Process development for automated solar cell and module production. Task 4: Automated array assembly

Progress in the development of automated solar cell and module production is reported. The unimate robot is programmed for the final 35 cell pattern to be used in the fabrication of the deliverable modules. The mechanical construction of the automated lamination station and final assembly station phases are completed and the first operational testing is underway. The final controlling program is written and optimized. The glass reinforced concrete (GRC) panels to be used for testing and deliverables are in production. Test routines are grouped together and defined to produce the final control program

Automated robotic liquid handling assembly of modular DNA devices

Recent advances in modular DNA assembly techniques have enabled synthetic biologists to test significantly more of the available "design space" represented by "devices" created as combinations of individual genetic components. However, manual assembly of such large numbers of devices is time-intensive, error-prone, and costly. The increasing sophistication and scale of synthetic biology research necessitates an efficient, reproducible way to accommodate large-scale, complex, and high throughput device construction. Here, a DNA assembly protocol using the Type-IIS restriction endonuclease based Modular Cloning (MoClo) technique is automated on two liquid-handling robotic platforms. Automated liquid-handling robots require careful, often times tedious optimization of pipetting parameters for liquids of different viscosities (e.g. enzymes, DNA, water, buffers), as well as explicit programming to ensure correct aspiration and dispensing of DNA parts and reagents. This makes manual script writing for complex assemblies just as problematic as manual DNA assembly, and necessitates a software tool that can automate script generation. To this end, we have developed a web-based software tool, http://mocloassembly.com, for generating combinatorial DNA device libraries from basic DNA parts uploaded as Genbank files. We provide access to the tool, and an export file from our liquid handler software which includes optimized liquid classes, labware parameters, and deck layout. All DNA parts used are available through Addgene, and their digital maps can be accessed via the Boston University BDC ICE Registry. Together, these elements provide a foundation for other organizations to automate modular cloning experiments and similar protocols. The automated DNA assembly workflow presented here enables the repeatable, automated, high-throughput production of DNA devices, and reduces the risk of human error arising from repetitive manual pipetting. Sequencing data show the automated DNA assembly reactions generated from this workflow are ~95% correct and require as little as 4% as much hands-on time, compared to manual reaction preparation

Validation & Verification of an EDA automated synthesis tool

Reliability and correctness are two mandatory features for automated synthesis tools. To reach the goals several campaigns of Validation and Verification (V&V) are needed. The paper presents the extensive efforts set up to prove the correctness of a newly developed EDA automated synthesis tool. The target tool, MarciaTesta, is a multi-platform automatic generator of test programs for microprocessors' caches. Getting in input the selected March Test and some architectural details about the target cache memory, the tool automatically generates the assembly level program to be run as Software Based Self-Testing (SBST). The equivalence between the original March Test, the automatically generated Assembly program, and the intermediate C/C++ program have been proved resorting to sophisticated logging mechanisms. A set of proved libraries has been generated and extensively used during the tool development. A detailed analysis of the lessons learned is reporte

Development of a machine vision system for automated structural assembly

Research is being conducted at the LaRC to develop a telerobotic assembly system designed to construct large space truss structures. This research program was initiated within the past several years, and a ground-based test-bed was developed to evaluate and expand the state of the art. Test-bed operations currently use predetermined ('taught') points for truss structural assembly. Total dependence on the use of taught points for joint receptacle capture and strut installation is neither robust nor reliable enough for space operations. Therefore, a machine vision sensor guidance system is being developed to locate and guide the robot to a passive target mounted on the truss joint receptacle. The vision system hardware includes a miniature video camera, passive targets mounted on the joint receptacles, target illumination hardware, and an image processing system. Discrimination of the target from background clutter is accomplished through standard digital processing techniques. Once the target is identified, a pose estimation algorithm is invoked to determine the location, in three-dimensional space, of the target relative to the robots end-effector. Preliminary test results of the vision system in the Automated Structural Assembly Laboratory with a range of lighting and background conditions indicate that it is fully capable of successfully identifying joint receptacle targets throughout the required operational range. Controlled optical bench test results indicate that the system can also provide the pose estimation accuracy to define the target position

Digitisation of a moving assembly operation using multiple depth imaging sensors

Several manufacturing operations continue to be manual even in today’s highly automated industry because the complexity of such operations makes them heavily reliant on human skills, intellect and experience. This work aims to aid the automation of one such operation, the wheel loading operation on the trim and final moving assembly line in automotive production. It proposes a new method that uses multiple low-cost depth imaging sensors, commonly used in gaming, to acquire and digitise key shopfloor data associated with the operation, such as motion characteristics of the vehicle body on the moving conveyor line and the angular positions of alignment features of the parts to be assembled, in order to inform an intelligent automation solution. Experiments are conducted to test the performance of the proposed method across various assembly conditions, and the results are validated against an industry standard method using laser tracking. Some disadvantages of the method are discussed, and suggestions for improvements are suggested. The proposed method has the potential to be adopted to enable the automation of a wide range of moving assembly operations in multiple sectors of the manufacturing industry

Applications of robust optimization to automated test assembly

Executive Summary In automated test assembly (ATA), 0-1 linear programming (0-1 LP) methods are applied to select questions (items) from an item bank to assemble an optimal test. The objective in this 0-1 LP optimization problem is to assemble a test that measures, in as precise a way as possible, the ability of candidates. Item response theory (IRT) is commonly applied to model the relationship between the responses of candidates and their ability level. Parameters that describe the characteristics of each item, such as difficulty level and the extent to which an item differentiates between more and less able test takers (discrimination) are estimated in the application of the IRT model. Unfortunately, since all parameters in IRT models have to be estimated, they do have a level of uncertainty to them. Some of the other parameters in the test assembly model, such as average response times, have been estimated with uncertainty as well. General 0-1 LP methods do not take this uncertainty into account, and overestimate the predicted level of measurement precision. In this paper, alternative robust optimization methods are applied. It is demonstrated how the Bertsimas and Sim method can be applied to take this uncertainty into account in ATA. The impact of applying this method is illustrated in two numerical examples. Implications are discussed, and some directions for future research are presented

National Launch System: Structures and materials

The National Launch System provides an opportunity to realize the potential of Al-Li. Advanced structures can reduce weights by 5-40 percent as well as relax propulsion system performance specifications and reduce requirements for labor and materials. The effect on costs will be substantial. Advanced assembly and process control technologies also offer the potential for greatly reduced labor during the manufacturing and inspection processes. Current practices are very labor-intensive and, as a result, labor costs far outweigh material costs for operational space transportation systems. The technological readiness of new structural materials depends on their commercial availability, producibility and materials properties. Martin Marietta is vigorously pursuing the development of its Weldalite 049 Al-Li alloys in each of these areas. Martin Marietta is also preparing to test an automated work cell concept that it has developed using discrete event simulation