Automated freeform assembly of threaded fasteners

Over the past two decades, a major part of the manufacturing and assembly market has been driven by its customer requirements. Increasing customer demand for personalised products create the demand for smaller batch sizes, shorter production times, lower costs, and the flexibility to produce families of products - or different parts - with the same sets of equipment. Consequently, manufacturing companies have deployed various automation systems and production strategies to improve their resource efficiency and move towards right-first-time production. However, many of these automated systems, which are involved with robot-based, repeatable assembly automation, require component- specific fixtures for accurate positioning and extensive robot programming, to achieve flexibility in their production. Threaded fastening operations are widely used in assembly. In high-volume production, the fastening processes are commonly automated using jigs, fixtures, and semi-automated tools. This form of automation delivers reliable assembly results at the expense of flexibility and requires component variability to be adequately controlled. On the other hand, in low- volume, high- value manufacturing, fastening processes are typically carried out manually by skilled workers. This research is aimed at addressing the aforementioned issues by developing a freeform automated threaded fastener assembly system that uses 3D visual guidance. The proof-of-concept system developed focuses on picking up fasteners from clutter, identifying a hole feature in an imprecisely positioned target component and carry out torque-controlled fastening. This approach has achieved flexibility and adaptability without the use of dedicated fixtures and robot programming. This research also investigates and evaluates different 3D imaging technology to identify the suitable technology required for fastener assembly in a non-structured industrial environment. The proposed solution utilises the commercially available technologies to enhance the precision and speed of identification of components for assembly processes, thereby improving and validating the possibility of reliably implementing this solution for industrial applications. As a part of this research, a number of novel algorithms are developed to robustly identify assembly components located in a random environment by enhancing the existing methods and technologies within the domain of the fastening processes. A bolt identification algorithm was developed to identify bolts located in a random clutter by enhancing the existing surface-based matching algorithm. A novel hole feature identification algorithm was developed to detect threaded holes and identify its size and location in 3D. The developed bolt and feature identification algorithms are robust and has sub-millimetre accuracy required to perform successful fastener assembly in industrial conditions. In addition, the processing time required for these identification algorithms - to identify and localise bolts and hole features - is less than a second, thereby increasing the speed of fastener assembly

The NASA SBIR product catalog

The purpose of this catalog is to assist small business firms in making the community aware of products emerging from their efforts in the Small Business Innovation Research (SBIR) program. It contains descriptions of some products that have advanced into Phase 3 and others that are identified as prospective products. Both lists of products in this catalog are based on information supplied by NASA SBIR contractors in responding to an invitation to be represented in this document. Generally, all products suggested by the small firms were included in order to meet the goals of information exchange for SBIR results. Of the 444 SBIR contractors NASA queried, 137 provided information on 219 products. The catalog presents the product information in the technology areas listed in the table of contents. Within each area, the products are listed in alphabetical order by product name and are given identifying numbers. Also included is an alphabetical listing of the companies that have products described. This listing cross-references the product list and provides information on the business activity of each firm. In addition, there are three indexes: one a list of firms by states, one that lists the products according to NASA Centers that managed the SBIR projects, and one that lists the products by the relevant Technical Topics utilized in NASA's annual program solicitation under which each SBIR project was selected

NASA SBIR abstracts of 1991 phase 1 projects

The objectives of 301 projects placed under contract by the Small Business Innovation Research (SBIR) program of the National Aeronautics and Space Administration (NASA) are described. These projects were selected competitively from among proposals submitted to NASA in response to the 1991 SBIR Program Solicitation. The basic document consists of edited, non-proprietary abstracts of the winning proposals submitted by small businesses. The abstracts are presented under the 15 technical topics within which Phase 1 proposals were solicited. Each project was assigned a sequential identifying number from 001 to 301, in order of its appearance in the body of the report. Appendixes to provide additional information about the SBIR program and permit cross-reference of the 1991 Phase 1 projects by company name, location by state, principal investigator, NASA Field Center responsible for management of each project, and NASA contract number are included

Machining-based coverage path planning for automated structural inspection

The automation of robotically delivered nondestructive evaluation inspection shares many aims with traditional manufacture machining. This paper presents a new hardware and software system for automated thickness mapping of large-scale areas, with multiple obstacles, by employing computer-aided drawing (CAD)/computer-aided manufacturing (CAM)-inspired path planning to implement control of a novel mobile robotic thickness mapping inspection vehicle. A custom postprocessor provides the necessary translation from CAM numeric code through robotic kinematic control to combine and automate the overall process. The generalized steps to implement this approach for any mobile robotic platform are presented herein and applied, in this instance, to a novel thickness mapping crawler. The inspection capabilities of the system were evaluated on an indoor mock-inspection scenario, within a motion tracking cell, to provide quantitative performance figures for positional accuracy. Multiple thickness defects simulating corrosion features on a steel sample plate were combined with obstacles to be avoided during the inspection. A minimum thickness mapping error of 0.21 mm and a mean path error of 4.41 mm were observed for a 2 m² carbon steel sample of 10-mm nominal thickness. The potential of this automated approach has benefits in terms of repeatability of area coverage, obstacle avoidance, and reduced path overlap, all of which directly lead to increased task efficiency and reduced inspection time of large structural assets

Geometrical Error Analysis and Correction in Robotic Grinding

The use of robots in industrial applications has been widespread in the manufacturing tasks such as welding, finishing, polishing and grinding. Most robotic grinding focus on the surface finish rather than accuracy and precision. Therefore, it is important to advance the technology of robotic machining so that more practical and competitive systems can be developed for components that have accuracy and precision requirement. This thesis focuses on improving the level of accuracy in robotic grinding which is a significant challenge in robotic applications because of the kinematic accuracy of the robot movement which is much more complex than normal CNC machine tools. Therefore, aiming to improve the robot accuracy, this work provides a novel method to define the geometrical error by using the cutting tool as a probe whilst using Acoustic Emission monitoring to modify robot commands and to detect surfaces of the workpiece. The work also includes an applicable mathematical model for compensating machining errors in relation to its geometrical position as well as applying an optimum grinding method to motivate the need of eliminating the residual error when performing abrasive grinding using the robot. The work has demonstrated an improved machining precision level from 50µm to 30µm which is controlled by considering the process influential variables, such as depth of cut, wheel speed, feed speed, dressing condition and system time constant. The recorded data and associated error reduction provide a significant evidence to support the viability of implementing a robotic system for various grinding applications, combining more quality and critical surface finishing practices, and an increased focus on the size and form of generated components. This method could provide more flexibility to help designers and manufacturers to control the final accuracy for machining a product using a robot system

Rapid 3D Modeling and Parts Recognition on Automotive Vehicles Using a Network of RGB-D Sensors for Robot Guidance

This paper presents an approach for the automatic detection and fast 3D profiling of lateral body panels of vehicles. The work introduces a method to integrate raw streams from depth sensors in the task of 3D profiling and reconstruction and a methodology for the extrinsic calibration of a network of Kinect sensors. This sensing framework is intended for rapidly providing a robot with enough spatial information to interact with automobile panels using various tools. When a vehicle is positioned inside the defined scanning area, a collection of reference parts on the bodywork are automatically recognized from a mosaic of color images collected by a network of Kinect sensors distributed around the vehicle and a global frame of reference is set up. Sections of the depth information on one side of the vehicle are then collected, aligned, and merged into a global RGB-D model. Finally, a 3D triangular mesh modelling the body panels of the vehicle is automatically built. The approach has applications in the intelligent transportation industry, automated vehicle inspection, quality control, automatic car wash systems, automotive production lines, and scan alignment and interpretation

Tele-Autonomous control involving contact

Object localization and its application in tele-autonomous systems are studied. Two object localization algorithms are presented together with the methods of extracting several important types of object features. The first algorithm is based on line-segment to line-segment matching. Line range sensors are used to extract line-segment features from an object. The extracted features are matched to corresponding model features to compute the location of the object. The inputs of the second algorithm are not limited only to the line features. Featured points (point to point matching) and featured unit direction vectors (vector to vector matching) can also be used as the inputs of the algorithm, and there is no upper limit on the number of the features inputed. The algorithm will allow the use of redundant features to find a better solution. The algorithm uses dual number quaternions to represent the position and orientation of an object and uses the least squares optimization method to find an optimal solution for the object's location. The advantage of using this representation is that the method solves for the location estimation by minimizing a single cost function associated with the sum of the orientation and position errors and thus has a better performance on the estimation, both in accuracy and speed, than that of other similar algorithms. The difficulties when the operator is controlling a remote robot to perform manipulation tasks are also discussed. The main problems facing the operator are time delays on the signal transmission and the uncertainties of the remote environment. How object localization techniques can be used together with other techniques such as predictor display and time desynchronization to help to overcome these difficulties are then discussed

Watch Your Step! Terrain Traversability for Robot Control

Watch your step! Or perhaps, watch your wheels. Whatever the robot is, if it puts its feet, tracks, or wheels in the wrong place, it might get hurt; and as robots are quickly going from structured and completely known environments towards uncertain and unknown terrain, the surface assessment becomes an essential requirement. As a result, future mobile robots cannot neglect the evaluation of terrain’s structure, according to their driving capabilities. With the objective of filling this gap, the focus of this study was laid on terrain analysis methods, which can be used for robot control with particular reference to autonomous vehicles and mobile robots. Giving an overview of theory related to this topic, the investigation not only covers hardware, such as visual sensors or laser scanners, but also space descriptions, such as digital elevation models and point descriptors, introducing new aspects and characterization of terrain assessment. During the discussion, a wide number of examples and methodologies are exposed according to different tools and sensors, including the description of a recent method of terrain assessment using normal vectors analysis. Indeed, normal vectors has demonstrated great potentialities in the field of terrain irregularity assessment in both on‐road and off‐road environments

Traceability of on-machine tool measurement: a review

Nowadays, errors during the manufacturing process of high value components are not acceptable in driving industries such as energy and transportation. Sectors such as aerospace, automotive, shipbuilding, nuclear power, large science facilities or wind power need complex and accurate components that demand close measurements and fast feedback into their manufacturing processes. New measuring technologies are already available in machine tools, including integrated touch probes and fast interface capabilities. They provide the possibility to measure the workpiece in-machine during or after its manufacture, maintaining the original setup of the workpiece and avoiding the manufacturing process from being interrupted to transport the workpiece to a measuring position. However, the traceability of the measurement process on a machine tool is not ensured yet and measurement data is still not fully reliable enough for process control or product validation. The scientific objective is to determine the uncertainty on a machine tool measurement and, therefore, convert it into a machine integrated traceable measuring process. For that purpose, an error budget should consider error sources such as the machine tools, components under measurement and the interactions between both of them. This paper reviews all those uncertainty sources, being mainly focused on those related to the machine tool, either on the process of geometric error assessment of the machine or on the technology employed to probe the measurand