Title: Increased Intelligence in Digital Design and Manufacturing of Humanoid Robots, and Other Devices Summary: Approaching increased intelligence will occur from both ends of the manufacturing process. Description: Digital design and manufacturing requires that design and simulation environments are increasingly accurate and detailed to avoid delays in construction and waste in models. Tests for safety and reliability can be conducted using CAD models In turn, mobile robots, and industrial models need to obtain greater environmental awareness. This can be accomplished by mounting additional sensors to allow them to gauge misaligned components without continuous operator monitoring, and will allow mobile robots to move more easily through non-controlled environments.

Humanoid Robot Design, Modeling, Application Scope, and Real-World Demonstrations Project Leader: Paul G. Ranky, PhD Full Tenured Professor, Industrial and Manufacturing Engineering Department and the NJIT IS / IT Program, New Jersey Institute of Technology, GITC Bldg., Newark, NJ 07102 (Please view this site with Safari, or FireFox; not fully compatible with IE7. Please use QuickTime to play the 3DVR objects: FREE download.) Contact email: ranky@njit.edu More about Professor Ranky's research at: http://www.cimwareukandusa.com/aboutpgr.htm Project Team: Richard G. Ranky, BS(Hons) NJIT, and Gregory N. Ranky, BS(Hons) NJIT Abstract: This project and the series of interactive workshops at LSC discuss the design, modeling and application scope of some humanoid robots within an advanced digital design, and digital manufacturing / assembly/ test framework. We illustrate and discuss humanoid robot design and manufacturing principles, methods and tools with exciting and practical interactive 3D solid model simulation and real-world robot demonstrations. The application areas focus on a large variety of different industries. The presentations in the Liberty Science Center follow an enjoyable interactive multimedia format, with live presenters, including Professor Ranky, and his students, demonstrating simple-to-more complex virtual and real-world cases. The workshops are illustrated by web-executable 3D interactive simulation examples, 3D objects, videos, text and images, as well as real-world, sensory-interactive, multiple, collaborative, and networked robot demonstrations. This program is ideal for teaching and learning about science and engineering with exciting practical examples. Contents Introduction to Humanoid Robots Symmetry in Direction Environmental Feedback for Goals Increased Intelligence in Digital Design and Manufacturing of Humanoid Robots, and Other Devices Robonova Arm Simulation Digital Design Models of Manipulators Mathematical Modeling: Analysis-driven Design Digital Manufacturing Simulation Manipulator Demonstration Biomimetic Characteristics Mathematical Logic and Robot Programming Q/A Period Future Workshop Topics, Plans and Feedback Acknowledgements & Sponsors References and Bibliography Forthcoming Interactive Workshop Dates: The first two presentations will take place at LSC on August 23, 2007, at 10 am, and at 11.30 am. Each interactive workshop lasts about 1 hour. (Please view this site with Safari, or FireFox; not fully compatible with IE7. Please use QuickTime to play the 3DVR objects: FREE download.) Please visit our Digital Design and Digital Manufacturing page too! .... .... ... ..

Downloadable Media Files (following web-standards: please view it with Safari, or FireFox; not fully compatible with IE7): Interactive Workshop Media Files: Images of the August 23 presentations at LSC. July 11, 2007: Liberty Science Center Regional Educators Day Pictures: Please review some pictures taken on the Regional Educators Day at the Liberty Science Center. These pictures reflect the excitement and enthusiasm we all share about LSC and these projects. (Click on PictureMap-1, PictureMap-2, and Picture-Map3) (Please use QuickTime to play the 3DVR objects. Please note, that this page contains standard web-objects. FREE download.)

Q/A Period

Do you have any questions about our presentations, about Robots, Humanoid Robots, Product Design & Development in general, about Digital Design and Digital Manufacturing, and related subjects?

We are keen to hear from you!

Please email Professor Ranky your questions, and he'll be pleased to respond as soon as he can.

Future Workshop Topics, Plans and Feedback

Do you have any suggestions for future workshop topics?

We are keen to hear from you! We'll try to accomodate all realistic ideas.

Please tell your teachers and friends about this web site. Thanks!

Please email Professor Ranky your ideas, and he'll be pleased to respond as soon as he can.

Acknowledgements & Sponsors

We would like to hereby thank NJIT and our Provost Dr. Priscilla Nelson for funding this research collaborative project between NJIT and LSC. We would also like to thank Dr. James Geller at NJIT, Ruben Rosario at LSC, and all the directors and staff of LSC for their enthusiastic support. Furthermore we would like to thank our sponsoring companies, including IBM, Dassault Systemes, Delmia, Fanuc, Lego, Robovillage, and others for their support. Special thanks are due to Richard G. Ranky and Gregory N. Ranky for volunteering their summer working on these projects, and my family for the additional financial support needed to accomplish our project goals.

References & Bibliography

The subject has a huge number of references in both the R&D as well as in the industrial domain. The list below illustrates mostly our research in the area. (If you are interested in more references, suggest to search NJIT's excellent digital library (http://library.njit.edu), as well as the web.

Ranky, P.G.: A 3D –web Collaborative Concurrent Automotive Engineering Method Based on Our ‘Distributed Digital Factory’ and ‘Digital Car’ Models, Society of Automotive Engineers World Congress, Detroit, March, 2003 (In the Proceedings; Paper No.: 2003-01-0668)

Ranky, P.G.: 3D Engineering Multimedia Cases. A Customizable 3D Web-enabled Library with Reusable Objects, ASEE (American Society of Engineering Educators) Mid-Atlantic Conference, Kean University, NJ, USA, April, 2003 (In the Proceedings)

Ranky, P.G.: A Biomedical Engineering Case with 3D Lower Back Interactive Virtual Anatomy Tours Inside and Outside the Human Body with Automated Post-test Student Assessment, ASEE (American Society of Engineering Educators) Mid-Atlantic Conference, Kean University, NJ, USA, April, 2003 (In the Proceedings)

Ranky, P.G., Subramanyam, M., Caudill, R.J., Limaye, K., and Alli, N.: A Dynamic Scheduling and Balancing Method and Software Tool for Lean and Reconfigurable Disassembly Lines, 2003 IEEE (USA) International Symposium on Electronics and the Environment & the IAER Electronics Recycling Summit, May 19-22, Boston, MA, USA (In the Proceedings)

Ranky, P.G., Morales, C., and Caudill, R.J.: Lean Disassembly Line Layout, Process and Network Simulation Models and Cases, Based on Real-world Data, 2003 IEEE (USA) International Symposium on Electronics and the Environment & the IAER Electronics Recycling Summit, May 19-22, Boston, MA, USA (In the Proceedings)

Ranky, P.G., and Nadler, S.F.: A New, Web-enabled Multimedia Approach with 3D Virtual Reality Internal and External Body Tours to Support Low Back Pain Diagnosis, The 4th Annual Faculty Best Practices Showcase in NJ, March 2003 at the Kean University, NJ (In the Proceedings)

Ranky, P.G. and Nadler, S.F.: A Novel Multimedia Approach to Low Back Pain Diagnosis with Internal and External 3D Interactive Body Tours, 29th Annual Northeast Bioengineering Conference, New Jersey Institute of Technology, University Heights, Newark, NJ, March, 2003 (in the Proceedings)

Ranky, P.G.: Rapid Prototyping Cases for Integrated Design and Manufacturing Engineering Education with 3D Internet Support, ASEE, American Society of Engineering Educators, US National Meeting, Design in Engineering Education Division, June 2003 in Nashville, USA (In the proceedings)

Ranky, P.G.: Interactive 3D Multimedia Cases for Manufacturing Engineering Education with Internet Support, ASEE, American Society of Engineering Educators, US National Meeting, Manufacturing Engineering Education Division, June 2003 in Nashville, USA (In the proceedings)

Ranky, P.G.: A Novel 3D Internet-based Multimedia Method for Teaching and Learning About Engineering Management Requirements Analysis, ASEE, American Society of Engineering Educators, US National Meeting, Engineering Management Education Division, June 2003 in Nashville, USA (In the proceedings)

Ranky, P.G.: Interactive 3D Multimedia Cases for Engineering Education with Internet Support, ASEE, American Society of Engineering Educators, US National Meeting, Computers in Education Division, June 2003 in Nashville, USA (In the proceedings)
Ranky, P.G.: A 3D Multimedia Approach to Biomedical Engineering: Low Back Analysis, ASEE, American Society of Engineering Educators, US National Meeting, Biomedical Engineering Division, June 2003 in Nashville, USA (In the proceedings)

Ranky, P.G.: An Interactive 3D Multimedia problem-based Library for Manufacturing Engineering Technology Education with Internet Support, ASEE, American Society of Engineering Educators, US National Meeting, Engineering technology Division, June 2003 in Nashville, USA (In the proceedings)

Ranky, P.G.: A New Approach for Teaching and Learning About Engineering Process Failure Risk Analysis with IE (Industrial Engineering) Case Studies, ASEE, American Society of Engineering Educators, US National Meeting, Industrial Engineering Division, June 2003 in Nashville, USA (In the proceedings)

Interactive 3D Multimedia CD-ROM/web/ eBook: Ranky, P.G.: A 3D Multimedia Case: Component Oriented Disassembly Failure Risk Analysis, An interactive multimedia publication with 3D objects, text and videos in a browser readable format on CD-ROM/ intranet by http://www.cimwareukandusa.com, CIMware USA, Inc. and CIMware Ltd., UK, ISBN 1-872631-47-9, 2001-2003. Multimedia design & programming by P G Ranky and M F Ranky. (Published 6 volumes of this main title with different risk analysis challenges explained).

Interactive 3D Multimedia CD-ROM/web/ eBook: Ranky, P.G.: A 3D Multimedia Case: Component Oriented Disassembly User Requirements Analysis, An interactive multimedia eBook publication with 3D objects, text and videos in a browser readable format on CD-ROM/ intranet by http://www.cimwareukandusa.com, CIMware USA, Inc. and CIMware Ltd., UK, ISBN 1-872631-50-9, 2001-2003-2005. Multimedia design & programming by P G Ranky and M F Ranky. (Published 7 volumes of this main title with different requirements analysis challenges explained).

Interactive 3D Multimedia CD-ROM/web/ eBook: Ranky, P.G.: Key R&D and eTransition Trends in US and International Collaborative Design & Manufacturing Enterprises: An interactive multimedia eBook publication with 3D objects, text and videos in a browser readable format on CD-ROM/ intranet by http://www.cimwareukandusa.com, CIMware USA, Inc. and CIMware Ltd., UK, ISBN 1-872631-65-7, 2003-2005. Multimedia design & programming by P G Ranky and M F Ranky

Interactive 3D Multimedia CD-ROM/web/ eBook: Nadler .S. F., Ranky, P.G and Ranky, M., 2002-2003: A 3D Multimedia Approach to the Diagnosis of Low Back Pain (Vol. 1 18 & 40 year old males), An Interactive 3D Multimedia Presentation on CD-ROM with off-line Internet support (650 Mbytes, approx. 150 interactive screens, 50 minutes of digital videos, 3D internal and external body tour, animation and 3DVR objects), by CIMware (IEE and IMechE Approved Professional Developer), ISBN 1-872-631-63-0, 2002-2006, Multimedia design & Programming by P G Ranky and M F Ranky.

Interactive 3D Multimedia CD-ROM/web/ eBook: Nadler .S. F., Ranky, P.G and Ranky, M., 2003: A 3D Multimedia Approach to the Diagnosis of Low Back Pain (Vol. 2. in preparation, to be published soon)

Interactive 3D Multimedia CD-ROM/web/ eBook: Roman, H.T. and Ranky, P.G.: A Case-based Introduction to Service Robotics; An interactive multimedia eBook publication with 3D objects, text and videos in a browser readable format on CD-ROM/ intranet by http://www.cimwareukandusa.com, CIMware USA, Inc. and CIMware Ltd., UK, ISBN 1-872631-48-7, 2003-2006. Multimedia design & programming by P G Ranky and M F Ranky.

Interactive 3D Multimedia CD-ROM/web/ eBook: Loose, D.C. and Ranky, P.G.: A Case-based Introduction to IBM’s Telematics Solutions; An interactive multimedia eBook publication with 3D objects, text and videos in a browser readable format on CD-ROM/ intranet by http://www.cimwareukandusa.com, CIMware USA, Inc. and CIMware Ltd., UK, ISBN 1-872631-73-8, 2003-2006. Multimedia design & programming by P G Ranky and M F Ranky

Interactive 3D Multimedia CD-ROM/web/ eBook: Ranky, P.G.: An Introduction to Digital Factory & Digital Telematic Car Modeling with R&D and Industrial Case Studies; An interactive multimedia eBook publication with 3D objects, text and videos in a browser readable format on CD-ROM/ intranet by http://www.cimwareukandusa.com, CIMware USA, Inc. and CIMware Ltd., UK, ISBN 1-872631-66-5, 2003-2005. Multimedia design & programming by P G Ranky and M F Ranky

Ranky, P G: Novel Automated Inspection Methods, Tools and Technologies: Assembly Automation, An International Journal, Vol. 23, No. 3, Emerald Publishing Ltd., England, pp. 252-257.

Ranky, P G: Advanced Machine Vision Systems and Application Examples: Sensor Review, An International Journal, Vol. 23, No. 3, 2003, Emerald Publishing Ltd., England, pp. 242-245.

Interactive 3D Multimedia CD-ROM/web/ eBook:: Ranky, P.G.: An Introduction to Alternative Energy Sources: Hybrid & Fuel Cell Vehicles; An interactive multimedia eBook publication with 3D objects, text and videos in a browser readable format on CD-ROM/ intranet by http://www.cimwareukandusa.com, CIMware USA, Inc. and CIMware Ltd., UK, ISBN 1-872631-97-5, 2003-2006. Multimedia design & programming by P G Ranky and M F Ranky.

Interactive 3D Multimedia CD-ROM/web/ eBook:: Ranky, P.G.: Customer Needs, Wants & Requirements Analysis: Automotive Exterior Rearview Mirror; An interactive multimedia eBook publication with 3D objects, text and videos in a browser readable format on CD-ROM/ intranet by http://www.cimwareukandusa.com, CIMware USA, Inc. and CIMware Ltd., UK, ISBN 1-872631-67-3, 2003-2006. Multimedia design & programming by P G Ranky and M F Ranky.

Project Management Institute (PMI): New Jersey Chapter: Ranky, Paul G.: An Integrated PM Approach, Including: Process Modeling, Requirements Analysis, Risk Analysis, Statistical Tools and 3D Multimedia, January, 2006.

Ranky, Paul G.: A Generic, Analytical Method to Assess Process-related Risk with Case Studies. The Project Management Institute (PMI) Risk SIG and the Institute for International Research (IIR): Annual US National Project Risk Symposium. May 22 – May 26, 2006 in Houston, TX.

Ranky, P.G., Ranky, G.N., Ranky, R. G.: An Integrated, Analytical Product, Process and Service System Design Innovation Method, Tools, and Examples, within a Statistical and 3D Interactive Multimedia Framework, The 2006 International Symposium on Flexible Automation (ISFA), Osaka, Japan, sponsored by NSF, National Science Foundation, (USA) by the Institute of Systems, Control and Information Engineering, The Dynamic Systems and Control Division of American Society of Mechanical Engineers. Participating Societies include: The Japan Society of Mechanical Engineers, The Japan Society for Precision Engineering, The Society of Instrument and Control Engineers of Japan, The Robotics Society of Japan, IEEE Robotics and Automation Society, July 10-12, 2006

Ranky, P.G., Ranky, G.N., Ranky, R. G.: Radio Frequency Identification (RFID) Methods and Solutions for Advanced Flexible Automation, and Global Supply Chain Operations in Digital Manufacturing Networks, The 2006 International Symposium on Flexible Automation (ISFA), Osaka, Japan, sponsored by NSF, National Science Foundation, (USA) by the Institute of Systems, Control and Information Engineering, The Dynamic Systems and Control Division of American Society of Mechanical Engineers. Participating Societies include: The Japan Society of Mechanical Engineers, The Japan Society for Precision Engineering, The Society of Instrument and Control Engineers of Japan, The Robotics Society of Japan, IEEE Robotics and Automation Society, July 10-12, 2006

Ranky, P.G., P.T. Rayson, Wong, C., Poon, P., Ranky, G.N.: An Interactive Multimedia Knowledge Management and Distribution Approach for Globally Networked, Collaborative Flexible Automation R&D Teams, The 2006 International Symposium on Flexible Automation (ISFA), Osaka, Japan, sponsored by NSF, National Science Foundation, (USA) by the Institute of Systems, Control and Information Engineering, The Dynamic Systems and Control Division of American Society of Mechanical Engineers. Participating Societies include: The Japan Society of Mechanical Engineers, The Japan Society for Precision Engineering, The Society of Instrument and Control Engineers of Japan, The Robotics Society of Japan, IEEE Robotics and Automation Society, July 10-12, 2006

Ranky, P.G.: Knowledge Management Challenges for Complex, Hi-technology Products, Processes, Manufacturing / Assembly Systems, and Services. Pre-conference Research Seminar at the 2006 International Symposium on Flexible Automation (ISFA), Osaka, Japan, sponsored by NSF, National Science Foundation, (USA) by the Institute of Systems, Control and Information Engineering, The Dynamic Systems and Control Division of American Society of Mechanical Engineers. Participating Societies include: The Japan Society of Mechanical Engineers, The Japan Society for Precision Engineering, The Society of Instrument and Control Engineers of Japan, The Robotics Society of Japan, IEEE Robotics and Automation Society, July 9, 2006

Ranky, P.G.: Eighteen ‘monozukuri-focused’ assembly line design and visual factory management principles, with Denso industrial examples, Assembly Automation, Feature Article, 27/1, (2007) p.12-16, Emerald Group Publising Ltd.
Ranky, P.G.: Some Tested Methods and Tools for Real-life Exposure in an Academic Setting for Millennial Generation Engineering Students, Spring 2007 ASEE (American Soc. of Engineering Educators) Mid-Atlantic Section Conference, April 13-17, NJIT, NJ, USA. In the Proceedings.

Ranky, P.G.: MagneMotion's linear synchronous motor (LSM) driven assembly automation and material handling system designs, Assembly Automation ISSN: 0144-5154 Feature Article, 2007 Volume: 27 Issue: 2, Page: 97 - 102.

Ranky, P.G.: Engineering Management-focused Radio Frequency Indentification (RFID) Model Solutions, Engineering Management Review, IEEE, 2007, Vol. 35, Issue 2, Page: 20-30

Webpage Design & Programming by Paul G. Ranky, Gregory N. Ranky and Richard G. Ranky. Please email if you have any comments or suggestions. Thank you! All media in this web page © Copyright 2007 by Paul G Ranky, Gregory N Ranky and Richard G Ranky. (Please use QuickTime to play the 3DVR objects. Please note, that this page contains standard web-objects. FREE download.)

Title: Robonova Arm Simulation Summary: Transfer of kinematic constraints from existing arm to computer simulation. Description: When designing a modification to an existing system, it is important that the computer simulation mimic the existing system as closely as possible. In these videos, observe the kinematic limitations of the real arm, and how the computer model follows the same boundaries. Other ‘real-world’ constraints programmed into the simulation include: material properties, heat transfer characteristics, geometric features, and electrical conductivity. As more characteristics are embedded to the simulation, the model becomes increasingly complex. It is up to the design team engineers to determine how many of these characteristics are worth inputting in the first place. Digital Design relies heavily on using the computer simulations to determine effectiveness of a design feature’s characteristics, as well as discover problems in implementation before the first prototype is even built.

Title: Digital Design Models of Manipulators Summary: Complete computer model and integration sequence of proposed innovation. Description: This manipulator design iteration includes a set of parallel surfaces. As the computer model is built up piece by piece it becomes more complex. Sequences like these are also utilized for analyzing the construction sequence of the design, and close examination of connection points and mating surfaces. The complete model fly around sequence is useful to demonstrate quickly new design features and iteration to team members, and allows fast visualization of proposed concepts.

Title: Mathematical Modeling: Analysis-driven Design Summary: With the material properties imbedded into the computer models, stress simulations determine deformation geometry and failure points. (The example illustrates robot fingers.) Description: Although materials do have standard stress and strain characteristics, the geometry of a design greatly influences how it will bend, twist, or fail under expected real-world loads. This type of simulation allows the engineers to test thousands of possible scenarios and modify the design to account for them; all within a digital realm. The colors on these stress maps indicate which features are the most likely features to fail under the expected loading. Note that these simulated loads are usually three to four times higher than real-world expectancies to provide a reasonable factor of safety. The blue and green regions are undergoing the least amount of stress while the orange and red regions are experiencing the most extreme stresses.

Title: Digital Manufacturing Simulation Summary: Different manufacturing tools of Digital Design. Description: Rapid prototyping and simulation of the manufacturing procedures can greatly streamline the design process. In the images a 3D printer was used to create scale mockups of the linkage configuration. The simulation screen illustrates a step in the proposed machining cycle. Note that the gripper linkages in grey are contained within a green rectangular body. The green body is the volume of the starting material blank and the grey geometry will be the completed linkage. This type of simulation allows the engineer to optimize and predict the machining cycles before even the first test cut.

Title: Manipulator Demonstration Summary: Comparison of ‘Before’ and ‘After’ grasping capabilities. Description: Although certain design innovations may seem obvious and useful. A direct comparison between the original and modified systems objectively demonstrates the advantages of the addition. This particular sequence was selected to demonstrate the versatility of the grippers over a range of grasping styles and geometries. One style for instance, was being able to grasp the exterior or interior of the hollow cylinder with the right hand.

Title: Biomimetic Characteristics Summary: Anatomy represented by mechanical linkages. Description: There are different ways to represent organic anatomy using mechanics. In this case the challenge was to create a ‘grasping’ motion using only linkages and a single rotary input for power. The dark grey links make up the skeletal system of the arm whilst the light grey links take the place of muscle and sinew. The touch sensors attached to each hand send a ‘Stop’ command to the motor when they become pressed. This feedback loop allows them to grasp an object without straining the motor.

Title: Mathematical Logic and Robot Programming Summary: Sample of Mindstorms program to utilize random values for motion. Description: The pictured code generates random motion characteristics for a robot. The robot’s direction, speed, acceleration, and orientation are dictated by a random number generator. Note that each characteristic has a separate random number attached to it to increase the possible permutations of motion.

Title: Introduction to Humanoid Robots Summary: Humanoid robots are objects, that have one or more human-like attributes and behavior. Description: Humanoid robots are coming! This is because they are increasingly machine intelligent, and therefore can assist and support us, real humans in several different areas, such as healthcare, accident prevention and recovery, disaster recovery, various repetitive jobs, 24/7 security and many others. Our research attempts to address and demonstrate some aspects of humanoid robot modeling, simulation and real-world design and manufacture using modern digital design and digital manufacturing methods and tools.

Title: Symmetry in Direction Summary: Existing designs in both animals and machines use symmetry to move. Description: Both human-designed and biological systems incorporate symmetry in their direction of travel, which is why ears and eyes are paired. Vertebrates have sensory and motor controls in pairs, which conserves energy and space for a simple goal, allowing them to make minor corrections if their path changes. The Line Follower mimics this; by using paired light sensors it only needs to turn to make corrections to its overall path, compared to a single-sensor model which continuously changes direction.

Title: Environmental Feedback for Goals Summary: No designer can anticipate every situation, therefore sensory feedback is necessary. Description: Every tool or robot is designed for a specific purpose or goal, but unless the working environment remains constant, continuous feedback from its surroundings is necessary to fulfill its goals.  The sensors that allow this come in many different varieties, some of which have human analogues such as sight, sound and pressure; others include GPS, ultrasound and laser rangefinders.