A GPU-Resident Pipeline for Multi-Robot 3D Inspection with Limited Perception

We present a unified framework that turns a set of 6-DoF inspection viewpoints into a time-optimal, collision-free route for a 9-DoF robotic system. Unlike modular pipelines that fix a single inverse-kinematics (IK) configuration per viewpoint, build an all-pairs travel-time map, and then route, our method jointly optimizes the visiting order and the per-viewpoint configuration in a single global search. The three-dimensional self-motion manifold of each viewpoint is parameterized in closed form so that the pose constraint holds by construction, the rest-to-rest travel time is approximated by a closed-form admissible double-integrator surrogate, and the tour is encoded by random keys. A derivative-free optimizer (CMA-ES) minimizes a cheap penalized objective over order and configuration, after which direct-collocation trajectory optimization is applied only to the edges of the selected route to certify dynamic feasibility and torque limits, and to return exact timings. This reduces the trajectory solves from quadratic to linear in the number of viewpoints and removes the decoupling that prevents modular pipelines from being globally time-optimal. Simulations and real-robot experiments on a KUKA LBR iiwa with a 2-DoF linear stage validate feasibility, smooth execution, and reduced end-to-end inspection time relative to modular and naive distance-based baselines.

Inspection planning seeks a minimum-length collision-free robot tour that observes a given set of points of interest (POIs). Sampling-based methods reduce this continuous problem to a graph inspection planning (GIP) problem over a discrete roadmap, which is then solved using combinatorial solvers. Dense roadmaps capture diverse inspection viewpoints and motion shortcuts, and thus admit higher-quality solutions, but they induce large combinatorial search spaces on which state-of-the-art GIP solvers struggle to find good solutions within practical time budgets. Roadmap sparsification---restructuring a dense roadmap into a compact representation that preserves connectivity and path lengths---can alleviate this burden. However, existing sparsification approaches are either agnostic to the underlying inspection task, or strive to ensure coverage of the POIs without accounting for the quality of the resulting inspection plan. We present Inspection-SPARS, which is, to our knowledge, the first inspection-roadmap sparsifier with POI coverage and path-quality guarantees relative to the dense roadmap. To this end, we generalize the SPARS framework, a popular task-agnostic sparsifier, from purely geometric criteria to task-oriented ones, introducing an inspection-aware vertex admission mechanism that treats POI coverage as a first-class sparsification criterion alongside connectivity and path quality. Experiments in realistic 3D environments show that Inspection-SPARS reduces vertex and edge counts by 4-8x while preserving coverage, allowing the GIP solver to compute tours up to 25% shorter than with the dense roadmap or state-of-the-art inspection roadmap. More broadly, Inspection-SPARS shows that sparsification can be made task-aware without sacrificing guarantees on solution quality.

Inspection planning is concerned with computing the shortest robot path to inspect a given set of points of interest (POIs) using the robot's sensors. This problem arises in a wide range of applications from manufacturing to medical robotics. To alleviate the problem's complexity, recent methods rely on sampling-based methods to obtain a more manageable (discrete) graph inspection planning (GIP) problem. Unfortunately, GIP still remains highly difficult to solve at scale as it requires simultaneously satisfying POI-coverage and path-connectivity constraints, giving rise to a challenging optimization problem, particularly at scales encountered in real-world scenarios. In this work, we present highly scalable Mixed Integer Linear Programming (MILP) solutions for GIP that significantly advance the state-of-the-art in both runtime and solution quality. Our key insight is a reformulation of the problem's core constraints as a network flow, which enables effective MILP models and a specialized Branch-and-Cut solver that exploits the combinatorial structure of flows. We evaluate our approach on medical and infrastructure benchmarks alongside large-scale synthetic instances. Across all scenarios, our method produces substantially tighter lower bounds than existing formulations, reducing optimality gaps by 30-50% on large instances. Furthermore, our solver demonstrates unprecedented scalability: it provides non-trivial solutions for problems with up to 15,000 vertices and thousands of POIs, where prior state-of-the-art methods typically exhaust memory or fail to provide any meaningful optimality guarantees.