Coverage Path Planning for Robotic Quality Inspection with Control on Measurement Uncertainty

The optical scanning gauges mounted on the robots are commonly used in quality inspection, such as verifying the dimensional specification of sheet structures. Coverage path planning (CPP) significantly influences the accuracy and efficiency of robotic quality inspection. Traditional CPP strategies focus on minimizing the number of viewpoints or traveling distance of robots under the condition of full coverage inspection. The measurement uncertainty when collecting the scanning data is less considered in the free-form surface inspection. To address this problem, a novel CPP method with the optimal viewpoint sampling strategy is proposed to incorporate the measurement uncertainty of key measurement points (MPs) into free-form surface inspection. At first, the feasible ranges of measurement uncertainty are calculated based on the tolerance specifications of the MPs. The initial feasible viewpoint set is generated considering the measurement uncertainty and the visibility of MPs. Then, the inspection cost function is built to evaluate the number of selected viewpoints and the average measurement uncertainty in the field of views (FOVs) of all the selected viewpoints. Afterward, an enhanced rapidly-exploring random tree (RRT*) algorithm is proposed for viewpoint sampling using the inspection cost function and CPP optimization. Case studies, including simulation tests and inspection experiments, have been conducted to evaluate the effectiveness of the proposed method. Results show that the scanning precision of key MPs is significantly improved compared with the benchmark method.

WOOD: Wasserstein-based Out-of-Distribution Detection

The training and test data for deep-neural-network-based classifiers are usually assumed to be sampled from the same distribution. When part of the test samples are drawn from a distribution that is sufficiently far away from that of the training samples (a.k.a. out-of-distribution (OOD) samples), the trained neural network has a tendency to make high confidence predictions for these OOD samples. Detection of the OOD samples is critical when training a neural network used for image classification, object detection, etc. It can enhance the classifier's robustness to irrelevant inputs, and improve the system resilience and security under different forms of attacks. Detection of OOD samples has three main challenges: (i) the proposed OOD detection method should be compatible with various architectures of classifiers (e.g., DenseNet, ResNet), without significantly increasing the model complexity and requirements on computational resources; (ii) the OOD samples may come from multiple distributions, whose class labels are commonly unavailable; (iii) a score function needs to be defined to effectively separate OOD samples from in-distribution (InD) samples. To overcome these challenges, we propose a Wasserstein-based out-of-distribution detection (WOOD) method. The basic idea is to define a Wasserstein-distance-based score that evaluates the dissimilarity between a test sample and the distribution of InD samples. An optimization problem is then formulated and solved based on the proposed score function. The statistical learning bound of the proposed method is investigated to guarantee that the loss value achieved by the empirical optimizer approximates the global optimum. The comparison study results demonstrate that the proposed WOOD consistently outperforms other existing OOD detection methods.

Failure-averse Active Learning for Physics-constrained Systems

Active learning is a subfield of machine learning that is devised for design and modeling of systems with highly expensive sampling costs. Industrial and engineering systems are generally subject to physics constraints that may induce fatal failures when they are violated, while such constraints are frequently underestimated in active learning. In this paper, we develop a novel active learning method that avoids failures considering implicit physics constraints that govern the system. The proposed approach is driven by two tasks: the safe variance reduction explores the safe region to reduce the variance of the target model, and the safe region expansion aims to extend the explorable region exploiting the probabilistic model of constraints. The global acquisition function is devised to judiciously optimize acquisition functions of two tasks, and its theoretical properties are provided. The proposed method is applied to the composite fuselage assembly process with consideration of material failure using the Tsai-wu criterion, and it is able to achieve zero-failure without the knowledge of explicit failure regions.

A Robust Asymmetric Kernel Function for Bayesian Optimization, with Application to Image Defect Detection in Manufacturing Systems

Some response surface functions in complex engineering systems are usually highly nonlinear, unformed, and expensive-to-evaluate. To tackle this challenge, Bayesian optimization, which conducts sequential design via a posterior distribution over the objective function, is a critical method used to find the global optimum of black-box functions. Kernel functions play an important role in shaping the posterior distribution of the estimated function. The widely used kernel function, e.g., radial basis function (RBF), is very vulnerable and susceptible to outliers; the existence of outliers is causing its Gaussian process surrogate model to be sporadic. In this paper, we propose a robust kernel function, Asymmetric Elastic Net Radial Basis Function (AEN-RBF). Its validity as a kernel function and computational complexity are evaluated. When compared to the baseline RBF kernel, we prove theoretically that AEN-RBF can realize smaller mean squared prediction error under mild conditions. The proposed AEN-RBF kernel function can also realize faster convergence to the global optimum. We also show that the AEN-RBF kernel function is less sensitive to outliers, and hence improves the robustness of the corresponding Bayesian optimization with Gaussian processes. Through extensive evaluations carried out on synthetic and real-world optimization problems, we show that AEN-RBF outperforms existing benchmark kernel functions.

Task Allocation and Coordinated Motion Planning for Autonomous Multi-Robot Optical Inspection Systems

Autonomous multi-robot optical inspection systems are increasingly applied for obtaining inline measurements in process monitoring and quality control. Numerous methods for path planning and robotic coordination have been developed for static and dynamic environments and applied to different fields. However, these approaches may not work for the autonomous multi-robot optical inspection system due to fast computation requirements of inline optimization, unique characteristics on robotic end-effector orientations, and complex large-scale free-form product surfaces. This paper proposes a novel task allocation methodology for coordinated motion planning of multi-robot inspection. Specifically, (1) a local robust inspection task allocation is proposed to achieve efficient and well-balanced measurement assignment among robots; (2) collision-free path planning and coordinated motion planning are developed via dynamic searching in robotic coordinate space and perturbation of probe poses or local paths in the conflicting robots. A case study shows that the proposed approach can mitigate the risk of collisions between robots and environments, resolve conflicts among robots, and reduce the inspection cycle time significantly and consistently.

Partitioned Active Learning for Heterogeneous Systems

Cost-effective and high-precision surrogate modeling is a cornerstone of automated industrial and engineering systems. Active learning coupled with Gaussian process (GP) surrogate modeling is an indispensable tool for demanding and complex systems, while the existence of heterogeneity in underlying systems may adversely affect the modeling process. In order to improve the learning efficiency under the regime, we propose the partitioned active learning strategy established upon partitioned GP (PGP) modeling. Our strategy seeks the most informative design point for PGP modeling systematically in twosteps. The global searching scheme accelerates the exploration aspect of active learning by investigating the most uncertain design space, and the local searching exploits the active learning criterion induced by the local GP model. We also provide numerical remedies to alleviate the computational cost of active learning, thereby allowing the proposed method to incorporate a large amount of candidates. The proposed method is applied to numerical simulation and real world cases endowed with heterogeneities in which surrogate models are constructed to embed in (i) the cost-efficient automatic fuselage shape control system; and (ii) the optimal design system of tribocorrosion-resistant alloys. The results show that our approach outperforms benchmark methods.

NP-ODE: Neural Process Aided Ordinary Differential Equations for Uncertainty Quantification of Finite Element Analysis

Finite element analysis (FEA) has been widely used to generate simulations of complex and nonlinear systems. Despite its strength and accuracy, the limitations of FEA can be summarized into two aspects: a) running high-fidelity FEA often requires significant computational cost and consumes a large amount of time; b) FEA is a deterministic method that is insufficient for uncertainty quantification (UQ) when modeling complex systems with various types of uncertainties. In this paper, a physics-informed data-driven surrogate model, named Neural Process Aided Ordinary Differential Equation (NP-ODE), is proposed to model the FEA simulations and capture both input and output uncertainties. To validate the advantages of the proposed NP-ODE, we conduct experiments on both the simulation data generated from a given ordinary differential equation and the data collected from a real FEA platform for tribocorrosion. The performances of the proposed NP-ODE and several benchmark methods are compared. The results show that the proposed NP-ODE outperforms benchmark methods. The NP-ODE method realizes the smallest predictive error as well as generates the most reasonable confidence interval having the best coverage on testing data points.

Neural Network Gaussian Process Considering Input Uncertainty for Composite Structures Assembly

Developing machine learning enabled smart manufacturing is promising for composite structures assembly process. To improve production quality and efficiency of the assembly process, accurate predictive analysis on dimensional deviations and residual stress of the composite structures is required. The novel composite structures assembly involves two challenges: (i) the highly nonlinear and anisotropic properties of composite materials; and (ii) inevitable uncertainty in the assembly process. To overcome those problems, we propose a neural network Gaussian process model considering input uncertainty for composite structures assembly. Deep architecture of our model allows us to approximate a complex process better, and consideration of input uncertainty enables robust modeling with complete incorporation of the process uncertainty. Based on simulation and case study, the NNGPIU can outperform other benchmark methods when the response function is nonsmooth and nonlinear. Although we use composite structure assembly as an example, the proposed methodology can be applicable to other engineering systems with intrinsic uncertainties.

StressNet: Deep Learning to Predict Stress With Fracture Propagation in Brittle Materials

Catastrophic failure in brittle materials is often due to the rapid growth and coalescence of cracks aided by high internal stresses. Hence, accurate prediction of maximum internal stress is critical to predicting time to failure and improving the fracture resistance and reliability of materials. Existing high-fidelity methods, such as the Finite-Discrete Element Model (FDEM), are limited by their high computational cost. Therefore, to reduce computational cost while preserving accuracy, a novel deep learning model, "StressNet," is proposed to predict the entire sequence of maximum internal stress based on fracture propagation and the initial stress data. More specifically, the Temporal Independent Convolutional Neural Network (TI-CNN) is designed to capture the spatial features of fractures like fracture path and spall regions, and the Bidirectional Long Short-term Memory (Bi-LSTM) Network is adapted to capture the temporal features. By fusing these features, the evolution in time of the maximum internal stress can be accurately predicted. Moreover, an adaptive loss function is designed by dynamically integrating the Mean Squared Error (MSE) and the Mean Absolute Percentage Error (MAPE), to reflect the fluctuations in maximum internal stress. After training, the proposed model is able to compute accurate multi-step predictions of maximum internal stress in approximately 20 seconds, as compared to the FDEM run time of 4 hours, with an average MAPE of 2% relative to test data.

Online Structural Change-point Detection of High-dimensional Streaming Data via Dynamic Sparse Subspace Learning

High-dimensional streaming data are becoming increasingly ubiquitous in many fields. They often lie in multiple low-dimensional subspaces, and the manifold structures may change abruptly on the time scale due to pattern shift or occurrence of anomalies. However, the problem of detecting the structural changes in a real-time manner has not been well studied. To fill this gap, we propose a dynamic sparse subspace learning (DSSL) approach for online structural change-point detection of high-dimensional streaming data. A novel multiple structural change-point model is proposed and it is shown to be equivalent to maximizing a posterior under certain conditions. The asymptotic properties of the estimators are investigated. The penalty coefficients in our model can be selected by AMDL criterion based on some historical data. An efficient Pruned Exact Linear Time (PELT) based method is proposed for online optimization and change-point detection. The effectiveness of the proposed method is demonstrated through a simulation study and a real case study using gesture data for motion tracking.