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

Development of a truss joint for robotic assembly of space structures

This report presents the results of a detailed study of mechanical fasteners which were designed to facilitate robotic assembly of structures. Design requirements for robotic structural assembly were developed, taking into account structural properties and overall system design, and four candidate fasteners were designed to meet them. These fasteners were built and evaluated in the laboratory, and the Hammer-Head joint was chosen as superior overall. It had a high reliability of fastening under misalignments of 2.54 mm (0.1 in) and 3 deg, the highest end fixity (2.18), the simplest end effector, an integral capture guide, good visual verification, and the lightest weight (782 g, 1.72 lb). The study found that a good design should incorporate chamfers sliding on chamfers, cylinders sliding on chamfers, and hard surface finishes on sliding surfaces. The study also comments on robot flexibility, sag, hysteresis, thermal expansion, and friction which were observed during the testing

Design and implementation of a compliant robot with force feedback and strategy planning software

Force-feedback robotics techniques are being developed for automated precision assembly and servicing of NASA space flight equipment. Design and implementation of a prototype robot which provides compliance and monitors forces is in progress. Computer software to specify assembly steps and makes force feedback adjustments during assembly are coded and tested for three generically different precision mating problems. A model program demonstrates that a suitably autonomous robot can plan its own strategy

Robotic assembly of threaded fasteners in a non-structured environment

Over the past two decades, a major part of the manufacturing and assembly market has been driven by the increasing demand for customised products. This has created the need for smaller batch sizes, shorter production times, lower costs, and the flexibility to produce families of products—or to assemble 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. Threaded fastening operations are widely used in assembly and are typically time-consuming and costly. In high-volume production, fastening operations are commonly automated using jigs, fixtures, and semi-automated tools. However, in low-volume, high-value manufacturing, fastening operations are carried out manually by skilled workers. The existing approaches are found to be less flexible and robust for performing assembly in a less structured industrial environment. This motivated the development of a flexible solution, which does not require fixtures and is adaptable to variation in part locations and lighting conditions. As a part of this research, a novel 3D threaded hole detection and a fast bolt detection algorithms are proposed and reported in this article, which offer substantial enhancement to the accuracy, repeatability, and the speed of the processes in comparison with the existing methods. Hence, the proposed method is more suitable for industrial applications. The development of an automated bolt fastening demonstrator is also described in this article to test and validate the proposed identification algorithms on complex components located in 3D space

Autonomous space processor for orbital debris

This work continues to develop advanced designs toward the ultimate goal of a Get Away Special to demonstrate economical removal of orbital debris using local resources in orbit. The fundamental technical feasibility was demonstrated in 1988 through theoretical calculations, quantitative computer animation, a solar focal point cutter, a robotic arm design, and a subscale model. Last year improvements were made to the solar cutter and the robotic arm. Also performed last year was a mission analysis that showed the feasibility of retrieving at least four large (greater than 1500-kg) pieces of debris. Advances made during this reporting period are the incorporation of digital control with the existing placement arm, the development of a new robotic manipulator arm, and the study of debris spin attenuation. These advances are discussed here

Micro-motion controller

Micro-motions in surgical applications are small motions in the range of a few millimeters and are common in ophthalmic surgery, neurosurgery, and other surgeries which require precise manipulation over short distances. Robotic surgery is replacing traditional open surgery at a rapid pace due to the obvious health benefits, however, most of the robotic surgical tools use robotic motion controllers that are designed to work over a large portion of the human body, thus involving motion of the entire human arm at shoulder joint. This requirement to move a large inertial mass results in undesirable, unwanted, and imprecise motion. This senior design project has created a 2-axis micro-motion “capable” platform, where the device studies the most common linear, 2-D surgical micro-motion of pinched human fingers in a damped and un-damped state. Through a system of printed and modeled parts in combination with motors and encoders a microsurgical controller was developed which can provide location-based output on a screen. Mechanical damping was introduced to research potential stability of micro-motion in any surgeon’s otherwise unsteady hand. The device is to also serve as a starter set for future biomedical device research projects in Santa Clara University’s bioengineering department. Further developments in the microsurgical controller such as further scaling, addition of a third axis, haptic feedback through the microcontroller, and component encasing to allow productization for use on an industrial robotic surgical device for clinical applications

Exomusculature Robotic Sleeve for Upper Limb Stroke Rehabilitation

Traditional physical therapy for upper-limb post- stroke hemiparetic patients often fails to reach the maximum potential for recovery and is unable to provide a complete, quantitative assessment of a patient’s progress. Through the use of robotics the team aimed to create a device free of these faults which would provide a holistic physical therapy solution. The sleeve achieves exomuscular actuation through Bowden cables linked to DC motors housed remotely and is able to flex and extend the fingers and elbow and control pronation and supination of the wrist. Through a sensor array located throughout, a feedback system is able to collect quantitative data on joint angles, fingertip forces, and control all degrees of freedom utilizing this data and several on-board processors

Design and Testing of a Novel Adhesion and Locomotion Method for Wall Climbing Vehicles

The objective of this project was to design, construct and test a wall climbing vehicle which uses a novel vacuum tread system for both adhesion and locomotion. The design and manufacturing of this proof of concept vehicle is detailed with particular emphasis on the design decisions that proved most impactful to the performance of both the vehicle and the tread system. Adhesion performance was characterized by a series of tests that validate the concept, but also identify improvements and design recommendations for future embodiments of the adhesion/locomotion system

A novel design process of low cost 3D printed ambidextrous finger designed for an ambidextrous robotic hand

This paper presents the novel mechanical design of an ambidextrous finger specifically designed for an ambidextrous anthropomorphic robotic hand actuated by pneumatic artificial muscles. The ambidextrous nature of design allows fingers to perform both left and right hand movements. The aim of our design is to reduce the number of actuators, increase the range of movements with best possible range ideally greater than a common human finger. Four prototypes are discussed in this paper; first prototype is focused on the choice of material and to consider the possible ways to reduce friction. Second prototype is designed to investigate the tendons routing configurations. Aim of third and fourth prototype is to improve the overall performance and to maximize the grasping force. Finally, a unified design (Final design) is presented in great detail. Comparison of all prototypes is done from different angles to evaluate the best design. The kinematic features of intermediate mode have been analysed to optimize both the flexibility and the robustness of the system, as well as to minimize the number of pneumatic muscles. The final design of an ambidextrous finger has developed, tested and 3D printed