To enable safe and effective human-robot collaboration (HRC) in smart manufacturing, seamless integration of sensing, cognition, and prediction into the robot controller is critical for real-time awareness, response, and communication inside a heterogeneous environment (robots, humans, and equipment). The proposed approach takes advantage of the prediction capabilities of nonlinear model predictive control (NMPC) to execute a safe path planning based on feedback from a vision system. In order to satisfy the requirement of real-time path planning, an embedded solver based on a penalty method is applied. However, due to tight sampling times NMPC solutions are approximate, and hence the safety of the system cannot be guaranteed. To address this we formulate a novel safety-critical paradigm with an exponential control barrier function (ECBF) used as a safety filter. We also design a simple human-robot collaboration scenario using V-REP to evaluate the performance of the proposed controller and investigate whether integrating human pose prediction can help with safe and efficient collaboration. The robot uses OptiTrack cameras for perception and dynamically generates collision-free trajectories to the predicted target interactive position. Results for a number of different configurations confirm the efficiency of the proposed motion planning and execution framework. It yields a 19.8% reduction in execution time for the HRC task considered.

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