Optimal motion planning in redundant robotic systems for automated composite lay-up process

The thesis deals with the optimal motion planning in redundant robotic systems for automation of the composite lay-up processes. The primary goalis to improve the lay-up workcell productivity by developing a novel methodology of optimizing coordinated motions of the robotic manipulator,workpiece positioner and workspace extension unit,which ensure the shortest processing time and smooth movements of all mechanical components. In contrast to the previous works, the proposed methodology provides high computational efficiencyand also takes into account both the technological constraints and the robotic system constraints, which describe capacities of the actuators and are expressed by the maximum allowable velocities and accelerations in the actuated joints. The developed technique is based on conversion of the original continuous problem into a combinatorial one, where all possible configurations of the mechanical components are represented as a directed multi layergraph and the desired time-optimal motion is generated using dynamic programming principle for searching the shortest path on the graph satisfying the smoothness constraints. It is also proposed an enhancement of this technique by dividing the optimization procedure in two stages combining global and local searches. At the first stage, the developed algorithm is applied in the global search space generated with large discretization step. Then,the same technique is applied in the local search space, which is created with smaller step in the neighborhood of the obtained trajectory. The advantages of the developed methodology are confirmed by industrial implementation on the factory floor that deals with manufacturing of the high pressure vessel.