Robotic Wire Arc Additive Manufacturing (WAAM) is a metal additive manufacturing technology, offering flexible 3D printing while ensuring high quality near-net-shape final parts. However, WAAM also suffers from geometric imprecision, especially for low-melting-point metal such as aluminum alloys. In this paper, we present a multi-robot framework for WAAM process monitoring and control. We consider a three-robot setup: a 6-dof welding robot, a 2-dof trunnion platform, and a 6-dof sensing robot with a wrist-mounted laser line scanner measuring the printed part height profile. The welding parameters, including the wire feed rate, are held constant based on the materials used, so the control input is the robot path speed. The measured output is the part height profile. The planning phase decomposes the target shape into slices of uniform height. During runtime, the sensing robot scans each printed layer, and the robot path speed for the next layer is adjusted based on the deviation from the desired profile. The adjustment is based on an identified model correlating the path speed to change in height. The control architecture coordinates the synchronous motion and data acquisition between all robots and sensors. Using a three-robot WAAM testbed, we demonstrate significant improvements of the closed loop scan-n-print approach over the current open loop result on both a flat wall and a more complex turbine blade shape.

In many modern astronomical facilities, multi-object telescopes are crucial instruments. Most of these telescopes have thousands of robotic fiber positioners(RFPs) installed on their focal plane, sharing an overlapping workspace. Collisions between RFPs during their movement can result in some targets becoming unreachable and cause structural damage. Therefore, it is necessary to reasonably assess and evaluate the collision probability of the RFPs. In this study, we propose a mathematical models of collision probability and validate its results using Monte Carlo simulations. In addition, a new collision calculation method is proposed for faster calculation(nearly 0.15% of original time). Simulation experiments have verified that our method can evaluate the collision probability between RFPs with both equal and unequal arm lengths. Additionally, we found that adopting a target distribution based on a Poisson distribution can reduce the collision probability by approximately 2.6% on average.

A compact large-range six-degrees-of-freedom (six-DOF) parallel positioning system with high resolution, high resonant frequency, and high repeatability was proposed. It mainly consists of three identical kinematic sections. Each kinematic section consists of two identical displacement amplification and guiding mechanisms, which are finally connected to a limb. Each limb was designed with a universal joint at each end and connected to a moving stage. A computational model of the positioner was built in the ANSYS software package, hence, the input stiffness, output compliance, range, and modal analysis of the system were found. Furthermore, a monolithic prototype made of Acrylonitrile Butadiene Styrene (ABS) was successfully manufactured by the 3D-printing process. It was actuated and sensed by piezoelectric actuators (PEAs) and capacitive displacement sensors, respectively. Finally, the performances of this proposed positioner were experimentally investigated. The positioning resolution was achieved as 10.5nm {\times} 10.5nm {\times} 15nm {\times} 1.8{\mu}rad {\times} 1.3{\mu}rad {\times} 0.5{\mu}rad. The experimental results validate the behavior and capabilities of the proposed positioning system, and also verify the nanometer-scale spatial positioning accuracy within the overall stroke range. Practical applications of the proposed system can be expanded to pick-and-place manipulation, vibration-canceling in microsurgery/micro-assembly, and collaborative manipulators systems.

In this paper, we solve the complete coordination problem of robotic fiber positioners using supervisory control theory. In particular, we model positioners and their behavioral specifications as discrete-event systems by the discretization of their motion spaces. We synthesize a coordination supervisor associated with a specific set of positioners. In particular, the coordination supervisor includes the solutions to the complete coordination problem of its corresponding positioners. Then, we use the backtracking forcibility technique of supervisory control theory to present an algorithm based on a completeness condition to solve the coordination problem similar to a reconfiguration problem. We illustrate the functionality of our method using an example.