The automatic detection of small defects (of up to 0.2mm in diameter) on car body surfaces following the painting process is currently one of the greatest issues facing quality control in the automotive industry. Although several systems have been developed during the last decade to provide a solution to this problem, these, to the best of our knowledge, have been focused solely on flat surfaces and have been unable to inspect other parts of the surfaces, namely style lines, edges and corners as well as deep concavities. This paper introduces a novel approach using deflectometry-and vision-based technologies in order to overcome this problem and ensure that the whole area is inspected. Moreover, since our approach, together with the system used, computes defects in less than 15 seconds, it satisfies cycle time production requirements (usually of around 30 seconds per car). Hence, a two-step algorithm is presented here: in the first step, a new pre-processing step (image fusion algorithm) is introduced to enhance the contrast between pixels with a low level of intensity (indicating the presence of defects) and those with a high level of intensity (indicating the absence of defects); for the second step, we present a novel post-processing step with an image background extraction approach based on a local directional blurring method and a modified image contrast enhancement, which enables detection of defects in the entire illuminated area. In addition, the post-processing step is processed several times using a multi-level structure, with computed image backgrounds of different resolution. In doing so, it is possible to detect larger defects, given that each level identifies defects of 1 Corresponding author. different sizes. Experimental results presented in this paper are obtained from the industrial automatic quality control system QEyeTunnel employed in the production line at the Mercedes-Benz factory in Vitoria, Spain. A complete analysis of the algorithm performance will be shown here, together with several tests proving the robustness and reliability of our proposal.

This paper introduces a new approach to detect defects cataloged as dings and dents on car body surfaces, which is currently one of the most important issues facing quality control in the automotive industry. Using well-known optical flow algorithms and the deflectometry principle, the method proposed in this work is able to detect all kind of anomalies on specular surfaces. Hence, our method consists of two main steps: first, in the pre-processing step, light patterns projected on the body surface sweep uniformly the area of inspection, whilst a new image fusion law, based on optical flow, is used to obtain a resulting fused image holding the information of all variations suffered by the projected patterns during the sweeping process, indicating the presence of anomalies; second, a new post-processing step is proposed that avoids the need of using pre-computed reference backgrounds in order to differentiate defects from other body features such as style-lines. To that end, the image background of the resulting fused image is estimated in the first place through a method based on blurring the image according to the direction of each pixel. Afterwards, the estimated image background is used in a new subtraction law through which defects are well differentiated from other surface deformations, allowing the detection of defects in the entire illuminated area. In addition, since our approach, together with the system used, computes defects in less than 15 seconds, it satisfies the assembly plants time requirements. Experimental results presented in this paper are obtained from the industrial automatic quality control system QEyeTunnel employed in the production line at the Mercedes-Benz factory in

This work presents a hybrid position-force control of robots in order to apply surface treatments such as polishing, grinding, finishing, deburring, etc. The robot force control is designed using sliding mode concepts to benefit from robustness. In particular, the sliding mode force task is defined using equality constraints to attain the desired tool pressure on the surface, as well as to keep the tool orientation perpendicular to the surface. In order to deal with sudden changes in material stiffness, which are ultimately transferred to the polishing tool and can produce instability and compromise polishing performance, several adaptive switching gain laws are considered and compared. Moreover, a lower priority tracking controller is defined to follow the desired reference trajectory on the surface being polished. Hence, deviations from the reference trajectory are allowed if such deviations are required to satisfy the constraints mentioned above. Finally, a third-level task is also considered for the case of redundant robots in order to use the remaining degrees of freedom to keep the manipulator close to the home configuration with safety in mind. The main advantages of the method are increased robustness and low computational cost. The applicability and effectiveness of the proposed approach is substantiated by experimental results using a redundant 7R manipulator: the Rethink Robotics Sawyer collaborative robot.

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There are some industrial tasks that are still mainly performed manually by human workers due to their complexity, which is the case of surface treatment operations (such as sanding, deburring, finishing, grinding, polishing, etc.) used to repair defects. This work develops an advanced teleoperation and control system for industrial robots in order to assist the human operator to perform the mentioned tasks. On the one hand, the controlled robotic system provides strength and accuracy, holding the tool, keeping the right tool orientation and guaranteeing a smooth approach to the workpiece. On the other hand, the advanced teleoperation provides security and comfort to the user when performing the task. In particular, the proposed teleoperation uses augmented virtuality (i.e., a virtual world that includes non-modeled real-world data) and haptic feedback to provide the user an immersive virtual experience when remotely teleoperating the tool of the robot system to treat arbitrary regions of the workpiece surface. The method is illustrated with a car body surface treatment operation, although it can be easily extended to other surface treatment applications or even to other industrial tasks where the human operator may benefit from robotic assistance. The effectiveness of the proposed approach is shown with several experiments using a 6R robotic arm.