw .