Assembly of large structures requires large fixtures, often referred to as monuments. Their cost and massive size limit flexibility and scalability of the manufacturing process. Numerous small mobile robots can replace these large structures and, therefore, replicate the efficiency of the assembly line with far more flexibility. An assembly line made up of mobile manipulators can easily and rapidly be reconfigured to support scalability and a varied product mix, while allowing for near optimal resource assignment. The challenge to using small robots in place of monuments is making their joint behavior precise enough to accomplish the task and efficient enough to execute subtasks in a reasonable period of time. In this paper, we describe a set of techniques that we combine to achieve the necessary precision and overall efficiency to build a large structure. We describe and demonstrate these techniques in the context of a testbed we implemented for assembling a wing ladder.

Current manufacturing practices require complete physical separation between people and active industrial robots. These precautions ensure safety, but are inefficient in terms of time and resources, and place limits on the types of tasks that can be performed. In this paper, we present a real-time, sensor-based approach for ensuring the safety of people in close proximity to robots in an industrial workcell. Our approach fuses data from multiple 3D imaging sensors of different modalities into a volumetric evidence grid and segments the volume into regions corresponding to background, robots, and people. Surrounding each robot is a danger zone that dynamically updates according to the robot's position and trajectory. Similarly, surrounding each person is a dynamically updated safety zone. A collision between danger and safety zones indicates an impending actual collision, and the affected robot is stopped until the problem is resolved. We demonstrate and experimentally evaluate the concept in a prototype industrial workcell augmented with stereo and range cameras.