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Alvarez, Mariano José
Instituto Politécnico de Bragança
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- Prototyping and Control of an Educational Manipulator RobotPublication . Coelho, João Paulo; Brancalião, Laiany Suganuma; Alvarez, Mariano José; Costa, Paulo Gomes da; Gonçalves, JoséThis article presents the prototyping of an educational manipulator robot, based on the “EEZYbotARM Mk2” robot, tailored for first-year master’s students in the field of robotics. The project encompasses the assembly of the robot arm, computation of both forward and inverse kinematics, and analysis of two path-planning movement algorithms. These features are consolidated into an Arduino library to streamline the process for students to generate instructions for the robot. The “EEZYbotARM Mk2” features a three-degree-of-freedom revolute arm with a gripper that remains parallel to its base at all times, enhancing its suitability for educational applications such as pick-and-place tasks. The article provides detailed descriptions of the materials and methods employed, along with proposed challenges for student engagement.
- Automated ceramics tableware finishing: non-circular geometries case studyPublication . Alvarez, Mariano José; Brancalião, Laiany Suganuma; Carneiro, Jorge; Costa, Paulo Gomes da; Coelho, João Paulo; Gonçalves, JoséThis paper is devoted to present the most recent results regarding the ongoing work carried out in the scope of the STC 4.0 HP project, which aims to automate the finishing process of ceramic tableware at the GRESTEL S.A. industry, focusing on non-circular shaped plates. A collaborative robot is in charge of handling the tableware and making it go around its entire perimeter through a sponge, to perform the finishing. An array, with the distances from the center to the different points of the plate, is applied as data to trace the path that the robot must follow. The final goal of this prototype is to obtain an even finish while maintaining a constant force along the entire perimeter of the ceramic tableware. After carrying out a seriesof tests, it was possible to conclude that the current approach was able to manipulate 3D-printed tableware made for testing and travel its perimeter to carry out the finishing.
- Programming Mobile Robots in an Educational Context: a Hardware-in-the-loop ApproachPublication . Brancalião, Laiany Suganuma; Alvarez, Mariano José; Coelho, João Paulo; Conde, Miguel Ángel; Costa, Paulo Gomes da; Gonçalves, JoséIn this paper it is presented a Hardware-in-theloop (HIL) mobile robot programming approach, to be applied in a robotics educational context. The motivation to apply this approach is the fact that students can program the robots without access to the robot hardware, but still maintain some important closed loop control critical features, such as a realistic lag time and the possibility for a larger number of students to program at the same time. Therefore, the developed software is applied to the real hardware without any change. The HIL approach was applied to provide a simulation close to reality, once the processing occurs in the real robot processor and the actuation and sensorization inside the simulation, adding to the advantage to test the firmware avoiding damage in the physical robot.
- Towards a more accurate time of flight distance sensor to be applied in a mobile robotics applicationPublication . Brancalião, Laiany; Alvarez, Mariano Jose; Conde, Miguel Ángel; Costa, Paulo Gomes da; Gonçalves, José; Alvarez, Mariano JoséIn this paper, it is presented a field of view analysis of a time of flight sensor, that will be applied in a mobile robotics application. The sensor was configured in order to obtain a tradeoff between reactiveness and accuracy. It was used a microcontroller development board to acquire data and a manipulator to perform the movements, assuring repeatability and accuracy in the data acquisition process. The results of this paper will be used as an input to a simulation, in order to assist in the development of a mobile robotics application and also to be applied in educational contexts.
- Automated ceramics tableware finishing: a laboratory prototype for concept validationPublication . Alvarez, Mariano José; Brancalião, Laiany; Carneiro, Jorge; Costa, Paulo Gomes da; Coelho, João Paulo; Gonçalves, JoséIn this paper, it is presented an integration between a finishing device and a collaborative robot in order to automate the sanding process of a ceramic industry in Portugal. The finishing device and the collaborative robot are described as well as the communication between the devices. It was used a computer responsible for decision making and control of all the system. The system was able to control the position of the finishing device according to the force done in the sponge by the ceramic. The final system behavior was presented and discussed, which was satisfactory and performed well. The presented experimental setup is not intended for industrial use, but it is suitable for concept prove, in laboratory. The outputs that will emerge here will be applied in a future industrial application, with requisites compatible with the application environment, regarding robustness and repeatability.
- Data analysis for trajectory generation for a robot manipulator using data from a 2D industrial laserPublication . Gomes, Diogo; Alvarez, Mariano José; Brancalião, Laiany; Carneiro, Jorge; Gonçalves, Gil; Costa, Paulo Gomes da; Gonçalves, José; Pinto, Vítor H.Nowadays, the automation of factory floors is necessary for extensive manufacturing processes to meet the ever-increasing competitiveness of current markets. The technological advances applied to the digital platforms have led many businesses to automate their manufacturing processes, introducing robotic manipulators collaborating with human operators to achieve new productivity, manufacturing quality, and safety levels. However, regardless of the amount of optimization implemented, some quality problems may be introduced in production lines with many products being designed and produced. This project proposes a solution for feature extraction that can be applied to automatic shape- and position-detection using a 2-dimension (2D) industrial laser to extract 3-dimension (3D) data where the movement of the item adds the third dimension through the laser’s beam. The main goal is data acquisition and analysis. This analysis will later lead to the generation of trajectories for a robotic manipulator. The results of this application proved reliable given their small measurement error values of a maximum of 2 mm.
- Prototyping and control of an automatic ceramic tableware finishing devicePublication . Alvarez, Mariano José; Gonçalves, José; Coelho, João Paulo; Gutierrez, GuillermoGarantir a qualidade da etapa de acabamento em produtos cerâmicos é uma questão fundamental em qualquer indústria de fabricação de louças. Essa qualidade de acabamento é um desafio a ser realizado por um sistema de automação quando as peças apresentam geometrias muito irregulares. Este trabalho foca-se neste problema e tem como objetivo descrever as etapas de prototipagem e teste de um sistema mecatrónico a ser utilizado no processo de acabamento na empresa GRESTEL - Produtos Cerâmicos S.A., onde atualmente é feito manualmente. Este trabalho foi desenvolvido sob os auspícios do projeto STC 4.0 HP e envolve o controle, em malha fechada, da força de contato e velocidade de rotação de uma esponja úmida que será utilizada no processo de alisamento das peças cerâmicas antes de serem submetidas à processo de cozimento. A estrutura mecânica da solução projetada foi prototipada usando uma tecnologia baseada em FDM. Uma impressora 3D foi utilizada para a fabricação das peças estruturais para suportar a esponja rotativa e os sensores de medição. Além disso, um controle baseado em PID é usado para controlar o sistema. Uma vez que o protótipo foi projetado e montado, uma série de testes e medições foram realizados levando à conclusão de que a abordagem proposta é adequada para atender aos requisitos de projeto.
- Modeling and control of an educational manipulator robot jointPublication . Coelho, J. A. B.; Brancalião, Laiany Suganuma; Alvarez, Mariano José; Costa, Paulo; Gonçalves, JoséIntegrating physical robots in an educational context often entails acquiring Expensive equipment that often operates using proprietary software. Both conditions restrict the students from exploring and fully understanding the internal operation of robots. In response to these limitations, a three-degree-of-freedom robotic manipulator, based on the “EEZYbotARM MK2” open-source design by Carlo Franciscone, is being repurposed and integrated within the SimTwo simulation environment to operate within a hardware-in-the-loop architecture. To accomplish this objective, first, an open-source Arduino-based library was developed aiming at the robot’s online and offline programming akin to industrial robots. The firmware is able to communicate with the SimTwo software in which the digital twin’s robot is living. The dynamic behavior of the robot’s digital twin must be properly parametrized and aligned with the physical robot’s dynamics. This article describes the modeling of the robot joint’s actuator and its closed-loop controller formulation. The obtained results show that the dynamic behavior of the robot joint digital twin closely matches both open and closed-loop, the one of its physical counterpart.
- Laser Engraving for 3D Surfaces: A Robotized Application Case StudyPublication . Alvarez, Mariano José; Brancalião, Laiany Suganuma; Carneiro, Jorge; Costa, Paulo; Coelho, João Paulo; Gonçalves, JoséOne of the industry’s most common applications of lasers is engraving, which is generally performed on flat surfaces. However, there are many situations where the object to be engraved has an unevenly curved geometry. In those cases, the light power density will be different along the surface for a fixed head, leading to a poor engraving result. This work deals with this problem by designing a robotic application capable of detecting variations on the object surface and automatically creating a trajectory to engrave on it correctly. This was made possible through a robotic manipulator, a time-of-flight distance sensor, and a data processing algorithm over the measured data. Obtained results were acquired using a custom-made test rig and validated by delivering consistent engraving results on irregular surface shapes.
- Realistic simulation for dataset generation in a mobile robotics educational contextPublication . Brancalião, Laiany Suganuma; Alvarez, Mariano José; Coelho, J. A. B.; Conde, Miguel; Costa, Paulo; Gonçalves, JoséIn the context of mobile robotics education, realistic and accessible datasets are fundamental for supporting the development and testing of algorithms. However, collecting real-world data is a limited and challenging task because it is time-consuming and error-prone. Therefore, this paper presents the generation of a synthetic dataset through realistic simulation using the SimTwo environment—a physics-based simulator, and modeling techniques of sensors and actuators. The physical and simulated mobile robot was developed to perform tasks such as following a line, following a wall, and avoiding obstacles. The proposed approach facilitates the creation of customized datasets for training and evaluation algorithms while supporting remote and inclusive learning. Results show that a simulated dataset can effectively replicate real-world behaviors, making them a valuable resource for educational contexts, research, and development. Some emergent machine learning algorithms can be applied to this dataset, being this approach increasingly used to enhance robot localization, by leveraging ML, robots can improve the accuracy, robustness, and adaptability of their localization systems, especially in complex and dynamic environments.