Improving dependability in robotized bolting operations

Industrial robots are widely used in manufacturing, yet most manipulation still depends on fixed waypoint scripts that are brittle to environmental changes. Learning-based control offers a more adaptive alternative, but it remains unclear whether such methods, still mostly confined to laboratory demonstrations, can sustain hours of reliable operation, deliver consistent quality, and behave safely around people on a live production line. Here we present Learning-Augmented Robotic Automation, a hybrid system that integrates learned task controllers and a neural 3D safety monitor into conventional industrial workflows. We deployed the system on an electric-motor production line to automate deformable cable insertion and soldering under real manufacturing constraints, a step previously performed manually by human workers. With less than 20 min of real-world data per task, the system operated continuously for 5 h 10 min, producing 108 motors without physical fencing and achieving a 99.4% pass rate on product-level quality-control tests. It maintained near-human takt time while reducing variability in solder-joint quality and cycle time. These results establish a practical pathway for extending industrial automation with learning-based methods.

Industrial panel operation is knowledge-intensive and safety-critical. Beyond control recognition and action generation, execution must satisfy constraints in operation manuals and safety regulations. While foundation-model-based planners show strong semantic capability, they typically lack computable, localizable, and reproducible mechanisms for violation detection and repair. To address this, we propose PanelShield, a verifiable closed-loop safety planning framework for manual-guided industrial panel operation. The framework generates parameterized action primitive sequences from task-relevant manual evidence and applies dual formal verification with LTL and a Safety FSM to enforce cross-step temporal correctness and local transition legality. When violations occur, it outputs a structured counterexample with the earliest violating step and cause, enabling targeted repair and re-verification. We build a multi-level long-horizon planning benchmark covering three representative industrial device panels, and evaluate the framework in simulation and real-world robotic experiments. Results show that PanelShield improves complex safety-constrained task performance over foundation-model-only planning baselines while reducing the violation rate to 2.7%, with 4.1 s total latency. Real-world experiments demonstrate end-toend feasibility. Overall, PanelShield offers a verifiable approach to robotic panel operation that balances flexibility, safety, and auditability.

Redundant robotic manipulators operating in constrained and human-interactive environments require accurate task-space tracking together with rigorous safety guarantees under dynamic uncertainties. Classical operational space computed torque controller (OSCTC) relies on accurate dynamic models and degrades in the presence of disturbances. In contrast, the data-driven paradigm of residual learning approximates disturbances as functions learned from full-state measurements, which are often noisy in practice, lack rigorous theoretical guarantees, and introduce additional design complexity. This paper proposes a robust OSCTC framework that integrates an extended state observer (ESO) with conformal prediction to combine model-based robustness and data-driven adaptability. The ESO estimates lumped disturbances directly in operational space without requiring full-state measurements as in residual learning, and a robust control barrier function (CBF) is constructed to enforce safety under uncertainty. However, robust CBFs require a known disturbance-variation bound to guarantee absolute safety, which often leads to conservatism in practice. To address this limitation, we further employ a sliding-window conformal prediction mechanism to estimate the bound online in a distribution-free manner, thereby achieving practical probabilistic safety guarantees. Experiments on a 7-DoF Franka Research 3 manipulator demonstrate millimeter-level tracking accuracy and real-time safe control at 1~kHz under various disturbances.