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214
Use of a Low-Cost Humanoid
for Tiling as a Study in On-Site
Fabricaon
Mathew Schwartz
Advanced Instutes of
Convergence Technology,
Seoul Naonal University
Techniques and Methods
ABSTRACT
Since the me architecture and construcon began embracing robocs, the pre-fab movement
has grown rapidly. As the possibilies for new design and fabricaon emerge from creavity and
need, the applicaon and use of new roboc technologies becomes vital. This movement has been
largely focused on the deployment of industrial-type robots used in the (automobile) manufacturing
industry for decades, as well as trying to apply these technologies into o-site building construc-
on. Beyond the pre-fab (o-site) condions, on-site fabricaon oers a valuable next step to
implement new construcon methods and reduce human work-related injuries. The main challenge
in introducing on-site roboc fabricaon/construcon is the diculty in calibrang robot navigaon
(localizaon) in an unstructured and constantly changing environment. Addionally, advances in
roboc technology, similar to the revoluon of at-home 3D prinng, shi the ownership of modes
of producon from large industrial enes to individuals, allowing for greater levels of design and
construcon customizaon. This paper demonstrates a low-cost humanoid robot as highly custom-
izable technology for oor ling. A novel end-eector design to pick up les was developed, along
with a localizaon system that can be applied to a wide variety of robots.
1 The NAO robot with moon
capture markers aached while
inside the capture volume of the
moon capture studio.
1
215
GENERATIVE ROBOTICS
INTRODUCTION
Construction Injury
While robocs plays an important role in increasing eciency
and quality in manufacturing, it is also vital in reducing workers’
exposure to dangerous and hazardous manufacturing and
construcon processes. Although the displacement of jobs
connues to be a highly controversial topic, the reducon of
construcon injuries is of great benet, as manufacturing and
construcon industries represent a large share of both fatal and
non-fatal work accidents (OECD 2007). While many factors,
such as regulaons, have reduced workplace deaths, the early
1990s had seen a risk of death in construcon three mes higher
than all other workers combined (Jeong 1998). Based on current
conversaons within manufacturing about compliant robocs
being necessary for human-robot coexistence, workplace inju-
ries in construcon have been in large part accidents caused
by slipping or falling objects, rather than direct contact with
machinery (Jeong 1998). In 2002, falling totaled 56% of injuries,
while being hit by falling objects was 17%, suggesng that such
injuries connue to be a common on-site issue (Haslam et al.
2005). Furthermore, injuries are not limited to an immediate loss
of life or health, but include long-term eects from sicknesses
and diseases from exposure to lead, asbestos, or even radiaon.
As seen from the March 11, 2011 earthquake disaster in Japan,
human exposure during reconstrucon and debris removal is
extremely dangerous and results in a wide range of health condi-
ons. For these and other reasons, it would be highly benecial
for society to develop strategies for on-site roboc construcon,
even without considering economic and design benets.
Teleoperation
In this regard, the robot can be controlled with either
one-to-one mapping or from a remote site with some degree
of autonomy. A popular applicaon of teleoperaon is in the
medical eld of surgery. The surgeon is able to control the
robot through an interface, such as a hapc feedback pen,
allowing for more accurate and ne-tuned control during the
procedure (Marohn and Hanly 2004). While this is close to a
one-to-one mapping, other aspects of medical robocs, such
as wrist injuries during ultrasounds, may benet from a more
intelligent teleoperated roboc assistant (Con, Park, and
Khab 2014). In the case of surgery and ultrasound imaging,
the roboc system is in a xed locaon. In unstructured envi-
ronments, such as buildings, a dierent type of robot would
be required.
Immediately aer the Japan disaster, teleoperated systems were
originally deployed using unmanned construcon technologies
(OSUMI 2014). These remote-control technologies may include
greater autonomy, to the degree that a single human operator
could concurrently control mulple machines (Bock, Linner, and
Ikeda 2012).
During 2014 and 2015, researchers had prepared for the DARPA
Robocs Challenge (DRC) (Johnson et al. 2015), which aimed to
advance the state-of-the-art for robocs research. Based on the
disaster in Fukushima, the need for robots to navigate unstruc-
tured environments that were designed for people became
apparent. Oen, the general public views humanoid robots as
futurisc servants dealing with house chores and taking coats
from guests. Even so, current household robots for chores such as
vacuum cleaning have been reduced to simple cylinders on wheels.
However, as the built environment is designed for people, the
simplest way for robots to ulize the same space is to share
similar features and general physical qualies of humans. This
was seen as a crical part of the DRC, since robots were required
to climb stairs or even a ladder, and be able to operate (shut o)
a valve. A secondary aspect to the DRC was the intermient
communicaon between the operator and robot. The operator
was able to receive a limited amount of data from the robot,
requiring the implementaon of three general approaches: long
periods of waing (in which a me rule was implemented), a fully
autonomous robot able to complete the tasks, or a combinaon
of both. In all cases, the human was removed from danger, and
in each case, various levels of research were needed. While this
research is sll ongoing, the goal is to develop diversied robots
to navigate an unspecied space with various obstacles, rather
than develop special machinery for each task in which it may
rarely need to be teleoperated (Hasunuma et al. 2002).
On Site
One reason pre-fab has more successfully implemented robocs is
the presence of structured environments. When robots move on
site to an unstructured environment, similar tasks become more
dicult (Feng et al. 2015). While the use of a robot on site was
acknowledged in the research of Ariza and Gazit (2015), the robot
relied on a structured environment through predened rotaons.
The discussion on using robots for on-site construcon is not
new. In 1985, while recognizing that commercial robots for
construcon in any sense were non-existent, the feasibility of
an on-site robot was doubted due to the need for “program-
ming and installaon for each parcular case” (Warszawski and
Sangrey 1985). Understandably, the idea of automaon in terms
of roboc autonomy was not yet suciently developed to the
point that it would seem valuable.
Addionally, manufacturing of large complex systems can be
viewed in a similar way as on-site construcon, as in the case of
216
Tiling Robots
There has been a sporadic history in the use of robots for ling
or mosaic operaons. When the panel is already available, albeit
a single ceramic le or a composed mosaic, researchers have
explored the process of laying the le on site. In the work of
Ahamed Khan et al. (2011), the oor ling system is semi-auton-
omous. In this case, the roboc system is a method of reducing
strain on the worker as well as speeding up the process. In
contrast, other researchers theorize an autonomous machine
to lay les by comparing specic aspects of a robot’s capability
with small-scale experiments with studies of human labor cost
and fague (Navon 2000; Apostolopoulos, Schempf, and West
1996). These robots are large machines intended for large-scale
installaons and have not demonstrated the capability for actual
development and implementaon.
Current State
This research demonstrates the current ecacy and capacity of
a low-cost humanoid meant for consumer experimentaon. The
basis for replacing humans on the construcon site is due to the
dangers of the construcon industry, and the benets of robots
being able to perform construcon tasks directly on site aords
value beyond safety. In keeping with the target point of the robot
used, a novel end eector for the le pickup was designed for
temporary use and implementaon with 3D prinng and low
cost manufacturing. Although the system used here is based
on moon capture, the methods in which the robot’s kinemac
frame is found within the space can be transferred to other local-
izaon systems as well as other robots.
While the robots in the DRC used a variety of onboard vision
sensors, this work relies solely on an external localizaon system
and kinemac calculaons. For single-use robots, an external
localizaon system may be ideal, and a network of construcon
robots or a permanent live-in robot would greatly benet from a
data center to coordinate and control robot posions and tasks.
As an inial step, this research focuses on the ability to rely
purely on kinemacs based on an external localizaon system,
making this a visually unassisted on-site robot.
LOCALIZATION METHODOLOGY
System Overview
This research uses the V4 NAO robot from Aldebaran, controlled
using the C++ API and the inverse kinemacs soluon as
detailed in the work of Konas, Orfanoudakis, and Lagoudakis
(2013). The method for controlling the humanoid walk is similar
to the methods aorded through the API with a few variables
modied to compensate for the le weight.
The moon capture system is from Vicon, with (12) T-160
Use of a Low Cost Humanoid for Tiling as a Study in On-Site Tiling Schwartz
airplanes. Recognizing the need for versale lightweight robots
to navigate the structure, AirBus Group has begun research
into implemenng humanoids for their airplane manufacturing
(Stasse et al. 2014). In this type of situaon, a wheeled robot
may not be the most praccal choice, but rather one with some
type of legs. Construcon sites in general are dangerous areas,
regulated by governmental bodies and laws (Weil 1992). The
ulizaon of robots on site, albeit through autonomy or teleop-
eraon, can be lifesaving. Further, the use of humanoid robots
allows for a versale robot to use a variety of tools to accomplish
a variety of tasks within a space developed for humans. This use
of humanoids has implicaons for where the ulizaon of roboc
manufacturing begins and ends, as these robots are not limited
to manufacturing, and may be permanent or semi-permanent
agents in the space.
Another clear disncon with commonly used roboc techniques
in architecture and the proposed on-site methods is within the
generaon of toolpaths. Unlike the precisely pre-planned moons
used in CNC or roboc manufacturing, an on-site robot is given
a task, not a specic moon (such as joint angles over me). This
task is processed by the robot, and what would be considered a
toolpath is generated in real-me. Real-me generaon is needed
for the robot to navigate unstructured environments, where
modicaons to the moon control are based on this new or
changing environment, in order to accomplish the given task. As
an example, the arm moon of picking or placing a le is depen-
dent on the robot’s orientaon to that le. The ability to calculate
the robot’s arm moon based on any orientaon, rather than
forcing the robot’s overall orientaon into an exact match each
me, allows the robot to adapt within the space. This workow is
further detailed in the methodology secon.
At Home
Just as the cost of 3D printed manufacturing dropped drama-
cally as it moved from industry to retail market, so has the cost
of robocs. Robots such as the humanoid NAO (Gouaillier et al.
2009) have begun entering a somewhat aordable price point
while maintaining high levels of funconality, as demonstrated
in the RoboCup soccer league (RoboCup Technical Commiee
2015). As with the use of humanoids for disaster situaons and
specialized manufacturing, the benet of a humanoid robot at
home, beyond the social aspect, is the ability for navigaon and
manipulaon in a built-for-people environment. Beyond the
dicules of a wheeled robot traversing ground with raised
secons, the bipedal form reduces the footprint required of the
robot, allowing for a smaller turning radius and ability to t into
more dicult spaces. Furthermore, the current state of low-cost
humanoids, and robots in general, is comparable to the avail-
ability of 3D prinng in the late 1990s.
217
GENERATIVE ROBOTICS
Once this inial frame is created, the frame of the robot in world
space must be created in order to save the oset between the
two frames, and connuously use the inial frame as a reference.
To do this, the head joints are rotated one aer the other. During
each rotaon on a single axis, any of the three original markers
are stored at three points in me. With these three points, the
axis of the motor can be found by circumscribing a circle. The
center point of the circle, which will be the center of the motor,
can be found using Equaon 2.
The motor axis can be found using the normal of the circum-
scribed circle using Equaon 3.
At this point, one of the head motor axes is known. The secondary
axis can be found the same way, represented in Figure 3.
With both motor axes found, two of the three required vectors
exist. However, due to manufacturing tolerances and the slight but
existent noise in the moon capture system, these axes are not
perfectly perpendicular. To esmate the origin of the neck frame,
the closest point to both vectors are found using Equaon 4.
2 Diagram represenng three markers or tracking points on the robot in any conguraon creang a frame.
cameras. Real-me streaming is accomplished with the Vicon
RealTime SDK through Nexus (Vicon 2014). The moon-capture
system is capable of sub millimeter accuracy, oering a viable
tesng plaorm for localizaon.
Localization
Two methods are used for localizaon of the robot. While in
perfect condions they would produce the same results, slight
errors in the encoders and manufacturing of the robot result in
a dierence of a few degrees between the calculated frames.
Both methods provide advantages and disadvantages. In the
rst method, the head joint is calibrated within the space. This
can be done with the robot placed directly in the space without
regard for orientaon as the markers are placed on that joint. In
the second method, a predened orientaon within the space is
designated as the inial robot end eector conguraon.
With an external localizaon system, it is necessary to calibrate
the robot posion of a known joint in order to correctly locate
the end eector in the space. In the case of a humanoid, the
head joint is suitable as it can have markers placed on it without
occlusion during moon. If an industrial arm is used, the base
frame would also be a viable candidate.
In order to begin calibraon, three markers must be placed on
the robot. In a dierent localizaon system, these markers would
be replaced with beacons, acve markers, or tracking markers for
camera-based systems. From these three points (P1, P2, P3), an
inial frame can be created, as seen in Equaon 1 and graphically
in Figure 2.
(1)
(2)
(3)
218
When the robot moves throughout the space, the marker posi-
ons are queried, the marker frame is created, and the stored
transformaon matrix is applied, giving the neck frame in world
space. As the Denavit-Hartenberg (DH) parameters from this
stored frame are known, the end eector locaon in world space
can be calculated. In the next secon, a faster method for calcu-
lang the robot frame is described if the end eector is able to
be placed in a known locaon within the localizaon system.
While the use of the base frame as a calibraon joint allows for
the operator to place the robot within the space without regard
for orientaon or posion, it does take more me and calcu-
laons than beginning at a known conguraon. This second
calibraon method requires the robot end eector to be placed
in a known conguraon and calibrates using the DH parameters
and encoders.
With the end eector in a known locaon, the frame of the end
eector {p} is known in world space {w}, and the transformaon
to the base frame {h} can be calculated (Equaon 8).
Where,
As with the head rotaon method, this stored transformaon is
applied during the ling operaon.
TILING METHODOLOGY
End Effector
While many methods for vacuum systems exist, the mobile
nature of a ling robot requires a portable and light-weight
soluon. Therefore, an externally powered vacuum system with
tubing was not appropriate, and a custom end eector for the
robot was developed. As seen in Figure 4, the components are
3 Using one of the marker references in three locaons aer motor rotaon, a circle center and normal can be extracted, corresponding to the motor posion and axis.
To calculate the nal orientaon, the vectors found previously are
used to generate the third vector, and the cross product is used
again to maintain the primary axis as perpendicular (Equaon 5).
(4)
To create the frame, the midpoint found in Equaon 4 is used in
the translaon (last) column of a 4x4 matrix, and the orientaon
vectors found in Equaon 5 are used for the rotaon. Equaon
6 shows the nal homogeneous transformaon matrix from the
world(w) to the calculated(c) frame.
(5)
(6)
This calculated frame exists in world space but must be relave
to the original marker frame. For this, a transformaon matrix
from the head markers to the calculated frame is stored by
Equaon 7.
(7)
(8)
Use of a Low Cost Humanoid for Tiling as a Study in On-Site Tiling Schwartz
219
GENERATIVE ROBOTICS
a 3D printed housing (which can be seen in the Results secon)
with puller, silicon tube, spring, stopper, and sucon cup.
In the inacve state, the vacuum can always be created, as
a normal sucon cup works as the spring pushes against
the stopper and into the tubing. When the robot ngers
are acvated, the stopper is pulled away from the tubing,
compressing the spring, and allowing air-ow, releasing the
vacuum. The second aspect to the design is the use of the ex-
ible tubing. As can be seen in Figure 4, the pulling lever is oset
from the locaon of the sucon cup. The ngers of the robot
are not in the center; as such, using a straight line for the end
eector would create another oset in the kinemac denion.
To simplify calculaons, the exible design is used to align the
sucon cup with the center of the wrist and elbow joints. With
this, the DH parameters can remain the same, with the nal
frame distance being extended by the length of the end eector.
This system can be applied to a variety of robots in order to
simplify the kinemacs. Addionally, the passive vacuum allows
for a reliable and low energy soluon, a necessity in mobile
robocs where baery life is vital and closely related to the
voltage demand of the motors.
The spring used in the system must be light enough for the robot
to compress, while being strong enough to overcome fricon of
the silicon tube in order to complete the seal. In this congura-
on, a spring was used which takes approximately 9 Newtons to
compress 6 mm, the distance needed to release the vacuum. With
a clean press of the end eector, a solid vacuum is formed, lasng
at least one hour during tesng. However, an o angle press of
the le drascally reduces the vacuum formed and can result in a
drop within a few minutes. Hence, it is vital for the end eector to
be suciently pressed against the le in this passive system.
Tile Planning
Once the robot is calibrated and reaches the le locaon, the end
eector must press against the le to pick it up. The le frame is
in world space and is the desired locaon of the end eector. For
simplicity, the le frame is then used as the end eector frame
for the inverse kinemacs soluon. As shown in the next secon,
State Machine, the frame is calculated before the robot picks up
or drops the le. If no soluon is found, the robot re-aligns to
the le. Once crouched in place for picking/dropping the le, the
frame from the le is copied vercally by a threshold under 30
mm. Mulple posions are queried by rotang the frame in order
to nd an inverse kinemacs soluon such that the path planning
is approached vercally.
State Machine
The state machine diagram shows the logic behind the robot
ling. As seen in Figure 6, calibraon occurs once at the
beginning. The methods for picking or dropping a le are the
same. Throughout the system, the robot queries the current
locaon of the markers in order to calculate the robot frame in
the world, using the oset described in the Methodology of
this paper.
4
5
4 Diagram of passive sucon end eector for robot.
5 Frame conguraon for pick/drop posion of robot arm. The le locaon is
coincident with the target posion of the end eector. The base frame is the
calibrated frame discussed in the localizaon secon, Joint 1 is the shoulder,
and Joint 2 is the elbow frame.
220
A main dierence between much of the work done in pre-
fab architectural/design research and this paper is the
implementaon of a state machine as the controlling factor. In
many cases, a CAD le or G-code is sent to the robot control
system to be interpreted as coordinates to move to. In this
system, the robot receives only a le lisng the colored les to be
used, and autonomously navigates to the goal posions. All steps
are handled within the state machine, including communicaon
delays and errors.
RESULTS
Although the main goal of implemenng robots on the construc-
on site is for safety and reducon of human injuries, both
accuracy and length of me for achieving the goals must be
considered. At the same me, implemenng this system in a
humanoid robot for at-home assistance may present dierent
challenges, such as a case where a person is unaware how to le,
or there is no me constraints on their project.
As this project is not focused on the development of a commer-
cial robot, but rather research and experimentaon for future
methods, accuracy and me-scale are not solved, but instead are
calculated to demonstrate the ecacy of the system, and what
would be required to solve them.
Experiment
The experimental results can be seen through mulple images
during a ling acon. The robot was set in the inial cong-
uraon on a wooden plaorm. The robot was commanded
to autonomously navigate to the le pickup locaon, as seen
in Figure 7. Black tape was used to repeatedly place the le
in the same posion within the moon capture space during
experiments. Aer pickup of the rst le (Red), the robot was to
move 1.5 meters to the back le and drop the le.
Aer picking the le, the robot recongures the arm posi-
on based on the state, ie. turning or walking. As the robot
approaches the goal posion, the le frame is calculated as the
end eector frame in the inverse kinemacs equaon. If a solu-
on is found, the robot will crouch down in order to pick/drop
the le as seen in Figure 8.
When dropping the nal le, the robot accurately places it. As
seen in Figure 8, the ngers grasp the lever, which releases the
vacuum on the le. However, retracon of the arm due to motor
limitaons is not directly vercal, shiing the orientaon of the
le by a few degrees.
Finally, the robot returns to the le pickup area to retrieve the
next le (Green), as seen in Figure 9. Due to baery limitaons
and accuracy of the end eector, the demonstraon experiment
concluded when the robot returned to the le pickup locaon.
Accuracy
While the localizaon system without the use of onboard vision
is shown to be eecve, the accuracy of picking a le prevents
a full mosaic from being created. The encoders on the robot are
within a reasonable tolerance, while the motors are either lacking
torque, or lack the appropriate low level drivers for incremental
moons. When commanding a joint a specic rotaon value, the
joint does not always achieve the desired locaon, and while
the encoder value acknowledges this, compensang for this
error is extremely dicult. A technique for overcompensang
in the opposite direcon of the motors failed aempt was
6 State machine diagram of the robot during the enre experiment. This state machine is independent of robot type and can be implemented with an industrial arm as well.
Use of a Low Cost Humanoid for Tiling as a Study in On-Site Tiling Schwartz
221
GENERATIVE ROBOTICS
implemented, but did not reduce the error to a useful degree.
For this reason, mulple aempts to pick up and drop a le are
done, increasing the me needed for a le cycle. While the robot
would be adequate as a placement system, a higher quality motor
is required for completely accurate ling.
However, applicaons of a limited accuracy robot may sll be
realisc. As recycled or damaged les can be used in mosaic
paerns, a combinaon of computer vision and the roboc
ling system can produce results similar to that of a non-spe-
cic mosaic le placement. Furthermore, input of the damaged
le’s shape and color can be processed by the robot to generate
numerous designs that t within the accuracy limits of the robot.
Times
The me to move from the calibraon locaon to a le, then a
drop locaon and back to the next le is broken down in Figure
10. By comparing this to the state diagram, it is clear that most of
the me spent is approaching the goal posion. While the robot
itself can walk at a moderate rate, as seen in both Tile Approach
secons, the inclusion of a le changes the mass locaon. To
compensate for this, the le is held in the front of the robot
during a forward walk, and low to the side for rotaon and minor
adjustments.
The second most me consuming aspect occurred during the
Drop Aempt. As the motors lack the torque to command small
movements, the nal end eector posion is not exact. Using
the encoders, the achieved posion can be calculated, and if
it is outside of the valid zone, the arm retracts and aempts
again, causing mulple Drop Aempts. As a conservave
esmate using the failed aempts in the meline, it takes 494
seconds to pickup, drop, and return to the pickup locaon. If
this was sustained, it would take 13 hours to le 100 les, a
1x1 meter square of 10 cm les—clearly not a reasonable length
of me for a construcon site, but sll achievable at a house
in order to make a mosaic oor paern autonomously over-
night. Furthermore, these mes can be drascally reduced by
a slight increase of torque in the motors, reducing the required
Drop Aempt mes. Second, further research into the mass
compensaon while carrying a le can reduce the approach
and adjustment mes. Assuming a 50% reducon in approach
me, and a single Drop Aempt, the single cycle would take 339
seconds, and 100 les 9.4 hours.
CONCLUSION
While this paper demonstrates the ability for a low cost
humanoid robot to place les in the correct locaons, it is neither
ecient nor accurate enough to be considered a viable opon
at this point. However, by either increasing the joint accuracy or
7
8
9
7 Snapshots of the robot in the moon capture space performing the experiment.
The black tape on the head secures the three markers described in the method-
ology. The end eector is 3D printed and secured around the hand with a metal
clasp.
8 Robot crouches down and places le in the desired locaon. The rst frame
shows the robot ngers relaxed and spread out, while the second frame shows
the ngers clenched, liing the end eector lever, and the nal image showing
the le dropped.
9 The robot returns to the le pickup locaon aer dropping the Red le at the
goal posion.
222
including an onboard vision feedback system, this work shows
that a soluon is within the near future. Addionally, the method
for calibrang the robot’s posion using an external localizaon
system can be used in the future. The end eector design is a
low cost and low power consuming opon for use with any type
of robot. Furthermore, integraon as a human-robot collabora-
on may increase eciency for aiding in drop placement while
providing a safe locaon for the laborer.
As buildings have autonomy built into them, the use of external
localizaon systems become common place. Either through
built in LIDAR or UWB for use in waynding, the cost of on-site
robocs decreases dramacally. When the robots need limited or
no vision capabilies due to control from a data center, the cost
per robot decreases while the cost per building increases, at the
same me aording exponenally more possibilies during the
life cycle of the building.
ACKNOWLEDGEMENTS
This research was funded in part by grant #AICT-2014-0011. The author
would like to thank the many interns of the Digital Human Research
Center over the last two years that have contributed their knowledge and
helped in the code development.
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IMAGE CREDITS
All Photography: Schwartz, 2016
Mathew Schwartz has a BFA and a MSc. in Architecture with a focus
on digital technology from the University of Michigan. He is currently
at the Advanced Instutes of Convergence Technology in South Korea,
where he is a research scienst who focuses on human factors. His work,
which bridges science and engineering with art and design, makes use of
cung-edge robocs and moon capture technology to mimic human
characteriscs which he then incorporates into commercial applicaons,
architecture, and models used in scienc research.