Robotic system architecture and control processes

A system, comprising:

• one or more robotic manipulators configured to support a manipulation tool for accessing a workpiece;
• one or more image capture devices configured to generate two-dimensional images of the workpiece;
• and
• one or more processors configured to:
• create a projection matrix based on a first 2D image of the workpiece from the one or more image capture devices and a three-dimensional model of a part;
• determine, based on the projection matrix, a set of 3D coordinates for the workpiece that correspond to an indication of a defect associated with a surface of the workpiece in a second 2D image from the one or more image capture devices;
• create a graph including nodes representing clusters of 3D coordinates from the set, each node having a size based on a size of the manipulation tool;
• wherein the graph is created based on grouping 3D coordinates of a set according to the size of the manipulation tool, the grouping being accomplished by creating from the set of 3D coordinates a plurality of point clusters, each point cluster including a subset of the set of 3D coordinates that is within a common region of the workpiece having a size based on the size of the manipulation tool;
• control the one or more robotic manipulators based on the graph and one or more predefined motion criteria to create one or more tool paths;
• wherein the one or more processors are further configured to generate one or more control signals based on the one or more tool paths on the surface of the workpiece for the manipulation tool to interact with the surface of the workpiece, and wherein crossover between different tool paths on the surface of the workpiece is controlled to have the manipulation tool contact the indication of the defect a minimal number of times and to simultaneously obtain full coverage of an entire area of the indication of the defect by the manipulation tool.

A method, comprising:

• identifying from at least one two-dimensional image (2D) of a workpiece an indication of a defect corresponding to a surface of the workpiece for robotic manipulation by a manipulation tool;
• mapping a set of 2D coordinates from the at least one 2D image to a set of three-dimensional (3D) coordinates corresponding to the indication of the defect based on a projection matrix;
• generating one or more tool paths for manipulating the surface of the workpiece with a tool based on grouping 3D coordinates of the set according to a size of the manipulation tool;
• and
• generating from the one or more tool paths one or more control signals for a robotic manipulator based on one or more predefined motion criteria;
• wherein generating the one or more tool paths comprises:
• creating one or more point clusters from the set of three-dimensional (3D) coordinates, each point cluster including a subset of the set of 3D coordinates based on the size of the manipulation tool;
• generating a graph to connect the one or more point clusters based on one or more constraints;
• and
• traversing the graph to calculate the one or more tool paths, crossover between different tool paths on the surface of the workpiece is controlled to have the manipulation tool contact the indication of the defect a minimal number of times and to simultaneously obtain full coverage of an entire area of the indication of the defect by the manipulation tool.