MagNav: A Dual-Core Magnetic Track Guidance Framework for Lighting-Invariant Navigation in Two-Wheeled Robots

We propose a hierarchical control framework to address severe dynamic instabilities and navigational drift that arise when a two-wheeled inverted pendulum (TWIP) robot attempts asymmetric object manipulation. While two-wheeled platforms are highly manoeuvrable, their constant balancing adjustments make onboard odometry highly unreliable for precise navigation. Furthermore, the addition of a side-mounted robotic arm introduces unactuated lateral roll moments when a payload is lifted, a challenge heavily compounded on uneven terrain. To solve these coupled problems, our architecture divides the workload. An offboard vision system tracks overhead ArUco markers to provide high-latency global waypoint navigation, bypassing odometry drift. Simultaneously, a low-latency onboard control loop rejects active physical disturbances using inertial and encoder data. In our physical experiments, this dual-loop approach enabled the custom-built robot to navigate accurately, reject transient impacts from speed bumps, adapt to a dynamic seesaw ramp, and carry a payload securely without falling over its narrow wheelbase.

Low-cost unmanned ground vehicles are often used in indoor places like warehouses, inspection corridors, and farm rows, where painted floor lines guide the robot. Line following is useful because it only needs one camera and little computing power, but it can fail when the line is blocked or turns sharply and goes out of view. Sensor-rich platforms tolerate this through hardware redundancy (LiDAR, GPS, multiple cameras), but camera-only systems must recover at runtime with no additional infrastructure. This paper presents a lightweight, two-stage recovery approach that restores guideline tracking without LiDAR, GPS, or a GPU. When the line is lost, the robot first turns in place while slowly relaxing its color checks and waiting for confirmation across multiple frames (Stage 1). If the line is still not found, monocular visual odometry moves the robot back to saved breadcrumb positions before it tries again (Stage 2). The system uses a depth-gated HSV line tracker, a YOLOv8n obstacle detector, and a visual odometry breadcrumb mapper, and it runs at 20 Hz on CPU-only hardware. The controller embeds a complete MAPE-K loop within a single 50 ms control tick, with no external adaptation manager required. The approach is evaluated across 119 fault-injected episodes on three Webots simulation courses. The method was successful in 86.6% of cases, with a median recovery time of 3.26 seconds. These results demonstrate that reliable visual recovery is feasible on camera-only UGVs within practical cost and computational limits.

Magnetic levitation (MagLev) systems have great potential for application in high-mix, low-volume manufacturing due to their scalability and flexibility, enabling highly reconfigurable in-machine material flow. However, their manipulation capabilities remain largely unexploited, as current applications almost exclusively focus on transportation. To enable grasping and manipulation directly on MagLev systems without requiring additional costly handling equipment, such as industrial robot arms, we present the Gripper MagBot, a low-cost parallel 6-DoF manipulator with an integrated 1-DoF gripper that mechanically couples three MagLev movers. The Gripper MagBot supports two operating configurations: a default mode and a single-track mode, selectable depending on the required stability and workspace footprint. To reconfigure a machine, the MagBot can be autonomously dropped off and picked up using a docking station. We showcase pick-and-place examples in simulation, as well as with the real Gripper MagBot using our inverse kinematics controller. CAD files, assembly instructions, a component list, and videos are available at https://sites.google.com/view/gripper-magbot.