Advanced Humanoid Robotic Arm Technologies

The R2 hand and forearm assembly represents the cutting edge of humanoid robotics technologies. The highly modular design provides significant improvements over prior humanoid robotic hands, especially in the areas of strength, speed, sensing, and ability to approximate human grasps. Hand, Finger, and Wrist Assembly Design: The robotic humanoid lower arm design (U.S. Patent No. 9,505,134) includes novel robotic finger (U.S. Patent No. 8,562,049), thumb (U.S. Patent No. 8,424,941), and wrist (U.S. Patent No. 8,498,741) assemblies. Actuation & Control System: A novel finger actuation system (U.S. Patent No. 8,467,903) – comprised of an actuator, tendon, conduit, tension sensor (U.S. Patent No. 8,371,177), and terminator – is perhaps the primary enabling technology for R2’s compact, high performance robotic hand. The actuation system is packaged in the wrist (U.S. Patent No. 8,401,700) and reduces the number of actuators, providing significant space savings. Control systems include methods for tensioning (U.S. Patent Nos. 8,412,376, 8,618,762, & 8,056,423) and controlling torque (U.S. Patent No. 8,565,918) of the tendon-driven robotic fingers. The finger actuation control system (U.S. Patent No. 8,489,239) can operate using force- or position-based control laws. Tactile System: R2’s hands feature an innovative tactile system that grant the robot a sense of touch (e.g., measurement of external contact forces, shear force, and slippage of objects held in the hand) – an important requirement for robots designed to perform complex tasks in an automated fashion. The tactile system is enabled by novel six degree of freedom (DoF) force torque sensors (U.S. Patent No. 7,784,363), three of which are integrated into the fingers (at the proximal, medial, and distal phalanges) and two in the thumb (medial and distal phalanges). A calibration system (U.S. Patent No. 8,265,792) ensures the sensors maintain high accuracy throughout operation. Autonomous Grasping: A novel grasp assist device (U.S. Patent No. 9,878,452 & 9,067,319) enables reliable, autonomous interaction with a broad range of objects (e.g., tools). A particle filter-based contact state estimation device (U.S. Patent No. 8,280,837) performs object localization and characterization.

Technologies for Safe Workspace Control of Humanoid Robots: Safety is critical in scenarios where humans (e.g., factory workers or astronauts) are working in proximity to, or interacting with, R2. Methods for applying workspace limitations in velocity-controlled robotic mechanisms (U.S. Patent No. 8,676,382) and force or impedance-controlled robots (U.S. Patent No. 8,483,877) help to ensure such safety. Autonomous Control Systems for Humanoid Robotics: A multiple priority operation space impedance control system (U.S. Patent No. 8,170,718) provides arm control, including programmable Cartesian stiffness. An interactive robot control architecture (U.S. Patent Nos. 8,364,314, and 8,260,460, and 8,706,299), including a simple GUI, provides an interactive development and work environment that integrates sensor data and feedback generated by R2. An additional system selects and controls appropriate manipulators to perform grasping operations (U.S. Patent No. 8,483,882). Humanoid Robotic Health Management System: A diagnostics, prognostics, and health management system for human robotics (U.S. Patent No. 8,369,992) operates at all hardware and software levels of the robotic system, enabling system-wide observability, controllability, maintainability, scalability, and extensibility. Electromagnetic Motor Braking: Electromagnetic fail-safe brakes (U.S. Patent No. 8,067,909) allow for selective, reliable braking of robotic motors (e.g., brushless DC motors) to ensure safe and effective operation. Highly Durable Connector Pin: To address the high failure rate of connectors in robotic systems with flexible members, a highly durable connector pin (U.S. Patent No. 8,033,876) was developed. The pin increases durability of connectors that are frequently flexed – a condition that causes deformation and compromises connectivity.

Visual Perception System: Key to enabling humanoid robotics to perform dexterous tasks, R2’s visual perception system (U.S. Patent No. 8,244,402) – comprised of machine vision cameras, processors, and novel algorithms – allows robots to find, track, and measure objects automatically in their field of view. Tendon Tension Sensor: Unique tendon tensions sensors (U.S. Patent Nos. 8,371,177 & 8,056,423) are embedded in R2’s palms to enable granular force control of the fingers via a redundant network of tendons. R2’s tendons are coupled to, and used to actuate, the robot’s finger joints. Thus, tendon tension measurements provided by the sensor allow for the external loads experienced by its robotic fingers to be derived. Tactile System: R2’s hands feature an innovative tactile system that grant the robot a sense of touch (e.g., measurement of external contact forces, shear force, and slippage of objects held in the hand) – an important requirement for robots designed to perform complex tasks in an automated fashion. The tactile system is enabled by novel six degree of freedom (DoF) force torque sensors (U.S. Patent No. 7,784,363), which are integrated into the fingers at each phalange (14 per hand). A calibration system (U.S. Patent No. 8,265,792) ensures the sensors maintain high accuracy throughout operation. Contact State Estimation: A contact state estimation sensor (U.S. Patent No. 8,280,837), based on the use of a particle filter, enables R2 to perceive the location, orientation, and shape of objects when in contact with the robot’s hands (i.e., tracks hand-object state). The contact state estimation system leverages a novel motion model, which characterizes the motion of a robotic hand as it moves relative to an object of interest. Series Elastic Actuator (SEA) Sensing: R2’s SEAs achieve fine torque sensing at each of its joints without sacrificing strength or payload capacity. The robot uses two 19-bit absolute angular position sensors, calibrated using a novel technique (U.S. Patent No. 8,250,901), to measure the deflection of each spring in real time.

R2's unique systems allow the robot to be used in many telemedicine applications and in many medical scenarios. For example, R2 can assist a surgeon and the surgical team before, during, and after a procedure with multiple tasks. The robot has the vision, dexterity, and the ability to perform tasks tirelessly 24 hours a day, seven days a week. R2 can work safely around humans, so it can be integrated into a dynamic hospital environment. The R2 technology capabilities in telemedicine are being explored through partnerships with medical institutions. After a quick medical procedure training, a R2 teleoperator was able to guide the robot and perform an ultrasound scan on a medical mannequin. Humans at the controls were able to guide the robot to perform the task correctly and efficiently by using R2's dexterity to apply the appropriate level of force and were able to track their progress using the robot's vision system. The technology was also used to experiment using a syringe and an intubation procedure with a mannequin to demonstrate R2's telemedicine capabilities. R2 is well suited to be used by physicians to conduct medical procedures on humans in remote locations.

While robotic technologies are already being used in several industries like logistics and distribution, R2 allows for much more complex and delicate operations that require a more sophisticated level of interaction. In terms of handling inventory, R2's dexterity would allow it to handle a multitude of items, including delicate ones. In addition, it can perform in close proximity to humans, allowing for the use of robotics in areas where it's not currently safe or practical. R2 is equipped to navigate obstacles, fixed or moving and has the capability of handling frequent, random, and unexpected movement of people, products, or equipment as well as items that vary in shape, weight, and fragility. The robot encompasses four elemental systems. Hands: R2's unprecedented dexterity in its hands allows it to use many of the same tools that astronauts and industry workers currently use, significantly reducing the need for specialized tools to perform multiple tasks. Arms: R2's arms are soft at multiple levels and they have redundant force sensing. R2 can safely work side-by-side with humans. Sensing and Perception: R2 shares senses similar to humans like the ability to touch and see. Interface and Control: R2 can function autonomously or it can be controlled by direct teleoperation. When functioning autonomously, R2 understands what to do and how to do it based on sensory input, carrying out tasks in real time.