CARLOS

CooperAtive Robot for Large Spaces manufacturing

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 Obiettivo del progetto (Objective)

'The CARLoS project aims to apply recent advances in cooperative mobile robotics to a representative industrial scenario in shipyards. CARLoS robot will be built using off-the-shelf technology under a modular approach. The prototype will be demonstrated as a robot co-worker for fit-out operations inside blocks of ship superstructures. Most of technology for developing such a robot exists, but there is not yet a solution on the market with capabilities that meet the special requirements of shipyards. The CARLoS project will contribute to strength the technological level and market position of: -European SMEs that develop, supply, and integrate mechatronic, sensing, and electronic technologies for industrial applications. -European SMEs providing fit-out services to shipyards and to industrial and civil construction. The main features of CARLoS robot are: • high mobility inside ship blocks • semi-autonomous decision-making on the work to do • autonomous stud welding capability • autonomous pre-outfitting marking capability • easily controlled by a shipyard worker The working plan has been designed to develop a full robot for stud welding and marking. The project is divided in 7 WP including RTD, dissemination and management tasks, comprising: • Development of a mobile navigation system for shipyard blocks • Development of a sensing and control system for full automation of marking and stud welding • Development of a skilled human-robot interaction system suited to the tasks at hand • Continuous integration towards a final prototype • Demonstration and validation of the system in real-world conditions CARLoS will yield: • Higher flexibility, productivity, and reliability • Increase of the market share for the end users • Improved outfitting competitiveness • New market for high-tech products in which Europe stands out (e.g. mechatronics, machine vision, embedded processing)'

Introduzione (Teaser)

A mobile manipulator has been developed based on modular components to work inside blocks of ship superstructures. The robot navigates autonomously and performs bulkhead viewing and stud welding.

Descrizione progetto (Article)

Many repetitive processes in shipbuilding are still performed manually to the detriment of job conditions and of the competitive position of the numerous small and medium-sized enterprises (SMEs) that provide fit-out services to shipyards. CARLOS consortium is developing a robotic solution focused on stud welding and marking inside blocks of ship superstructures with EU support (http://carlosproject.eu/ (CARLOS)).

The robot will perform semi-autonomous navigation inside ship blocks. Using information from a computer-aided design file, it will automatically perform stud welding processes. In addition, it will mark information onto cabin walls to support fit-out operations (to equip the cabin as needed) by personnel.

Within the first nine months, the team has already made impressive progress. Investigators have designed, assembled and partially tested the main components of the robot, consisting of the platform, robotic arm, sensors and tools. Using the manipulator and a commercial welding gun attached to the robot's wrist, preliminary stud welding trials have produced promising results.

Initial versions of the control software for autonomous robot navigation, bulkhead sensing and process execution have been developed, as has a preliminary version of a user interface. In addition, the team has defined the laboratory testing protocols and benchmarking metrics to support full optimisation and validation.

The subcomponent technologies of mechatronics, sensing and electronics will support the viability and profitability of numerous SMEs. Automation will be an important step towards more reliable process control and process management.

Overall, CARLOS technology will enable an important increase in productivity and competitiveness for EU shipbuilders while reducing manufacturing faults. The platform will be of interest in other environments as well, including industrial manufacturing and civil construction.