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At least 19 records

A Real2Sim Digital Twin Pipeline for Photorealistic Robot Simulation: Evaluating VLA Policy Deployment on a Bimanual Mobile Robot

Digital twins that are automatically constructed from robot sensor data offer a promising pathway for scalable Real2Sim and Sim2Real transfer. However, it remains an open question whether photorealistic reconstruction alone is sufficient to support reliable deployment of vision-language-action (VLA) policies. We present a generative-AI-assisted Real2Sim pipeline that generates simulation-ready digital twins from real-world RGB observations with minimal manual intervention. The pipeline uses prompted segmentation to isolate scene components and a generative 3D model to directly produce simulation assets, eliminating the need for traditional multi-view reconstruction or manual 3D modeling.\r\nTo evaluate simulation fidelity, we deploy and compare policies from two VLA models in both the real robot and the reconstructed\r\nsimulation under identical tasks and initial conditions. We compare joint-level action trajectories and analyze how divergence evolves over time in closed-loop execution. Although the reconstructed environments are visually accurate, we observe increasing trajectory divergence during closedloop operation. These results indicate that photorealistic reconstruction alone is insufficient to preserve closed-loop control behavior\r\nin VLA policies, particularly in contact-rich manipulation settings where small perceptual errors compound over time.

97 MATHEMATICS AND COMPUTING↗

Synthetic Digital Environments for Training Robots on Earth & Beyond [Poster]

Creating physical replicas of real-world environments to train robots for challenging outdoor tasks, whether constructing energy infrastructure like solar farms on Earth or on the Moon and Mars, is prohibitively expensive. This project will prototype a high-fidelity digital twin framework using NVIDIA IsaacSim to create realistic digital representations of robotic systems and their operating conditions, including varied terrains and environmental factors, allowing robots to learn and adapt in a faster, safer, and more affordable way to tackle unpredictable challenges in terrestrial and extraterrestrial applications. The Robotic Space Exploration (RoSE) Lab at Colorado School of Mines focused on the development and testing of synthetic digital twins to explore multi-physics interactions between robots and unstructured environments, with emphasis on lunar conditions such as deformable regolith, reduced gravity, and terrain-robot contact dynamics. The Industrialized Construction Innovation (ICI) team at National laboratory of the Rockies (NLR), simulated robotic apparatus and construction workflows using synthetic digital twins to inform real-world deployment, targeting application-driven use cases such as robotic construction of a scaled prototype of a photovoltaic energy infrastructure. Joint efforts between RoSE and ICI are continuing to explore how environment-scale multi-physics modeling and application-level robotic system simulation could be integrated to support robotic construction of energy infrastructure in highly unstructured environments, including scenarios relevant to the Lunar South Pole.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Analysis of the Impact of Radiation on Cameras and Robotic Perception - 19242

Robotic systems are increasingly used for inspection, maintenance, and disaster assistance for nuclear power plants. These robots utilize increasingly high levels of autonomy to operate in environments that are unsafe for humans to operate the robot in or require more precise control over the robot than a human can offer. In these cases, the robot must include perception and computation components to autonomously sense and navigate through the environment to fulfill its mission. This difficult task is complicated by radiation interfering with sensors' operation. The impact of this interference is largely unexplored, as existing works on radiation interference on sensors focus on estimating the incident radiation, rather than how it impacts a robotic system using the sensor. In this work, we seek to quantify and describe the impact of radiation on cameras, and how the radiation affects robotic performance. In this paper we study cameras that are suitable for small, lightweight unmanned aerial vehicles (UAVs) that are increasingly deployed to fly in confined areas in emergencies, where the surrounding environment is unsafe for workers to operate. These small UAVs lack the payload capacity to carry significant radiation shielding, so any onboard sensors will be affected by radiation. In the case of cameras, this radiation appears as noise in the camera imagery. This noise will interfere with the UAV's operation, by obscuring obstacles and interfering with localization and optical flow algorithms that detect detailed features in the environment. To date, there is a lack of information on how the radiation noise in the camera image impacts the overall robot system performance Existing work focuses on estimating the amount of incident radiation by measuring the corruption in the images. However, these works suffer several shortcomings for robotic systems. First, a robot must be able to successfully navigate its environment during a successful mission, and merely quantifying the amount of radiation noise in an image does not adequately explain how it may interfere with higher level navigation and perception tasks. Second, radiation estimation procedures rely on focusing the camera on a known and static background. This is unsuitable for robotic exploration tasks, where the robot frequently moves around an unknown environment that may be dynamically changing. Our work contains two contributions that address these shortcomings. First, we conduct a detailed analysis of the noise radiation causes in cameras by exposing cameras that are commonly used on UAVs [e.g., small form factor complementary metal-oxide-semiconductor (CMOS) cameras] to varying levels of radiation that may be present in emergency scenarios. From this exposure, we quantify not only how much noise is present, but quantify its appearance. By quantifying the appearance and amount of noise in a camera image, researchers can design mitigation strategies for the corruption, so that their robotic systems can operate in these challenging environments. Second, we demonstrate how to leverage this experimental data in robotic simulations. Using data from the first set of experiments allows us to test and verify the robots in simulation. Using simulators allows us to verify the robots will perform as expected during critical times without needing expensive test equipment or damaging valuable robot prototypes. Other researchers using robots for exploration of irradiated environments will benefit from our research by incorporating similar noise models in their research. 1 Southwest Research Institute{sup R} is a registered trademark of Southwest Research Institute in the United States and/or other countries. This will increase the reliability of robotic systems prior to deployment in emergency situations, which will in turn increase their effectiveness and speed the development of robots that would otherwise need expensive and time-consuming test procedures to validate. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

Robotics for Energy Infrastructure Construction on Earth and Beyond: Pilot Study Exploring Level 3-4 Semi-Autonomous Installation of a Reduced-Scale Photovoltaic Power Plant Prototype: Preprint

There is a growing need to build energy infrastructure at massive scale on both Earth and in space. On Earth, increasing electricity demand from applications such as AI data centers is driving rapid expansion of power systems, while in space, long-duration missions such as lunar operations require reliable and resilient energy infrastructure that can be deployed quickly. These needs outpace the capabilities of conventional construction methods. Robotic construction offers a path to faster, lower-cost, and more consistent deployment, yet most existing approaches focus on automating individual tasks rather than end-to-end assembly. The Industrialized Construction Innovation (ICI) team at the National Laboratory of the Rockies (NLR), in collaboration with the Colorado School of Mines, has been investigating robotics and automation strategies for rapid end-to-end energy infrastructure construction. This paper presents a pilot study demonstrating level 3-4 semi-autonomous, end-to-end robotic assembly of a reduced-scale photovoltaic power plant prototype under terrestrial conditions. The approach combines hardware redesign of photovoltaic components for robotic compatibility, discrete-event and physics-based robotic simulations in synthetic environments, and sim-to-real deployment to execute end-to-end robotic assembly of[NM1.1][NM1.2] tracking components, structural members, photovoltaic modules, and embedded electrical connections. The pilot identifies key limitations like tolerance management, perception and localization, end effector capability, fastening methods, and multi-physics simulation fidelity, that must be addressed to enable end-to-end robotic assembly of full-scale energy infrastructure. The study highlights how these insights inform scaling strategies for terrestrial energy infrastructure and adaptation to unstructured and extreme environments, including off-world scenarios such as robotic assembly of vertical tall lunar towers.

14 SOLAR ENERGY↗

ROS-DOE: Leveraging Open-Source Robotics Software for the DOE-EM Mission? - 17181

In order to establish a common software framework for its robotic systems, the United States Department of Energy - Environmental Management (DOE-EM) is considering the possibility of extending the Robot Operating System (ROS) open source robotics software to address the varied, complex challenges facing DOE-EM. The effort, preliminarily called ROS-DOE, would enhance the reliability, robustness, security, and user friendliness of ROS to meet the requirements of the nuclear waste remediation mission, and those of DOE as a whole. As envisioned, the ROS DOE program would also support rapid progress to mature cross-cutting capabilities including supervised autonomy, inter-operability with off-the-shelf industrial equipment, and physics-based robot simulation (i.e., Gazebo). This paper provides background context about the current state of ROS software and its supporting community, surveys DOE-EM needs and requirements for robotic solutions, and analyzes the gaps between the current state of ROS and those needed for DOE-EM robotics. It then identifies new capabilities that are recommended for ROS-DOE and outlines software development practices that could be leveraged to blend the best of the open-source world with high-reliability software development practices. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

Autonomous aerial flight path inspection using advanced manufacturing techniques

Robotic systems have shown capabilities to perform inspection tasks in dangerous and difficult-to-access environments, such as those found in different components of power plants. However, most of the current robotic inspection technology is designed for specific components. Aerial robots, commonly termed as Drones, have raised an option to inspect a wider range of structural components. Nevertheless, current aerial inspecting technology still relies on a human pilot with limited line of sight, field of view and a reduced perception as the drone flies away, which prevents performing close-quarter inspection in intricate, structurally complex and GPS-denied environments. This work introduces offline inspection path generation methods based on robotics-integrated to manufacturing techniques. One method uses computer-aided manufacturing (CAM) techniques and the other an additive manufacturing (AM) approach to generate the flight path. That is to say, the drone would fly along the path described by a 3D (Three Dimensional) printer’s extruder or a CNC (Computer Numerical Control) machining tool, enabling to fly very close the structure even in physical structures with a complex geometry. Once the trajectories are generated, they are introduced for its validation in the Gazebo robotics simulator. Simulation results demonstrate the proper performance of the method and confirm that this approach can be used for close inspection of structural components.

42 ENGINEERING↗

LANSCE Diagnostic Robot Localization

Los Alamos Neutron Science Center (LANSCE) operates a linear particle accelerator (LINAC) that is used for a number of scientific research projects. Due to the presence of harmful radiation, researchers are not allowed in the beam tunnel during operation. Since the beam tunnel is inaccessible, an autonomous mobile robot is to be developed and deployed in the tunnel, monitoring the accelerator during operation. The robot will present real time data for operators and scientists from sensors such as a video camera, thermal camera, microphones, and muon detectors; allowing for beam diagnostics previously unavailable. Localization is a fundamental step in autonomous navigation of mobile robots, answering the “where am I” question. For this project, an Extended Kalman Filter (EKF) algorithm is implemented as a positional estimator. The EKF relies on an odometric motion model to predict the robot’s position and LIDAR measurement data to update the robot’s position. The measurement model is based on v features extracted from the LIDAR point cluster using the Split-and-Merge algorithm, and the nearest neighbor algorithm associates the features to an a priori feature map of the beam tunnel. The predicted and measured positions are then joined using a weighted value by means of the Kalman gain. The effectiveness of this localization technique is demonstrated using the LabVIEW robotics simulator.

42 ENGINEERING↗

Design and Closed‐Loop Motion Planning of an Untethered Swimming Soft Robot Using 2D Discrete Elastic Rods Simulations

Despite tremendous progress in the development of untethered soft robots in recent years, existing systems lack the mobility, model‐based control, and motion planning capabilities of their piecewise rigid counterparts. As in conventional robotic systems, the development of versatile locomotion of soft robots is aided by the integration of hardware design and control with modeling tools that account for their unique mechanics and environmental interactions. Here, a framework for physics‐based modeling, motion planning, and control of a fully untethered swimming soft robot is introduced. This framework enables offline co‐design in the simulation of robot parameters and gaits to produce effective open‐loop behaviors and enables closed‐loop planning over motion primitives for feedback control of a frog‐inspired soft robot testbed. This pipeline uses a discrete elastic rods (DERs) physics engine that discretizes the soft robot as many stretchable and bendable rods. On hardware, an untethered aquatic soft robot that performs frog‐like rowing behaviors is engineered. Hardware validation verifies that the simulation has sufficient accuracy to find the best candidates for sets of parameters offline. The simulator is then used to generate a trajectory library of the robot's motion in simulation that is used in real‐time closed‐loop path following experiments on hardware.

Huang, Xiaonan↗

Integrating Risk in Humanoid Robot Control for Applications in the Nuclear Industry - 18230

This paper discuss the integration of risk into a robot control framework for decommissioning applications in the nuclear industry. Our overall objective is to allow the robot to evaluate a risk associated with several methods of completing the same task by combining a set of action sequences. If the environment is known and in the absence of sensing errors each set of actions would successfully complete the task. In this paper, instead of attempting to model the errors associated with each sensing system in order to compute an exact solution, a set of solutions are obtained along with a prescribed risk index. The risk associated with each set of actions can then be compared to possible payoffs or rewards, for instance task completion time or power consumption. This information is then sent to a high level decision planner, for instance a human teleoperator, who can then make a more informed decision regarding the robots actions. In order to illustrate the concept, we introduce three specific risk measures, namely, the collision risk and the risk of toppling and failure risk associated with grasping an object. We demonstrate the results from this foundational study of risk-aware compositional robot autonomy in simulation using NASA's Valkyrie humanoid robot, and the grasping simulator HAPTIX. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

Metamodels for Rapid Analysis of Large Sets of Building Designs for Robotic Constructability: Technology Demonstration Using the NASA 3D Printed Mars Habitat Challenge

Disruptive robotic construction technologies such as additive deposition of cementitious materials like concrete (or "3D concrete printing") require the synchronous operation of multiple pieces of equipment in the production setup. In such an environment, it is crucial to simulate the robotic motions (for toolpath clashes) and the cementitious material behavior (for toolpath failures) to ensure fail-proof constructability of the envisioned building geometry. However, toolpath clash detection requires 4D simulations of the production setup, which are computationally graphics intensive, whereas toolpath failure detection requires actual 3D printing of test parts from the geometry to identify areas prone to failure while 3D printing, which is physically tedious. Both these processes, being computationally and physically intensive, have largely curtailed designers from simulating and exploring large sets of design options with varying geometries and toolpath configurations. To overcome this and allow designers to explore large sets of design possibilities, this paper proposes two novel computational metamodels capable of performing robotic toolpath clash detection and failure detection with significantly reduced times than the earlier approaches. The developed metamodels were used to rapidly simulate large sets of building design options for robotic constructability in the NASA 3D-Printed Mars Habitat Challenge.

clash detection↗

Robotic Understanding of Spatial Relationships Using Neural-Logic Learning

Understanding spatial relations of objects is critical in many robotic applications such as grasping, manipulation, and obstacle avoidance. Humans can simply reason object's spatial relations from a glimpse of a scene based on prior knowledge of spatial constraints. The proposed method enables a robot to comprehend spatial relationships among objects from RGB-D data. This paper proposed a neural-logic learning framework to learn and reason spatial relations from raw data by following logic rules on spatial constraints. The neural-logic network consists of three blocks: grounding block, spatial logic block, and inference block. The grounding block extracts high-level features from the raw sensory data. The spatial logic blocks can predicate fundamental spatial relations by training a neural network with spatial constraints. The inference block can infer complex spatial relations based on the predicated fundamental spatial relations. Simulations and robotic experiments evaluated the performance of the proposed method.

Wang, Dali↗

Industrialized and Robotic Construction Advances in Terrestrial Construction and Opportunities in Space Construction

Advanced Building Construction (ABC) methods such as industrialized prefabrication and robotically controlled additive deposition are becoming promising technologies to support rapid construction of buildings at volume and scale. However, apart from the structural shell of the building, optimal integration of other systems – mechanical, electrical, plumbing, thermal, power generation, storage and distribution, is key to enabling functional buildings. Leveraging ABC methods to integrate such systems in the buildings requires the building design to be optimized for constructability constraints imposed by the industrialized and robotically controlled production setups entailing such ABC methods. The Industrialized Construction Innovation (ICI) team at the National Renewable Energy Laboratory (NREL) has been focusing on research and development of such ABC technologies and processes that can lead to production of buildings which are resilient to extreme climatic conditions at reduced cost and time. There is a potential synergy between such advancements in terrestrial construction, which can be leveraged for the benefit of space (orbital and extra-terrestrial) construction. Similarly, advances in space construction can lend itself to accelerated adoption of robotic construction methods in terrestrial construction. This presentation will give an overview of selective research efforts of the ICI team at NREL, along with a vision for potential collaborations with agencies like NASA.

3D printing↗

A Rainbow Coverage Path Planning for a Patrolling Mobile Robot With Circular Sensing Range

In this paper, we proposed a coverage path (CP) planning approach for a mobile robot moving in a dynamically changing environment. Our family of algorithms begins by finding the first path around the center of interior obstacles/disks of a given target region (TR) through the Graham scan algorithm. The first path is then used as a foundational path to generate a collision free, first order differentiable, and observable CP through a complete set of input and output transformation algorithms which together form the rainbow CP planning approach. The last algorithm of the rainbow CP planning approach finds a sufficient number of observation points on the CP needed to observe the TR. The novelty of our rainbow CP planning approach is that it partitions the TR into different shapes with different properties needed to obtain complete coverage while achieving first order path differentiability. The main technical contributions of the proposed approach is to provide a holistic solution that segments any TR, uses triangulation to determine the line of sights and observation points, and computes the collision-free CP within a quadratic runtime. The proposed method can be readily generalized to address problems of higher dimensions, and it is scalable with respect to the size of TR and the number of robots. Computer simulations are used to illustrate the effectiveness and correctness of the proposed approach.

54 ENVIRONMENTAL SCIENCES↗

Assess How Changes in Fuel Cycle Operation Impact Safeguards

Since the beginning of commercial nuclear power generation in the 1960s, the ability of researchers to understand and control the isotopic content of spent fuel has improved. It is therefore not surprising that both fuel assembly design and fuel assembly irradiation optimization have improved over the past 50+ years. It is anticipated that the burnup and isotopics of the spent fuel should exhibit less variation over the decades as reactor operators irradiate each assembly to the optimum amount. In contrast, older spent fuel is anticipated to vary more in burnup and resulting isotopics for a given initial enrichment. Modern fuel therefore should be more uniform in composition, and thus, measured safeguards results should be easier to interpret than results from older spent fuel. With spent fuel ponds filling up, interim and long-­term storage of spent fuel will need to be addressed. Additionally after long periods of storage, spent fuel is no longer self-­protecting and, as such, the IAEA will categorize it as more attractive; in approximately 20 years many of the assemblies from early commercial cores will no longer be considered self-­protecting. This study will assess how more recent changes in the reactor operation could impact the interpretation of safeguards measurements. The status quo for spent fuel assay in the safeguards context is that the overwhelming majority of spent fuel assemblies are not measured in a quantitative way except for those assemblies about to be loaded into a difficult or impossible to access location (dry storage or, in the future, a repository). In other words, when the assembly is still accessible to a state actor, or an insider, when it is cooling in a pool, the inspectorate does not have a measurement database that could assist them in re-­verifying the integrity of that assembly. The spent fuel safeguards regime would be strengthened if spent fuel assemblies were measured from discharge to loading into a difficult or impossible to access location. The primary driver for suggesting this shift in approach is the change in robotic technology and information technology in general. It should be possible, with minimal impact to the facility, to measure each assembly every time that it is moved in the pool, with the first measurements being made at discharge. The following conclusions were reached: The total neutron count rate can be accurately predicted at any future moment in time based upon the measured count rate at discharge, provided the initial enrichment and burnup of the assembly is known at discharge. It is expected that the total neutron count rate measured at discharge will be indicative of the initial enrichment and burnup of that assembly. If the automated robot were to focus on measuring the assemblies in the rack without moving them, the time available would increase immensely.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Robotics for Systems Integration in Buildings - Pilot Study of Viable Approaches to Install Hygrothermal and Rigid Electrical Systems: Preprint

The Industrialized Construction Innovation (ICI) team at the National Renewable Energy Laboratory (NREL) has been exploring the use of robotics to integrate hygrothermal, mechanical, electrical, and plumbing systems in prefabricated building assemblies (offsite construction) and 3D Printed buildings (onsite construction). Such multi-system integration tasks often require specialized robots and custom end-effectors for handling a range of rigid and non-rigid building components. This paper begins with a brief overview of the current state of robotics in construction, followed by a pilot study exploring the use of robotics to integrate a simple prototype multi-trade wall assembly composed of structural studs, hygrothermal layer, wall finishing, and electrical fixtures. The study was funded by the Department of Energy's (DOE) Advanced Materials and Manufacturing Technologies Office (AMMTO). Insights about the implementation of design for manufacturing and assembly (DfMA) principles in designing the prototype wall for robotic assembly, and selection of appropriate robotic end effector hardware for handling these components are included. Detailed comparison of computational toolpath simulations of the robotic assembly process and real-life demonstration of the same is presented. Finally, limitations and lessons learned from this study along with future research recommendations for robotic assembly of more complex multi-trade assemblies, including potential scenarios such as robotic outfitting of facilities in extra-terrestrial environments is included.

advanced manufacturing↗

Robotics for Systems Integration in Buildings: Pilot Study of Viable Approaches to Install Hygrothermal and Rigid Electrical Systems

The Industrialized Construction Innovation (ICI) team at the National Renewable Energy Laboratory (NREL) has been exploring the use of robotics to integrate hygrothermal, mechanical, electrical, and plumbing systems in prefabricated building assemblies (off-site construction) and 3D-printed buildings (on-site construction). Such multisystem integration tasks often require specialized robots and custom end effectors to handle a range of rigid and nonrigid building components. This paper begins with a brief overview of the current state of robotics in construction, followed by a pilot study exploring the use of robotics to integrate a simple prototype multitrade wall assembly composed of structural studs, hygrothermal layer, wall finishing, and electrical fixtures. The study was funded by the US Department of Energy's (DOE's) Advanced Materials and Manufacturing Technologies Office (AMMTO). Insights about the implementation of design for manufacturing and assembly (DfMA) principles in designing the prototype wall for robotic assembly, and selection of appropriate robotic end-effector hardware to handle these components are included. Detailed comparison of computational toolpath simulations of the robotic assembly process and real-life demonstration of the same are presented. Finally, limitations and lessons learned from this study are included, along with future research recommendations for robotic assembly of more complex multitrade assemblies, including potential scenarios such as robotic outfitting of facilities in extraterrestrial environments.

advanced manufacturing↗

TH-EF-BRB-08: Robotic Motion Compensation for Radiation Therapy: A 6DOF Phantom Study

Purpose: The high accuracy of frame-based stereotactic radiosurgery (SRS), which uses a rigid frame fixed to the patient’s skull, is offset by potential drawbacks of poor patient compliance and clinical workflow restrictions. Recent research into frameless SRS has so far resulted in reduced accuracy. In this study, we investigate the use of a novel 6 degree-of-freedom (6DOF) robotic head motion cancellation system that continuously detects and compensates for patient head motions during a SRS delivery. This approach has the potential to reduce invasiveness while still achieving accuracies better or equal to traditional frame-based SRS. Methods: A 6DOF parallel kinematics robotics stage was constructed, and controlled using an inverse kinematics-based motion compensation algorithm. A 6DOF stereoscopic infrared (IR) marker tracking system was used to monitor real-time motions at sub-millimeter and sub-degree levels. A novel 6DOF calibration technique was first applied to properly orient the camera coordinate frame to match that of the LINAC and robotic control frames. Simulated head motions were measured by the system, and the robotic stage responded to these 6DOF motions automatically, returning the reflective marker coordinate frame to its original position. Results: After the motions were introduced to the system in the phantom-based study, the robotic stage automatically and rapidly returned the phantom to LINAC isocenter. When errors exceeded the compensation lower threshold of 0.25 mm or 0.25 degrees, the system registered the 6DOF error and generated a cancellation trajectory. The system responded in less than 0.5 seconds and returned all axes to less than 0.1 mm and 0.1 degree after the 6DOF compensation was performed. Conclusion: The 6DOF real-time motion cancellation system was found to be effective at compensating for translational and rotational motions to current SRS requirements. This system can improve frameless SRS by automatically returning patients to isocenter with high 6DOF accuracy.

60 APPLIED LIFE SCIENCES↗