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All sourcesNASA NTRSDOE OSTI
DOE OSTI2026

A Modular Accelerator Robotics Framework for AD Robotics

Accelerator tunnels, such as the ones at Fermilab, remain highly radioactive after beam shutoff due to induced radiation from the beam. This residual radiation creates a hazardous environment for manual inspection and repair of beamline components. To minimize worker radiation dose and reduce beam downtime, the AD Robotics Initiative previously built a fleet of low-cost custom mobile robots. However, the custom Python sockets server-client architecture lacked standardization, causing development delays and complicating the integration of new sensors and actuators. Here, we developed a modular system using ROS2 and Docker to standardize the teleoperation and control interfaces. This system was validated by implementing a teleoperation controller with real-time, low-latency, and high-definition video feedback. The aim of this framework is for a new feature or even a robot to be integrated into the system simply by documenting the hardware configuration. Current integration of LiDAR, Odometry, and Depth Cameras provides the foundation for Simultaneous Localization and Mapping (SLAM) tasks. Finally, future work involves integration into the accelerator control system and the attachment of a 6 degree-of-freedom robotic arm for telemanipulation.

Rayyan Khan, M. [Fermilab; Rensselaer Poly.; Unlis↗
DOE OSTI2026

Modular Accelerator Robotics Framework Implementation For Accelerator Inspection

Accelerator tunnels, such as the ones at Fermilab, remain highly radioactive after beam shutoff due to induced radiation from the beam. This residual radiation creates a hazardous environment for manual inspection and repair of beamline components. To minimize worker radiation dose and reduce beam downtime, the AD Robotics Initiative previously built a fleet of low-cost custom mobile robots. However, the custom Python sockets server-client architecture lacked standardization, causing development delays and complicating the integration of new sensors and actuators. Here, we developed a modular system using ROS2 and Docker to standardize the teleoperation and control interfaces. This system was validated by implementing a teleoperation controller with real-time, low-latency, and high-definition video feedback. The aim of this framework is for a new feature or even a robot to be integrated into the system simply by documenting the hardware configuration. Current integration of LiDAR, Odometry, and Depth Cameras provides the foundation for Simultaneous Localization and Mapping (SLAM) tasks. Finally, future work involves integration into the accelerator control system and the attachment of a 6 degree-of-freedom robotic arm for telemanipulation.

Rayyan Khana, M. [Unlisted, US, IL] (ORCID:0009000↗
DOE OSTI2023

Cost‐benefit assessment framework for robotics‐driven inspection of floating offshore wind farms

Abstract Operations and maintenance (O&M) of floating offshore wind farms (FOWFs) poses various challenges in terms of greater distances from the shore, harsher weather conditions, and restricted mobility options. Robotic systems have the potential to automate some parts of the O&M leading to continuous feature‐rich data acquisition, operational efficiency, along with health and safety improvements. There remains a gap in assessing the techno‐economic feasibility of robotics in the FOWF sector. This paper investigates the costs and benefits of incorporating robotics into the O&M of a FOWF. A bottom‐up cost model is used to estimate the costs for a proposed multi‐robot platform (MRP). The MRP houses unmanned aerial vehicle (UAV) and remotely operated vehicle (ROV) to conduct the inspection of specific FOWF components. Emphasis is laid on the most conducive O&M activities for robotization and the associated technical and cost aspects. The simulation is conducted in Windfarm Operations and Maintenance cost‐Benefit Analysis Tool (WOMBAT), where the metrics of incurred operational expenditure (OPEX) and the inspection time are calculated and compared with those of a baseline case consisting of crew transfer vessels, rope‐access technicians, and divers. Results show that the MRP can reduce the inspection time incurred, but this reduction has dependency on the efficacy of the robotic system and the associated parameterization e.g., cost elements and the inspection rates. Conversely, the increased MRP day rate results in a higher annualized OPEX. Residual risk is calculated to assess the net benefit of incorporating the MRP. Furthermore, sensitivity analysis is conducted to find the key parameters influencing the OPEX and the inspection time variation. A key output of this work is a robust and realistic framework which can be used for the cost‐benefit assessment of future MRP systems for specific FOWF activities.

17 WIND ENERGY↗
DOE OSTI2026

Autonomous Coupler Alignment Using Position-Based Visual Servoing in a ROS 2 Framework

As robotic arms are becoming increasingly common alongside humans as collaborative robots, their high precision in motion enables tasks to be performed at significantly higher speeds with reduced disruption in the environment. The Fermi National Accelerator Laboratory is exploring this application by incorporating a UR16e from Universal Robots in a cleanroom setting during assembly of couplers to superconducting radio frequency cavities as part of the PIP-II project. The goal of the robotic assembly process is to precisely position the UR16e robot so that the coupler flange, mounted on the robot’s end-effector, is accurately aligned with and pressed against the cavity flange, requiring only final fastening by a lab technician. This thesis builds upon an initial system in which the robotic process was limited to the alignment phase using position-based visual servoing with an eye-in-hand camera to only align the coupler to the cavity with an offset distance. The objective of this thesis is to further advance autonomous robotic assembly by extending the process. To this end, the entire software framework was reconstructed, as the previous development environment posed significant challenges in modifying the software and adapting to hardware changes. The main contributions of this thesis are as follows: (i) a modular and scalable software framework based on ROS~2 was developed to facilitate performance expansion and interchangeability of software and hardware components; (ii) the desired alignment position for position-based visual servoing was parameterized to enable flexible configuration; and (iii) a methodology was developed to close the offset distance between the coupler and cavity utilizing the internal force-torque sensing capability of the UR16e, as visual feedback is not available during the offset-closing phase. The proposed autonomous robotic assembly reduces assembly time and technician involvement, thereby minimizing the risk of airborne particulate contamination, which is essential in the cleanroom setting. Moreover, the ROS~2-based framework provides a foundation for further expansion and continued advancement of robotic automation in Fermilab.

Giffen, Nickolas [Northern Illinois U.]↗
DOE OSTI2018

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↗
DOE OSTI2017

Towards Cooperative Control of Humanoid Robots for Handling High-Consequence Materials in Gloveboxes - 17291

In this paper, we describe our ongoing work with NASA's Valkyrie humanoid robot and present preliminary results on cooperative control of Valkyrie's hands for performing dexterous manipulation tasks inside gloveboxes commonly found in many nuclear facilities. First, we discuss our human-supervised robot control framework which is based on optimization-based whole-body motion and manipulation controllers. A key aspect of this approach is perception based grasping. We develop a grasping control module for realizing the grasps corresponding to sample tasks such as power, ball, key, pinch, and open palm grasps and their variations. Next, we introduce the notion of motion template library in order to develop generalizable robot grasping and manipulation. Motion template library stores the constraint setting information for the constrained motion planning methods and a framework which can implement the motion template library on different types of robots for accomplishing similar tasks. Motion templates are defined only based on the task requirements. As a result, they can be easily ported to different robot platforms. Lastly, we discuss our multi-modal interfaces designs which include a visual display for improved situational awareness as well as a tactile glove for robot hand control and feedback. Our goal is for the person tele-operating the Valkyrie robot to have better sensing and control than what he or she would have if actually standing at the glovebox doing the work. This improved sensing is comprised of the ability to 'see through' the robot's arms and hands in the gloves and to have an improved sense of touch. The paper concludes with a discussion of our validation strategy. Our success metrics are derived from the completion of a relatively complex experiment to be performed in the glovebox. We evaluate various realistic experiments and use them for task validation and demonstration with Valkyrie. We use speed, time of completion, accuracy, repeatability and reliability rates as success metrics by designing replicable experiments. (authors)

42 ENGINEERING↗
DOE OSTI2022

ROAM: A Remotely Operated Accelerator Monitor

Monitoring accelerators in operation is a well known challenge due to the radiation environment. However, there are significant benefits in being able to deploy particular sensors in specific locations of accelerator enclosures for monitoring or troubleshooting purposes. Learning from experience at other labs, we used Commercial Off The Shelf (COTS) components and an open source robot control software framework (ROS) to build a remotely controlled robot platform including a standard suite of instruments such as cameras, LIDAR, and ultrasound, with the ability to incorporate other ad-hoc sensors for specific measurements, such as a Gamma radiation monitor. Special attention was given to the robot's ability to maintain safety in the high risk environment of an accelerator, with multiple failure contingencies in place to ensure collision free operation. Testing was performed to prove the platform's viability and showcase its capability for accelerator monitoring.

Thayer, Thomas C.↗
DOE OSTI2017

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↗
DOE OSTI2024

Facile Integration of Robots into Experimental Orchestration at Scientific User Facilities

Integration of robots into scientific user facilities, such as the National Synchrotron Light Source II, improves their efficiency and capacity. Many such facilities use the opensource Bluesky project for experimental control and orchestration. However, there remains an open challenge in deploying robotic solutions at these facilities that are reconfigurable, extensible, and compatible with pre-existing software infrastructure. Herein, we introduce a framework that uses the Robotic Operating System 2 (ROS2) and Bluesky to provide extensible robotic applications, while working under the operational constraints of a large-scale user facility. We demonstrated this framework by integrating a robotic arm to pick and place a sample holder at a beamline, recording a 90% repeatability rate. This provides the groundwork for further new robotics applications at large-scale scientific user facilities that depend on Bluesky.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Online task-space motion control for positioner-coordinated multi-robot manufacturing systems

Incorporating multiple robotic manipulators into large-scale manufacturing systems enhances production efficiency and expands manufacturing capabilities beyond those of single-robot systems. Workpiece positioners in robotic manufacturing have demonstrated significant benefits for process optimization, but coordination strategies for multi-robot systems with shared positioners have received limited attention. This work presents a task-space coordinated trajectory-tracking control framework for multi-robot manufacturing systems, in which robots coordinate their motions within a shared, dynamic workpiece positioning frame. A workpiece positioner actively adjusts the pose of the manufactured component to enable greater operational concurrency and improve overall production efficiency. The proposed motion-coordination scheme employs a distributed and scalable architecture, supporting coordination across heterogeneous multi-robot systems. Two optimization methodologies are introduced to manage kinematic redundancies and maintain continuous, near-optimal operation throughout the manufacturing process. The first strategy exploits a task-space dimensionality reduction to achieve locally optimal configurations by leveraging symmetry-axis rotations of the tool. The second strategy utilizes the workpiece positioner to drive the coordinated robots toward stable and kinematically favorable configurations. For both optimization strategies, multiple objectives are defined to improve key performance metrics, including manipulability, configuration consistency, proximity to mechanical limits, and motion efficiency. Addressing a key limitation of existing coordination approaches, the framework is designed around online setpoint modification, allowing coordinated robots to respond effectively to in-situ process feedback. The proposed control framework is validated using the Robot Operating System (ROS) middleware on a combination of physical and simulated multi-robot system hardware.

Arbogast, Alex [ORNL] (ORCID:0000000154740723)↗
DOE OSTI2018

Control System Framework for Using G-Code-Based 3D Printing Paths on a Multi-Degree of Freedom Robotic Arm

This paper describes a control system framework using G-Code-based 3D printing paths on a serial link robot manipulator with multiple degrees of freedom. Usually, G-Code is created by a software application, commonly referred to as a slicer, meant for gantry systems. However, G-Code does not address the kinematic complexity nor take advantage of the flexibility available in serial link robot manipulators. This paper provides an overview of the additive manufacturing process and G-Code, types of additive manufacturing deposition movements, common terminology used, the roles of parsers and translators, step-by-step instructions on how to implement this control system, and results and findings from this research. The presented framework can be used for a number of additive manufacturing methods, hybrid solutions, or applications not directly related to additive manufacturing. The implementation was successfully tested on a manipulator with seven degrees of freedom that successfully performed hundreds of hours of large-scale wire arc metal deposition.

Nycz, Andrzej↗
DOE OSTI2025

Automating Testing of DUNE Electronics via a Finite State Machine

The Deep Underground Neutrino Experiment (DUNE) is a flagship international collaboration designed to study neutrinos tiny, nearly massless particles that may hold answers to fundamental questions about the Universe. Fermilab s Robotic Test Stand (RTS) plays a critical role in ensuring the quality of approximately 50,000 Application-Specific Integrated Circuit (ASIC) chips that will be used in DUNE s massive liquid argon detectors. These electronics will be inside the cryostat; therefore, they will need to have a high yield of working chips and low noise. To improve the automation and reliability of the RTS, this project focused on designing and implementing a Python-based finite state machine (FSM) to manage chip handling workflows. The FSM was developed as a modular software framework to coordinate robotic arm movements, manage chip tray positions, and monitor system states during testing. Key features include robust error handling routines, a pause/resume system for safe mid-cycle interruptions, and a simulation mode for iterative testing without hardware dependencies. The system was designed to prepare for seamless integration with RTS hardware components such as the robotic arm and vision system. This integration will streamline collaboration and enable efficient deployment of updates across the six total institutions performing testing. The outcomes of this internship contribute to Fermilab s mission to advance high-energy physics and support the DOE s national goals by directly improving the testing of equipment to be used in DUNE. The project also provided valuable experience in software design and contributing to the success of DUNE.

Kang, Caleb [William Rainey Harper Coll.]↗
DOE OSTI2025

Automating Testing of DUNE Electronics via a Finite State Machine

The Deep Underground Neutrino Experiment (DUNE) is a flagship international collaboration designed to study neutrinos—tiny, nearly massless particles that may hold answers to fundamental questions about the Universe. Fermilab’s Robotic Test Stand (RTS) plays a critical role in ensuring the quality of approximately 50,000 Application-Specific Integrated Circuit (ASIC) chips that will be used in DUNE’s massive liquid argon detectors. These electronics will be inside the cryostat; therefore, they will need to have a high yield of working chips and low noise. To improve the automation and reliability of the RTS, this project focused on designing and implementing a Python-based finite state machine (FSM) to manage chip handling workflows. The FSM was developed as a modular software framework to coordinate robotic arm movements, manage chip tray positions, and monitor system states during testing. Key features include robust error handling routines, a pause/resume system for safe mid-cycle interruptions, and a simulation mode for iterative testing without hardware dependencies. The system was designed to prepare for seamless integration with RTS hardware components such as the robotic arm and vision system. This integration will streamline collaboration and enable efficient deployment of updates across the six institutions performing testing. The outcomes of this internship contribute to Fermilab’s mission to advance high-energy physics and support the DOE’s national goals by directly improving the testing of equipment to be used in DUNE. The project also provided valuable experience in software design and contributing to the success of DUNE.

Kang, Caleb [Fermilab]↗
DOE OSTI2016

SU-G-JeP3-08: Robotic System for Ultrasound Tracking in Radiation Therapy

Purpose: For safe and accurate real-time tracking of tumors for IGRT using 4D ultrasound, it is necessary to make use of novel, high-end force-sensitive lightweight robots designed for human-machine interaction. Such a robot will be integrated into an existing robotized ultrasound system for non-invasive 4D live tracking, using a newly developed real-time control and communication framework. Methods: The new KUKA LWR iiwa robot is used for robotized ultrasound real-time tumor tracking. Besides more precise probe contact pressure detection, this robot provides an additional 7th link, enhancing the dexterity of the kinematic and the mounted transducer. Several integrated, certified safety features create a safe environment for the patients during treatment. However, to remotely control the robot for the ultrasound application, a real-time control and communication framework has to be developed. Based on a client/server concept, client-side control commands are received and processed by a central server unit and are implemented by a client module running directly on the robot’s controller. Several special functionalities for robotized ultrasound applications are integrated and the robot can now be used for real-time control of the image quality by adjusting the transducer position, and contact pressure. The framework was evaluated looking at overall real-time capability for communication and processing of three different standard commands. Results: Due to inherent, certified safety modules, the new robot ensures a safe environment for patients during tumor tracking. Furthermore, the developed framework shows overall real-time capability with a maximum average latency of 3.6 ms (Minimum 2.5 ms; 5000 trials). Conclusion: The novel KUKA LBR iiwa robot will advance the current robotized ultrasound tracking system with important features. With the developed framework, it is now possible to remotely control this robot and use it for robotized ultrasound tracking applications, including image quality control and target tracking.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2025

Dynamic Modeling, Trajectory Optimization, and Linear Control of Cable-Driven Parallel Robots for Automated Panelized Building Retrofits

The construction industry faces a growing need for automation to reduce costs, improve accuracy and productivity, and address labor shortages. One area that stands to benefit significantly from automation is panelized prefabricated building envelope retrofits, which can improve a building’s energy efficiency in heating and cooling interior spaces. In this paper, we propose using cable-driven parallel robots (CDPRs), which can effectively lift and handle large objects, to install these panels. However, implementing CDPRs presents significant challenges because of their nonlinear dynamics, complex trajectory planning, and precise control requirements. To tackle these challenges, this work focuses on a new application of established control and trajectory optimization theories in a CDPR simulation of a building envelope retrofit under real-world conditions. We first model the dynamics of CDPRs, highlighting the critical role of damping in system behavior. Building on this dynamic model, we formulate a trajectory optimization problem to generate feasible and efficient motion plans for the robot under operational and environmental constraints. Given the high precision required in the construction industry, accurately tracking the optimized trajectory is essential. However, challenges such as partial observability and external vibrations complicate this task. To address these issues, a Linear Quadratic Gaussian control framework is applied, enabling the robot to track the optimized trajectories with precision. Simulation results show that the proposed controller enables precise end effector positioning with errors under 4 mm, even in the presence of external wind disturbances. Through comprehensive simulations, our approach allows for an in-depth exploration of the system’s nonlinear dynamics, trajectory optimization, and control strategies under controlled yet highly realistic conditions. The results demonstrate the feasibility of CDPRs for automating panel installation and provide insights into their practical deployment.

CDPR↗
DOE OSTI2018

NeoN: Neuromorphic Control for Autonomous Robotic Navigation

In this paper we describe the use of a new neuromorphic computing framework to implement the navigation system for a roaming, obstacle avoidance robot. Using a Dynamic Adaptive Neural Network Array (DANNA) structure, our TENNLab (Laboratory of Tennesseans Exploring Neural Networks) hardware/software co-design framework and evolutionary optimization (EO) as the training algorithm, we create, train, implement, and test a spiking neural network autonomous robot control system using an array of neuromorphic computing elements built on an FPGA. The simplicity and flexibility of the DANNA neuromorphic computing elements allow for sufficient scale and connectivity on a Xilinx Kintex-7 FPGA to support sensory input and motor control for a mobile robot to navigate a dynamically changing environment. We further describe how more complex capabilities can be added using the same platform, e.g. object identification and tracking.

Mitchell, J. Parker↗