Lilly Tech Systems
Advanced
Best Practices
Safety protocols, testing strategies, deployment guidelines, and production-ready workflows for AI-powered robotics systems.
Safety First
Emergency Stops
Every robot must have hardware and software emergency stop mechanisms. E-stops should be easily accessible and tested regularly.
Speed & Force Limits
Enforce maximum speed and force limits at the controller level. Use collaborative robot (cobot) standards for human-robot interaction.
Safety Zones
Define safety zones around the robot. Use safety-rated sensors to detect human presence and reduce speed or stop accordingly.
Risk Assessment
Conduct formal risk assessments (ISO 12100, ISO 10218). Document hazards, mitigations, and residual risks before deployment.
Development Workflow
- Define requirements: Specify tasks, performance metrics, safety constraints, and operating environment
- Simulate first: Develop and test all algorithms in simulation before touching real hardware
- Unit test components: Test perception, planning, and control modules independently
- Integration testing: Combine components and test end-to-end in simulation
- Hardware-in-the-loop: Test with real sensors but simulated actuators
- Controlled real-world testing: Test in a safe, controlled environment with safety operators
- Gradual deployment: Increase autonomy and reduce supervision incrementally
Code Quality for Robot Software
- Use ROS 2 lifecycle nodes: Manage node states (unconfigured, inactive, active) for clean startup and shutdown
- Parameter management: Use YAML config files for all tunable parameters, never hardcode values
- Logging: Implement structured logging at appropriate levels (DEBUG, INFO, WARN, ERROR)
- Launch files: Use composable launch files with clear parameter passing
- CI/CD: Automated testing with colcon test, linting, and simulation-based integration tests
Common Pitfalls
| Pitfall | Impact | Solution |
|---|---|---|
| Skipping simulation | Damaged hardware, slow iteration | Always validate in simulation first |
| Ignoring timing | Missed deadlines, jerky motion | Profile latency, use real-time OS if needed |
| No fallback behavior | Robot freezes on errors | Implement safe fallback states for all failure modes |
| Overfit to simulation | Poor real-world performance | Domain randomization, real-world fine-tuning |
| Monolithic architecture | Hard to debug and maintain | Modular ROS nodes with clear interfaces |
Deployment Checklist
- All safety systems tested and verified (E-stop, speed limits, safety zones)
- Perception pipeline validated across lighting and weather conditions
- Motion planning tested with representative obstacle configurations
- Communication latency measured and within acceptable bounds
- Battery life and thermal behavior characterized
- Recovery procedures documented for all known failure modes
- Operators trained on emergency procedures
- Maintenance schedule established for hardware and software updates
Congratulations! You've completed the AI Robotics course. You now have a solid foundation in ROS development, robot perception, motion planning, simulation, and production deployment. Continue building and experimenting — the best way to learn robotics is by doing!