Proximity and Visuotactile Point Cloud Fusion for Contact Patches in Extreme Deformation

Equipping robots with the sense of touch is critical to emulating the capabilities of humans in real world manipulation tasks. Visuotactile sensors are a popular tactile sensing strategy due to data output compatible with computer vision algorithms and accurate, high resolution estimates of local object geometry. However, these sensors struggle to accommodate high deformations of the sensing surface during object interactions, hindering more informative contact with cm-scale objects frequently encountered in the real world. The soft interfaces of visuotactile sensors are often made of hyperelastic elastomers, which are difficult to simulate quickly and accurately when extremely deformed for tactile information. Additionally, many visuotactile sensors that rely on strict internal light conditions or pattern tracking will fail if the surface is highly deformed. In this work, we propose an algorithm that fuses proximity and visuotactile point clouds for contact patch segmentation that is entirely independent from membrane mechanics. This algorithm exploits the synchronous, high-res proximity and visuotactile modalities enabled by an extremely deformable, selectively transmissive soft membrane, which uses visible light for visuotactile sensing and infrared light for proximity depth. We present the hardware design, membrane fabrication, and evaluation of our contact patch algorithm in low (10%), medium (60%), and high (100%+) membrane strain states. We compare our algorithm against three baselines: proximity-only, tactile-only, and a membrane mechanics model. Our proposed algorithm outperforms all baselines with an average RMSE under 2.8mm of the contact patch geometry across all strain ranges. We demonstrate our contact patch algorithm in four applications: varied stiffness membranes, torque and shear-induced wrinkling, closed loop control for whole body manipulation, and pose estimation.