Manipulation of deformable objects is a desired skill in making robots ubiquitous in manufacturing, service, healthcare, and security. Common deformable objects (e.g., wires, clothes, bed sheets, etc.) are significantly more difficult to model than rigid objects. In this research, we contribute to the model-based manipulation of linear flexible objects such as cables. We propose a 3D geometric model of the linear flexible object that is subject to gravity and a physical model with multiple links connected by revolute joints and identified model parameters. These models enable task automation in manipulating linear flexible objects both in simulation and real world. To bridge the gap between simulation and real world and build a close-to-reality simulation of flexible objects, we propose a new strategy called Simulation-to-Real-to-Simulation (Sim2Real2Sim). We demonstrate the feasibility of our approach by completing the Plug Task used in the 2015 DARPA Robotics Challenge Finals both in simulation and real world, which involves unplugging a power cable from one socket and plugging it into another. Numerical experiments are implemented to validate our approach.

Humans are superior to robots in performing complex assembly tasks primarily due to their dexterity and sensorimotor abilities. When humans and robots collaborate to complete an assembly task, it is critical to provide the robot with sufficiently precise manipulation capabilities and formulate a shared control method that coordinates human and robot actions. In this study, we are investigating human-robot collaboration in completing an assembly task, namely the plug task. The plug task, motivated by the 2015 DARPA Robotics Challenge Finals, involves inserting a plug connected with a cable into a paired socket. The human holds the socket while the robot is grasping the cable and manages to insert the plug. We estimate an initial socket pose based on human subjects' data. With the statistically calculated initial guess, the robot could act instantly from the beginning to move the plug towards an initial target. The actual socket pose is updated using the Kalman filter in real-time. Besides, the system continuously updates the cable model and tracks the plug to enable visual servoing to complete the plug task. The result of an extensive experimental study demonstrates that the proposed approach demonstrates fast and accurate performance as well as flexibility when compared to a state-of-the-art method based on interactive probabilistic movement primitives.

This paper addresses a new strategy called Simulation-to-Real-to-Simulation (Sim2Real2Sim) to bridge the gap between simulation and real-world, and automate a flexible object manipulation task. This strategy consists of three steps: (1) using the rough environment with the estimated models to develop the methods to complete the manipulation task in the simulation; (2) applying the methods from simulation to real-world and comparing their performance; (3) updating the models and methods in simulation based on the differences between the real world and the simulation. The Plug Task from the 2015 DARPA Robotics Challenge Finals is chosen to evaluate our Sim2Real2Sim strategy. A new identification approach for building the model of the linear flexible objects is derived from real-world to simulation. The automation of the DRC plug task in both simulation and real-world proves the success of the Sim2Real2Sim strategy. Numerical experiments are implemented to validate the simulated model.