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Mechatronics 20 (2010) 213–223

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Mechatronics
journal homepage: www.elsevier.com/locate/mechatronics

Dead-reckoning sensor system and tracking algorithm for 3-D pipeline mapping
Dongjun Hyun a, Hyun Seok Yang a,*, Hyuk-Sung Park b, Hyo-Jun Kim c
a
Department of Mechanical Engineering, Yonsei University, 262, Seongsanno, Seodamun-gu, Seoul 120-749, Republic of Korea
b
Robogen, RM133, Yonsei Engineering Research Park, 262, Seongsanno, Seodaemun-gu, Seoul 120-749, Republic of Korea
c
Department of Mechanical Engineering, Kangwon National University, KyoDong, Samcheok, Kangwon Do 245-711, Republic of Korea

a r t i c l e i n f o a b s t r a c t

Article history: A dead-reckoning sensor system and a tracking algorithm for 3-D pipeline mapping are proposed for a tap
Received 11 March 2009 water pipeline for which the diameter is small and the inner surface is rough due to pipe scales. The goals
Accepted 30 November 2009 of this study are to overcome the performance limitations of small and low-grade sensors by combining
various sensors with complementary functions and achieve robustness against a severe environment. A
dead-reckoning sensor system consists of a small, low-cost micro electromechanical system inertial mea-
Keywords: surement unit (MEMS IMU) and an optical navigation sensor (used in laser mice). A tracking algorithm
3-D pipeline mapping
consists of a multi-rate extended Kalman filter (EKF) to fuse redundant and complementary data from
Dead reckoning
Multi-sensor fusion
the MEMS IMU and the optical navigation sensor and a geometry compensation method to reduce posi-
Extended Kalman filter tion estimation error using the end point of the pipeline. Two sets of experimental data have been
Optical navigation sensor obtained by driving a radio-controlled car equipped with the sensor system in a 3-D pipeline and on
asphalt pavement. Our study can be used to estimate the path of a 3-D pipeline or mobile robots.
Ó 2009 Elsevier Ltd. All rights reserved.

1. Introduction IMU to overcome the weakness of the optical navigation sensor. A


small, low-cost MEMS IMU is conventionally used with wheel-type
3-D pipeline mapping is important for the inspection and repair odometers, GPS, or a vision system, due to the bias drift [4–9].
of most pipelines. For pipelines buried under cities where incessant Optical navigation sensors typically used in mice measure dis-
construction increases the confusion of pipeline positioning, the placement with a noncontact-type sensor by comparing surface
need for 3-D mapping significantly increases in order to prevent images of the current and previous frame and, unlike wheel-type
the damage of pipelines from works such as excavation and con- odometers, are free from slip. Optical navigation sensors some-
struction. Tap water pipelines have several difficulties using 3-D times fail to measure the displacement, but this failure should be
pipeline mapping with established methods such as a geometry distinguished from the slipping of the wheel-type odometers, since
pig used in gas/oil industries or ground penetrating radar (GPR). detecting the failure of the optical navigation sensors is much eas-
A geometry pig equipped with a precise inertial measurement unit ier than slip error detection.
and wheel-type odometer is not suitable for most tap water pipe- The tracking algorithm consists of a multi-rate EKF to estimate
lines because the diameter of most tap water pipelines is much the states of the nonlinear system with redundant sensors that
smaller than that of gas/oil industries and the pipe scales of tap have different sampling rates and a geometry compensation meth-
water pipelines disturb the odometer. Complex underground con- od to minimize the position error of the estimated path by combin-
ditions and obstacles, such as buildings and walls, disturb and con- ing the two geometry curves obtained by forward and backward
fuse the GPR. estimation. Multi-rate EKF fuses the inertial and optical navigation
The sensor system and tracking algorithm proposed in this sensor measurements using multi-rate sampling that is necessary
study are designed to achieve acceptable performance, size reduc- to treat asynchronous sensor data and irregularly occurring optical
tion and robustness against severe environments by applying an navigation sensor failures. The position error reduction method
adequate sensor fusion algorithm and constructing a sensor system using the start and the end points in pipeline mapping was devel-
that consists of sensors with complementary function, although oped by backward smoothing filter in [10–12]. In this paper, the
the individual performance of sensors are low. geometric approach is applied to address the same problem.
The dead-reckoning sensor system consists of a small, low-cost
MEMS IMU and an optical navigation sensor, that is recently
substituted with an odometer in [1–3] but is fused with the MEMS 2. Dead-reckoning sensor system

* Corresponding author. Tel.: +82 2 2123 2824; fax: +82 2 312 2159. The dead-reckoning sensor system consists of a MEMS IMU, an
E-mail address: hsyang@yonsei.ac.kr (H.S. Yang). optical navigation sensor, a CPU module, and an SD card. The CPU

0957-4158/$ - see front matter Ó 2009 Elsevier Ltd. All rights reserved.
doi:10.1016/j.mechatronics.2009.11.009
214 D. Hyun et al. / Mechatronics 20 (2010) 213–223

module in this study is comprised of an S3C2440 processor using The optical navigation sensor is interfaced with SPI and provides
an ARM920T core, 4 MB Nor Flash, 64 MB Nand Flash, and 64 MB a sampling period of 5 ms or less. The dimensions of the MEMS
SDRAM. The CPU module has an elegant, low-power, simple, and IMU are 58  58  22 mm, and the optical navigation sensor is
fully static design for cost- and power-sensitive applications. The 55  55  31 mm. The dead-reckoning sensor system is so com-
CPU module stores the SD card with the MEMS IMU and optical pact that it fits on a small mobile robot. Fig. 1 shows an overview
navigation sensor measurements for the post-processing of exper- of the dead-reckoning sensor system.
imental data. The storage capacity of the SD card is 1 GB and sensor
measurements can be written for more than 20 h. The MEMS IMU
is interfaced with RS-232 and offers a sampling period of 10 ms.

Fig. 1. Overview of the tracking sensor system. Fig. 3. Linear motion experimental result of a MEMS accelerometer.

Fig. 2. Performance grade positioning of the IMU of [10] and MTi.


D. Hyun et al. / Mechatronics 20 (2010) 213–223 215

Fig. 4. Optical navigation sensor and new optical system.

Table 1
Process of the multi-rate EKF.

Process Multi-rate EKF


Measurement zkþ1 ¼ ½T ;Hkþ1 ¼ ½ and~ rkþ1 ¼ ½
 T T T
if z1;kþ1 ;zkþ1 ¼ ½zT zT1 Tkþ1 ;Hkþ1 ¼ ½HT HTz1 Tkþ1 and~rkþ1 ¼ ~r ~rz1 kþ1
.
if z2;kþ1 ;zkþ1 ¼ ½zT zT2 Tkþ1 ;Hkþ1 ¼ ½ HT HTz2 Tkþ1 and~ rTz2 kþ1 ..
T
rT ~
rkþ1 ¼ ½~

Prediction kþ1 ¼ f ðxk ; ukþ1 ; wkþ1 Þ


x
Pkþ1 ¼ Fkþ1 Pk FTkþ1 þ Q kþ1

Kalman if zkþ1 ;
filtering Rkþ1 ¼ diagð~rkþ1 Þ
Kkþ1 ¼ Pkþ1 HTkþ1 ðHkþ1 Pkþ1 HTkþ1 þ Rkþ1 Þ1
kþ1 þ Kkþ1 ðzkþ1  Hkþ1 x
xkþ1 ¼ x  kþ1 Þ
Pkþ1 ¼ ðI  Kkþ1 Hkþ1 ÞPkþ1
else
kþ1
xkþ1 ¼ x
Pkþ1 ¼ Pkþ1

2.1. MEMS IMU


Fig. 5. Results of the velocity and accelerometer bias estimation.

An Xsens MTi, which is a small, low-cost MEMS IMU, is used for


an inertial sensor and has a sensing range of ±300 deg/s (angular accumulated position/orientation errors in dead reckoning naviga-
rate) and ±2 g (acceleration). Fig. 2 shows the performance grade tion increase significantly over time.
positioning of IMU in [10] and MTi. Fig. 2 is originally defined by The feasibility of MEMS accelerometers in the MTi was tested
Wang and Williams [13] and is added with performance marks by attaching it to the block of the linear motion guide and intro-
of LN-200 and MTi according to their performance specs. The sta- ducing 800 mm of reciprocating linear motion. Fig. 3 shows the
bility performance of the inertial sensor used in this paper is displacement of the MTi as computed by the double integration
approximately a tenth of the IMUs conventionally used in geome- of acceleration measurements. Displacement measurement by
try mapping such as the IMU of [10]. Generally, a tenth of the sta- the MTi is acceptable for approximately 5 s from the beginning,
bility performance causes a much larger position error since the and was disturbed slightly due to bias drift between 5 s and 15 s.

Fig. 6. Concept of geometry compensation.


216 D. Hyun et al. / Mechatronics 20 (2010) 213–223

Fig. 7. Illustration of geometry compensation: (a) forward/backward estimation curves and (b) compensating procedure.

Afterwards, the MTi estimation deviated severely from the actual


displacement. Therefore, the MTi can perform independently as a
dead-reckoning sensor system for a very short period of time,
which is approximately 5 s, if the estimation of the initial bias is
exact. In the suggested tracking algorithm, the MTi performs as
an independent dead-reckoning sensor intermittently. The period
takes effect on the precision of tracking results but does not cause
any fatal error in the tracking algorithm.

2.2. Optical navigation sensor

An Avago Technologies ADNS6010 optical navigation sensor, is


usually applied to laser mice and is comprised of a 30  30 pixel
image sensor and a DSP for image processing. An optical navigation
sensor takes continuous snapshots of the surface and compares the
images to determine the distance and direction traveled. An optical
navigation sensor can be applied as an odometer and benefits from
Fig. 8. Dead reckoning sensor system on R/C car.
the fact that noncontact-type measurements do not experience the

Fig. 9. 3-D pipeline for experiments.


D. Hyun et al. / Mechatronics 20 (2010) 213–223 217

Fig. 10. 3-D pipeline mapping results of the (a) accelerometer and (b) optical navigation sensor without the sensor fusion.

slip ambiguity that plagues wheel-type odometers. However, an But, the optical navigation sensor with the afocal lens may not
optical navigation sensor sometimes fails to process the image of work properly at excessive height because the image sensor of
the surface when the optical navigation sensor moves on mirrors, the optical navigation sensor has low resolution. Fig. 4 shows the
glass, or glossy surfaces, or moves so fast that the sensor cannot newly designed optical system.
take continuous snapshots. Therefore, an optical navigation sensor
cannot be used independently as an odometer. However, the out-
age of the optical navigation sensor can be clearly detected and 3. Tracking algorithm
treated more easily than slip error by the estimation algorithm.
For the laser mice, the optical system is comprised of a lens and 3.1. Multi-rate EKF algorithm
a laser diode (as an illumination source), and functions only when
the optical navigation sensor is 2–3 mm away from the surface. If The EKF is the most popular recursive state estimator for non-
an optical navigation sensor is fitted to a mobile robot 2–3 mm linear system, despite several shortcomings. The multi-rate sam-
away from the surface, then the mobile robot should only move pling method is applied to EKF for an asynchronous sensor
on a smooth surface such, that the optical navigation sensor does system that consists of sensors with different sampling rate by
not conflict with a bumpy or inclined surface. Therefore, a new Armesto et al. [14]. Multi-rate EKF is most suitable for the sensor
optical system comprising of a micro lens and LEDs is designed system proposed in this paper because the MEMS IMU and optical
so that the optical navigation sensor is usable even when the opti- navigation sensor have different sampling rates and the outage of
cal navigation sensor is located 20–80 mm away from the surface. the optical navigation sensor occurs irregularly. Abnormal data
The micro lens is the afocal lens that is used for the camera of the from the outage of the optical navigation sensor can be removed
cellular phone and has infinite field of depth without autofocus. by the multi-rate sampling method to prevent abnormal data from

Fig. 11. Results of the sensor fusion. Fig. 12. Results of the geometry compensation.
218 D. Hyun et al. / Mechatronics 20 (2010) 213–223

disturbing proper state estimation. Table 1 shows that the process


of multi-rate EKF consists of measurement, prediction and Kalman
filtering steps.
The discrete model of states and measurements of this paper is
given by Eqs. (1)–(17)
xkþ1 ¼ f ðxk ; wk Þ ð1Þ
T T
xk ¼ ½ pT vT aT b qT xT k ð2Þ
0T T
wk ¼ ½ jT aT b k ð3Þ

xkþ1 ¼ Fk xk þ Gk wk ð4Þ
2 3
T2 3
I33 TI33 I
2 33
þ T6 ½xk  033 034 033
6 7
6 2 7
6 033
6 I33 TI33 þ T2 ½xk  033 034 033 7
7
6 7
6 033 033 I33 þ T½xk  033 034 033 7
6 7
Fk ¼ 6 7
6 033 033 033 I33 034 033 7
6 7
6 7
6   sin ðkxk k2Þ
T 7
6 043 043 043 043 cos kxk k T2 I44 X k 7
Fig. 13. Position error of the geometry compensation and forward estimation. 4 kxk k 5
033 033 033 033 033 I33
ð5Þ
2 3
3
T
I33 033 033
6 62 7
6T I
6 2 33 033 033 77
6 7
6 TI33 T½v k  033 7
Gk ¼ 6 7 ð6Þ
6 0
6 33 033 TI33 7
7
6 sin ðkxk kT2Þ
7
6 0
4 43 T
2 kxk k
Xk 033 75
033 TI33 033
2 3
0 xz xy
6 7
6 7
½xk  ¼ 6 xz 0 xx 7 ð7Þ
4 5
xy xx 0 k

2 3
0 vz v y
6 7
6 7
½v k  ¼ 6 v z 0 vx 7 ð8Þ
4 5
Fig. 14. Estimated velocity and optical navigation sensor. vy v x 0 k

Fig. 15. Estimated velocity and optical navigation sensor at (a) 48–52 s and (b) 60–68 s.
D. Hyun et al. / Mechatronics 20 (2010) 213–223 219

Fig. 16. Estimated states: (a) velocity, (b–d) acceleration and bias, (e) quaternion and (f) angular velocity.

2 3
q1 q2 q3 angular acceleration, and the derivative of bias. The full motion
6 7 model with noise are Eqs. (4)–(9) and detailed derivations are
6 q0 q3 q2 7
Xk ¼ 6
6 q
7 ð9Þ shown in the Section 3 of [14]. T is the sampling period.
4 3 q0 q1 7
5
q2 q1 q0 k zk ¼ hðxk Þ þ v k ¼ Hk x k þ v k ð10Þ
h iT
States, xk, consist of position, velocity, acceleration, acceleration T T
zk ¼ ½ zT1 zT2 zT3 k ¼ aTInertial xTInertial ddOptical ð11Þ
bias, quaternion, and angular rate. Plant noises, wk, consist of jerk, k
220 D. Hyun et al. / Mechatronics 20 (2010) 213–223

2 3
aInertial ¼ aInertial;raw  ½qk1 gn ¼ a þ b ð12Þ 2q20  1 þ 2q21 2q1 q2  2q0 q3 2q1 q3 þ 2q0 q2
6 7
2 3 ½q ¼ 4 2q1 q2 þ 2q0 q3 2q20  1 þ 2q22 2q2 q3  2q0 q1 5 ð20Þ
2q20  1 þ 2q21 2q1 q2 þ 2q0 q3 2q1 q3  2q0 q2 2q1 q3  2q0 q2 2q2 q3 þ 2q0 q1 2q20  1 þ 2q23
6 7
6 7
½qk1  ¼ 6 2q1 q2  2q0 q3 2q20  1 þ 2q22 2q2 q3 þ 2q0 q1 7
4 5
pnkþ1 ¼ pnk þ ½qkþ1 dpbkþ1 ð21Þ
2q1 q3 þ 2q0 q2 2q2 q3  2q0 q1 2q20  1 þ 2q23 k1
ð13Þ Eqs. (18)–(21) give position in reference axes, pnkþ1 . The differential
displacement in reference axes, dpn, is obtained by transforming the
xInertial ¼ x ð14Þ differential displacement in body axes, dpb, to reference axes with
1 the rotation matrix, [qk+1], because pk in xk is position in body
ddOptical ¼ T v þ T 2 a ð15Þ axes.
2
The estimation of states with acceleration bias included is very
2 3 2 3
Hz1 033 033 I33 I33 033 033 useful for the dead-reckoning sensor system, since sufficiently ex-
6 7 6 7 act estimation of acceleration bias provides the proper estimation
6 7 6 I33 7
Hk ¼ 6 Hz2 7 ¼ 6 033 033 033 033 033 7 ð16Þ of velocity during the intermittent outages of the optical naviga-
4 5 4 5
T 2 tion sensor. As shown on Fig. 3, if outage duration of the optical
Hz3 k 033 TI33 2
I33 033 033 033 k
navigation sensor is less than 5 s and sufficiently exact acceleration
2 3 bias is given then the MEMS accelerometer can give proper velocity
r1 0  0
60 estimation without any assistance. Fig. 5 shows that the velocity is
6 r2 07
7 estimated successfully based on proper accelerometer bias estima-
rk Þ ¼ 6
Rk ¼ diagð~ 6 .. .. 7;
7 ð17Þ
4 . . 05 tion in spite of the outages of the optical navigation sensor.

0 0 0 rn k
3.2. Geometry compensation algorithm
where ~ rk ¼ ½~rTz1 ~ rTz3 Tk ¼ ½ r 1 r 2    rn Tk .
rTz2 ~
Measurements, zk, consist of the acceleration, aInertial, and angu-
The geometry compensation algorithm proposed in this paper
lar rates, xInertial, of the MEMS IMU and the displacement, ddOptical,
represents a method to reduce error in the position estimation
of the optical navigation sensor. aInertial is obtained by subtracting
by combining the two curves obtained from the forward and back-
the gravity in body axes from aInertial,raw that are raw outputs of
ward estimations with a geometric approaching method. For the
accelerometers. gn is the gravity in reference axes and qk1 is the
3-D pipeline mapping, for which start and end points are given,
complex conjugate of the orientation quaternion at the previous
the maximum position error of the method using both forward
step. ½qk1  is the rotation matrix which transforms from refer-
and backward estimations can be less than half of the method
ence to body axes. Hk is measurement model which represents
using only forward estimation or backward estimation because
the relationship between three measurement vectors and six state
vectors. Rk is the measurement noise covariance matrix.

dpbkþ1 ¼ pbkþ1  pbk ð18Þ

dpn ¼ ½qdpb ð19Þ

Fig. 18. Results of the sensor fusion.

Fig. 17. Asphalt pavement measurements from (a) isometric and (b) side views. Fig. 19. Results of the geometry compensation.
D. Hyun et al. / Mechatronics 20 (2010) 213–223 221

General conceptual position error propagates as shown in


Fig. 6a. Maximum position error can be reduced by one forth with
a simple conjunction at the closest point between the results of
forward and backward estimations. However, for conjunction
using the quadratic Bezier curve, the maximum position error is
less than that of the simple conjunction and the continuity of the
estimated path improves.
The geometry compensation algorithm is implemented as
follows:

(1) Obtain the geometric curve from the forward estimations.


(2) Obtain the geometric curve from the backward estimations.
(3) Find a couple of closest points on the two curves respectively
and the middle point between the two points.
(4) Select p0, p1 and p2. p0 and p2 lies on the two estimation
curve respectively and are adequate distant from the clos-
est points. p1 is the middle point between the two closes
points.
(5) Construct the quadratic Bezier curve with p0, p1 and p2 using
Fig. 20. Position error of the geometry compensation and forward estimation. the following:

pBezier ðtÞ ¼ ð1  tÞ2 p0 þ 2ð1  tÞtp1 þ t2 p2 ; t 2 ½0; 1 ð22Þ

(1) Construct the geometric compensation curve as the


following:
8
< pForward Estimation
> ½pStart ; p0 
n
p ¼ pBezer ½p0 ; p2  ð23Þ
>
:
pBackward Estimation ½p2 ; pEnd 

Fig. 7 shows the illustration of the geometry compensation


algorithm.

4. Experimental results

4.1. Experiment and estimation result in a 3-D pipeline

The dead-reckoning sensor system developed in this study


Fig. 21. Estimated velocity and optical navigation sensor.
was tested with a radio-controlled (RC) car in a 3-D pipeline.
Fig. 8 shows the RC car equipped with the dead-reckoning
sensor system. Fig. 9 shows a pipeline whose inner diameter
the position error of dead reckoning navigation increases exponen- was 450 mm, the total length is 24.46 m, which was con-
tially over time and distance. structed from PVC pipes and three transparent acryl pipes for

Fig. 22. Estimated velocity and optical navigation sensor at (a) 34–38 s and (b) 294–289 s.
222 D. Hyun et al. / Mechatronics 20 (2010) 213–223

Table 2
Odometer and position error.

Experiment Total length Estimated length Odometer error Position error forward/geometry comp.
3-D pipeline 24.46 m 24.51 m 0.05 m (0.2%) 0.72 m (2.9%)
0.22 m (1.0%)
Asphalt pavement 855.4 m 850.7 m 4.7 m (0.6%) 22.4 m (2.6%0)
7.1 m (0.8%)

Fig. 23. Estimated states: (a) velocity, (b–d) acceleration and bias, (e) quaternion and (f) angular velocity.
D. Hyun et al. / Mechatronics 20 (2010) 213–223 223

observation. From an overhead viewpoint, the shape of the Fig. 23 shows estimated states by the multi-rate EKF algorithm.
pipeline is ‘@’ and the length, width and height were 7.4 m, Eqs. (22) and (23) shows selected values for R and Q matrix
9 m, and 2.4 m. based on experimental results
The RC car experienced many disturbances during the run. The
Q ¼ diag½ I13  1:5e2 I13  0:38 I13  0:5e  6  ð24Þ
inner surface of the PVC pipe was slippery and the tires of the RC
car continuously experienced slip while driving up the inclined R ¼ diag½ I13  0:1 I13  1e  5 I13  1e  8  ð25Þ
pipes. It was difficult to control the RC car due to the opaque
PVC pipes resulting in sudden accelerations, braking and rapid
5. Conclusions and future work
steering of the RC car at the corners of the pipeline. Additionally,
the intermittent acryl pipes disturb the optical navigation sensor.
The experiment has demonstrated that the dead-reckoning sen-
As a result, the dead-reckoning sensor system experienced a diffi-
sor system, including the optical navigation sensor developed for
cult environment.
this study, functions successfully under difficult conditions, and
Figs. 10a and b represent the position estimation results
the tracking algorithm successfully has estimated the path of the
without sensor fusion. Specifically in Fig. 10b, the optical navi-
RC car. In particular, the tracking algorithm has combined redun-
gation sensor loses considerable distance due to the transparent
dant and complementary measurements of the optical navigation
acryl pipes and irregular driving, such that the length of esti-
sensor and the low-cost MEMS IMU, and has restored displacement
mated path is much shorter than the actual length of the 3-D
of the optical navigation sensor measurements successfully.
pipeline.
Future research will aim to reduce the failure rate of the optical
Figs. 11 and 12 show estimation results of sensor fusion and
navigation sensor measurements and produce the tracking algo-
geometry compensation respectively. The sensor fusion algorithm
rithm process in real time. Reduction of the optical navigation sen-
effectively combined the complementary characteristics of the
sor failure can be achieved by improving the optical system. Real-
optical navigation sensor and inertial sensors, and the geometry
time processing can be achieved by preventing orientation errors
compensation algorithm reduced the position error of the esti-
that increase continuously over time. An additional algorithm
mated 3-D pipeline. The position error in Fig. 13 is minimum dis-
referring to the direction of the gravitational vector and odometers
tance between the reference points of the pipeline and estimated
on the right and left hand sides of the mobile robot can restrict the
path.
orientation error within an appropriate range.
Figs. 14 and 15 show the velocity of the estimated states and the
optical navigation sensor measurements. Failures of the optical
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