Improving dependability in robotized bolting operations

Abstract

Bolting operations are critical in industrial assembly and in the maintenance of scientific facilities, requiring high precision and robustness to faults. Although robotic solutions have the potential to improve operational safety and effectiveness, current systems still lack reliable autonomy and fault management capabilities. To address this gap, we propose a control framework for dependable robotized bolting tasks and instantiate it on a specific robotic system. The system features a control architecture ensuring accurate driving torque control and active compliance throughout the entire operation, enabling safe interaction even under fault conditions. By designing a multimodal human-robot interface (HRI) providing real-time visualization of relevant system information and supporting seamless transitions between automatic and manual control, we improve operator situation awareness and fault detection capabilities. A high-level supervisor (SV) coordinates the execution and manages transitions between control modes, ensuring consistency with the supervisory control (SVC) paradigm, while preserving the human operator's authority. The system is validated in a representative bolting operation involving pipe flange joining, under several fault conditions. The results demonstrate improved fault detection capabilities, enhanced operator situational awareness, and accurate and compliant execution of the bolting operation. However, they also reveal the limitations of relying on a single camera to achieve full situational awareness.