2024 Second International Conference on Inventive Computing and Informatics (ICICI)

2024 Second International Conference on Inventive Computing and Informatics (ICICI) | 979-8-3503-7329-5/24/$31.00 ©2024 IEEE | DOI: 10.1109/ICICI62254.2024.00119

Application and Optimization of Robot Systems in

Industrial Production Line
Min Tan*1, Zhenlai Liu2, Peng Wang3
1.2.3.ChongqingAerospace Polytechnic, Chongqing, China, Chongqing, 400021
1.
[email protected],2. [email protected], [email protected]

Abstract— This study focuses on the application and factories to conduct more intelligent production planning and
optimization of robotic systems in industrial production lines, forecasting, thereby enhancing production efficiency and
with the overall goal of increasing manufacturing efficiency and product quality. The establishment of digital factories not only
streamlining process automation. A pioneering vision-based enhances production efficiency but also presents new
methodology for industrial robot sensing is presented, which challenges and opportunities to traditional human resource
enables precise control mechanisms through improved management approaches. Employees require enhanced digital
environmental data acquisition. In addition, a comprehensive skills and interdisciplinary capabilities to adjust to the
methodology is presented for optimizing robot control at the production paradigm of the digital factory. Simultaneously,
physical level, thereby improving overall system efficiency and digital factories provide modern enterprises with expanded
performance. By combining insights from an exhaustive review
development opportunities, enabling them to effectively
of related literature with innovative methodologies, this study
makes a significant contribution to advancing the integration of
respond to market dynamics and customer demands, and
robotic systems in industrial production lines. The experimental accomplish industrial upgrading and transformation. Within
platform established for the visual target recognition and the realm of the digital factory, industrial production lines
grasping system of industrial robots has undergone rigorous stand out as the cornerstone, central to driving efficiency and
testing involving various objects commonly encountered in innovation. The integration of robot systems into these
industrial environments. The results showed remarkable success production lines is emerging as a paramount concern and an
rates in grasping various objects, with certain objects achieving essential focus for further advancement.
perfect success rates of 100% over multiple trials. In particular,
As shown in Figure 1, the illustration depicts the intricate
the bottle and small box showed exceptional performance, with a
perfect success rate across all trials. Conversely, some objects interplay of robotic systems within an industrial production
had comparatively lower success rates due to factors such as line. This visual representation serves as a reference point to
shape complexity or surface texture. These empirical results illustrate integration and importance of robotic technologies in
highlights the effectiveness of proposed methods in facilitating modern manufacturing processes.
reliable object recognition and gripping in industrial production
lines.

Keywords— Robotics; Industrial automation; Production

optimization; Manufacturing efficiency; Process automation

I. INTRODUCTION
Digital factories [1]-[3] represent forefront of
contemporary manufacturing. They entail not merely
digitizing traditional manufacturing processes but constituting
a comprehensive revolution. Digital transformation has
fundamentally altered all facets of production, manufacturing,
and product design. This transformation enhances not only the
efficiency of production process but also endows companies Fig. 1. The Robot Systems in Industrial Production Line (Original Image
with heightened flexibility and innovation capabilities. IoT Source: https://www.assemblymag.com/articles/97926-global-automotive-
industry-employs-one-million-robots)
technology plays a pivotal role in the establishment of digital
factories. Extensively deploying sensors and smart devices In this study, the application and optimization of robot
facilitates real-time monitoring and data collection across all systems in industrial production line will be discussed and the
factory domains, thereby automating and optimizing the primary contributions are:
production processes. Intelligent manufacturing technology
endows machines with heightened intelligence, enabling 1. A innovative vision-based methodology for industrial
production equipment to flexibly respond to diverse robot sensing is presented that aims to efficiently collect
production requirements and achieve customization. Cloud environmental data critical for precise control of robotic
computing technology furnishes digital factories with potent systems in production lines. This innovative approach
data storage and processing capabilities, facilitating revolutionizes the process by improving the collection of
centralized data management and real-time data sharing. The environmental information, thereby optimizing the control
integration of the artificial intelligence technology enables

979-8-3503-7329-5/24/$31.00 ©2024 IEEE 701

DOI 10.1109/ICICI62254.2024.00119
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 mechanisms of robotic systems for increased accuracy and capabilities and employ prioritization methods to resolve
efficiency in production operations. collision conflicts efficiently [7].
2. A groundbreaking methodology for optimizing robot Human-automaton collaboration is a focal point in
control at the physical level is presented, with the goal of Industry 4.0, with collaborative automatons offering enhanced
improving overall system control efficiency. This innovative productivity and flexibility. Roveda et al. introduce a model-
approach represents a significant advancement in the field, based reinforcement learning variable impedance controller to
providing refined techniques for managing the complex aid human operators in collaborative tasks. By employing
dynamics of robotic systems. artificial neural networks and model predictive control, the
proposed approach enhances collaboration and adjusts to
II. RELATED WORK uncertainties in human-automaton interaction dynamics [8].
The progression of robotic mechanisms has profoundly Tools for modeling and analyzing soft robots remain
influenced diverse sectors, spanning from industrial operations limited despite the growing interest in soft robotics. Mathew et
to medical practices. Soft-bodied automatons, characterized by al. address this gap by introducing the Soft Robot Simulator
their economical production, endurance, and flexibility, have (SoRoSim), a MATLAB toolbox that integrates the geometric
garnered considerable interest owing to their adaptability in variable-strain model of Cosserat rods. The toolbox facilitates
bio-integrated systems [4]. Unlike the conventional rigid the static and dynamic analysis of soft, rigid, and hybrid
automatons, soft robots boast infinite degrees of freedom and automaton systems, offering a valuable resource for the soft
nonlinear material characteristics, necessitating innovative robotics research community [9]. Adaptive control strategies
approaches to control. The swift advancements in material play a crucial role in addressing uncertainties in automaton
sciences, automation, and artificial intelligence have paved the systems. Yu et al. propose adaptive fuzzy full-state and
way for a plethora of actuation mechanisms and control output-feedback control schemes to enhance tracking accuracy
algorithms, enabling a myriad of control strategies such as and ensure output constraints in uncertain automaton
unidirectional regulation, interactive regulation, and manipulators. Through simulation examples and experimental
independent regulation. These strategies are evaluated based validation, the effectiveness of the proposed methods is
on their alignment with material compositions, application demonstrated, highlighting their practical applicability [10].
objectives, and deployment methodologies, with emerging Remote human-automaton collaboration systems offer
avenues focusing on harmonizing between controllers and flexibility and safety, particularly in hazardous manufacturing
actuators, underregulated control strategies, and the environments [11]. Liu and Wang present a cyber-physical
amalgamation of artificial intelligence [4]. Within the domain system for remote human-automaton collaboration, leveraging
of multi-robot systems, which hold tremendous promise for collaborative and industrial automatons to flexibly operate in
applications like sensory networks and surveillance, different modes. The system's implementation and testing
synchronization among automatons is pivotal [5]. Previous demonstrate its potential for hazardous manufacturing
endeavors have predominantly concentrated on devising environments [11].
control methodologies tailored to specific synchronization
tasks. However, Sakurama and Sugie propose a unified In the context of last-mile delivery, automated
approach to tackle various synchronization tasks by technologies offer opportunities to develop more efficient
formulating them as a generalized synchronization conundrum. systems. Simoni et al. propose a heuristic approach for
This approach harnesses group and graph theories to furnish a implementing an integrated truck-automaton system,
comprehensive solution applicable across diverse tasks, taking leveraging dynamic programming to optimize truck tours and
into account factors such as network topologies and desired automaton operations. The study highlights the efficiency of
configuration sets [5]. automaton-assisted last-mile delivery systems, especially in
congested areas [12]. The study discussed in [13] delves into
Safety remains a paramount concern in automaton systems, unmanned warehouse dispatching systems, employing a novel
especially in environments where automatons navigate approach rooted in a deep reinforcement learning algorithm,
dynamically [6]. Molnar et al. present a framework for safety- specifically the deep Q-network (DQN) algorithm. This
focused control of automaton systems, wherein safety is algorithm, amalgamating Q-learning, an empirical playback
defined within secure zones in the configuration expanse. To mechanism, and volume-based technology from productive
uphold safety, a secure velocity is synthesized based on neural networks, aims to tackle the challenge of multi-
control barrier function theory sans dependence on a – automaton path planning. The study endeavors to overcome
potentially intricate – high-fidelity dynamic model of the two significant obstacles in robot path-planning: slow
automaton. Subsequently, this velocity is tracked with a convergence and excessive randomness. Prior to commencing
tracking controller, culminating in model-independent safety- the algorithmic process, antecedent knowledge and rules are
critical control. The authors validate the method's theoretical leveraged to refine the DQN algorithm. Simulation results
safety assurances and demonstrate its applicability across showcase that the refined DQN algorithm exhibits faster
different automaton platforms [6]. convergence compared to traditional deep reinforcement
In the context of path planning and obstacle avoidance for learning algorithms and swiftly learns solutions to path-
distributed multi-automaton systems, Yang et al. propose a planning predicaments, thereby bolstering the efficiency of
bidirectional alternating jump point search A* algorithm multi-automaton path planning. Lastly, in the DARPA
(BAJPSA*) for global path planning. Additionally, they Subterranean Challenge, teams of mobile automatons are
introduce modifications to enhance obstacle avoidance tasked with exploring underground environments for search-

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 and-rescue missions [14]. Rouček et al. describe the multi- distortion and the working environment are also important. A
automaton exploration system of the CTU-CRAS team, which lens typically consists of an aperture and lens elements.
achieved significant success in the challenge. The study Adjusting the aperture and focal length based on the images
discusses the platforms, algorithms, and strategies employed, being captured allows you to obtain clear images, mitigate the
offering insights into the design and operation of effective effects of distortion, and optimize performance in a variety of
exploration systems. conditions. The working distance (W) is as shown in formula:
III. PROPOSED METHODOLOGY W L /D / f (1)
Where the L defines the camera size, D is the viewing
A. The Vision Optimization of Robot Systems
angle, f is the focal length. LED lights have a wide range of
Optimizing the vision modeling of robotic systems for colors to choose from, high brightness but low heat, long use
industrial production lines requires a holistic approach that time and low prices. Combined with the needs of shooting,
includes both hardware and software elements. LED ring lights are chosen as the lighting for this system.
In order to achieve target recognition and accurately guide Then, for the software level, the camera coordinate system
robot grasping, it is crucial to select appropriate hardware calibration [21] is firstly considered. During manufacturing
equipment. Key hardware includes cameras, lenses, light process, cameras are exposed to various adverse factors such
sources, and robots that perform the grasping. Optimizing as manufacturing techniques, processing equipment, and
these devices will improve the performance and reliability of temperature fluctuations, which create inherent distortion
the system to effectively support the automation tasks of the problems. Distortion can significantly alter captured images,
industrial production lines. In machine vision systems, image causing straight lines to appear curved and hindering
capture is the foundation for subsequent work. Choosing the subsequent processes. Therefore, camera calibration is
right camera, lens, and light source is critical to reducing the essential to determine true intrinsic and extrinsic parameters to
impact of the environment on image capture, improving image eliminate distortion effects and provide a solid foundation for
quality, and providing reliable data for subsequent processing a seamless workflow. Typically, cameras are shipped from the
and target recognition. There are two main types of cameras factory with initial intrinsic parameters set. However, the
available on the market: CCD (Charge Coupled Device) [15]- actual parameters can vary significantly from these defaults
[17] and CMOS (Complementary Metal Oxide for certain cameras. The degree of distortion in images is
Semiconductor) [18]-[20]. CCD cameras have a consistent and largely influenced by the distance of the pixels from the
stable signal, while CMOS cameras have faster capture speeds center: the farther from the center, the more distorted the
but less stability. Considering requirement of high-precision image. This non-linear distortion can be described by Equation
shooting and real-time image transmission of plastic 2.
membranes, it is more appropriate to choose a CMOS camera. ­° x x Q x x, y
Although CMOS cameras are less expensive, in terms of the ® (2)
balance between performance and real-time performance, °̄ y y Q y x, y
CMOS cameras are a better choice to meet the requirements of Where the x, y is the real image point coordinates, the
the system. In the Figure 2, the camera specifications are
presented. x, y is the distortion-free ideal coordinates of pixels
consistent with linear imaging model. The Q x ,Q y are the
nonlinear distortion value, which is related to the position of
the image point in the image which can be defined as:
Q x x, y -1x x 2  y 2 (3)
Q y x, y -2 x x 2  y 2 (4)
In general, the radial distortion in this model can already
express the nonlinear distortion well. However, according to
research results, adding too many nonlinear parameters
sometimes not only fails to improve the accuracy, but also
may lead to instability of the solution. Therefore, during the
distortion correction process, the number of the nonlinear
parameters must be weighed to ensure a balance between
accuracy and stability. Then, the formula 2 can be expressed
as updated formula 5:
­° x x 1  -1t 2
® (5)
°̄ y y 1  -2t 2
Fig. 2. The Camera Specifications
When choosing a lens, considerations go beyond camera The t is defined as formula 6:
position, field of view and focal length. Factors such as lens t x2  y 2 (6)

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 As the radial radius increases, the distortion will become and noise points, fitting surfaces, and identifying regions of
more obvious, that is, the distortion value will become larger interest (ROI). By calculating and fitting the normal vector of
as the distance from the center of the image increases. As the the work-piece plane, more characteristic information about
illustration, the Figure 3 shows the sample noise the curved work-piece can be obtained. These pre-processing
checkerboard. steps help to improve the quality and accuracy of the point
cloud data. Finally, using the proposed optimization model,
the problem of extracting and further analyzing the work-piece
surface features can be perfectly solved, providing a reliable
basis for subsequent work-piece processing and analysis.
B. The Vision based Control Optimization of Robot Systems
The robot-side program realizes two main functions: real-
time communication with the host computer and motion
control of the robot. The program adopts multi-process, front-
end and back-end modes. The background program is
responsible for the communication establishment, message
parsing, instruction identification, and execution of non-
motion instructions; the foreground program executes motion
instructions. The background program starts automatically
when the robot is powered on. After the robot starts, it
initializes and creates a TCP server to wait for a connection
Fig. 3. The Sample Noise Checkerboard from the host computer. Once connected, the background
Then, complex surface point cloud collection is designed program blocks receiving instructions and polls the robot for
for the efficient visual sensing for the robots. In this model, a status information, such as posture, running status, etc., so that
binocular stereo vision system is used to obtain point cloud the host computer can see the robot's status in real time. In
information on the work-piece surface based on the work- addition, the background program controls the opening and
piece surface characteristics and scene conditions. Traditional closing of the EGM mode in the foreground program and
controls the power on/off of the robot. When the EGM mode
binocular systems can usually only obtain two-dimensional
is off, the robot can move controlled by messages, and when it
information of the work-piece, and the depth information must is on, the robot can only be controlled in real time through
be derived by trigonometric principles, but its accuracy often UDP. After the robot is turned on, it is enabled to move and
cannot meet industrial standards. Therefore, structured light is can execute motion control commands; after it is turned off
often combined with a binocular vision system to form a and disabled, it can only communicate to query the status, but
binocular stereo vision measurement system. The structured refuses to execute motion control commands. This type of
light solution allows the camera to directly obtain the three- programming makes communication and motion control
dimensional coordinate information of the target work-piece between the robot and the host computer more flexible and
surface by projecting coded light strips or gratings, thereby secure. In the Figure 4, the host computer control block
achieving accurate depth measurement of the work-piece diagram for robot systems is presented.
surface. This system can overcome limitations of traditional
binocular vision systems in the depth perception, improve
measurement accuracy, and meet requirements of industrial
applications. Let the normal vector of the plane formed by
three non-collinear feature points be n. In order to establish the
structured light plane equation, define the vector Ti , j :
Ti, j >mij , aij , nij @
> x j  xi , y j  yi , z j  zi @ (7) Fig. 4. The Host Computer Control Block Diagram for Robot Systems

After conducting research on visual robot recognition and

If the structured light plane equation is: grasping technology, it is imperative to conduct an analysis of
d ax  by  cz (8) robot kinematics. This analysis investigates the relationship
Then, the depth of feature points on structured light in the between the motion variables of each joint during the
camera coordinate system can be expressed as follows: implementation of grasping motion by the robot, thereby
-x- y d establishing a theoretical foundation for motion trajectory
depth (9) planning, control, and workspace calculation. The studied
a- y u  u0  b-x u  u0  c-x- y motion variables include speed, acceleration, deflection angle,
Obtaining initial point cloud data of a part typically and displacement. The study employs a six-degree-of-freedom
requires two key steps: point cloud acquisition and pre- multi-joint serial robot. Its kinematics analysis necessitates
processing. First, a binocular vision system is used to acquire initially establishing a robot model. The method commonly
point cloud data of the measured object. Then, the collected utilized is the D-H method.
point cloud data is pre-processed, including removing outliers

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 This method establishes a model while disregarding joint
force and mass, and derives mathematical expressions of joint
motion by determining the geometric parameters and motion
rules between each joint of the robot. This analysis offers
essential theoretical underpinning for thorough comprehension
of robot motion characteristics and the optimization of motion
control and grasping processes. The Figure 5 shows the typical
robot link coordinate system.

Fig. 6. The Six DOF Model with Matlab Implementation

IV. RESULTS AND DISCUSSION

In the experimental platform for visual industrial robot
target recognition and grasping system for the production line
established in this study, besides hardware components, there
is also a configuration and construction of the software
Fig. 5. The Typical Robot Link Coordinate System system. For target recognition, an object detection model
The cylinders in the figure represent the joints of the robot, based on deep learning is utilized, enabling efficient detection
and their axis of rotation is the Z-axis of each joint coordinate of various objects, such as parts and products of diverse
system, and its positive direction is determined by the right shapes and sizes, on the industrial production line. To enhance
rule. The X-axis is the common perpendicular to the Z-axis of grasping success rate and efficiency, advanced motion
adjacent joints or the normal of the intersecting plane. The Y- planning and control algorithms, including model-based
axis is determined by the right rule and forms a right-handed reinforcement learning methods or optimization algorithms,
coordinate system with Z-axis and X-axis. The establishment are employed to ensure that the robotic claw grasps the target
of these coordinate systems provides a standardized reference object with optimal posture and strength. Furthermore,
alongside image processing and machine learning algorithms,
frame for describing the motion of each joint of the robot,
the experimental platform is outfitted with a comprehensive
which is very important for motion control and path planning
set of control software for real-time monitoring and control of
of the robot. In Figure 6, with the Matlab tool box, a the robot's movement. By organically combining software and
simulation of a simple six-degree-of-freedom robot model is hardware, experimental platform can efficiently and accurately
conducted. By specifying the length and angle of each joint, accomplish target recognition and grasping tasks, thereby
the program calculates and plots the robot's trajectory. During significantly supporting the automation and further
drawing, each joint is represented by a black line segment intelligence enhancement of industrial production lines.
connecting adjacent joints. The robot's end effector is
represented by a red sphere. The entire model is visualized We conducted crawling experiments on different selected
through a three-dimensional coordinate system, and the robot's crawling objects, and conducted 100 crawling experiments on
posture and movement in space can be clearly observed. each experimental object. In the Figure 7, the simulation result
is illustrated.

Fig. 7. The Simulation Result for Robot Grabbing Test

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