MScMS-II: an innovative IR-based indoor coordinate measuring system for large-scale metrology applications

According to the current great interest concerning large-scale metrology applications in many different fields of manufacturing industry, technologies and techniques for dimensional measurement have recently shown a substantial improvement. Ease-of-use, logistic and economic issues, as well as metrological performance are assuming a more and more important role among system requirements. This paper describes the architecture and the working principles of a novel infrared (IR) optical-based system, designed to perform low-cost and easy indoor coordinate measurements of large-size objects. The system consists of a distributed network-based layout, whose modularity allows fitting differently sized and shaped working volumes by adequately increasing the number of sensing units. Differently from existing spatially distributed metrological instruments, the remote sensor devices are intended to provide embedded data elaboration capabilities, in order to share the overall computational load. The overall system functionalities, including distributed layout configuration, network self-calibration, 3D point localization, and measurement data elaboration, are discussed. A preliminary metrological characterization of system performance, based on experimental testing, is also presente

High accuracy mobile robot positioning using external large volume metrology instruments

A method of accurately controlling the position of a mobile robot using an external large volume metrology (LVM) instrument is presented in this article. By utilising an LVM instrument such as a laser tracker or indoor GPS (iGPS) in mobile robot navigation, many of the most difficult problems in mobile robot navigation can be simplified or avoided. Using the real-time position information from the laser tracker, a very simple navigation algorithm, and a low cost robot, 5mm repeatability was achieved over a volume of 30m radius. A surface digitisation scan of a wind turbine blade section was also demonstrated, illustrating possible applications of the method for manufacturing processes. Further, iGPS guidance of a small KUKA omni-directional robot has been demonstrated, and a full scale prototype system is being developed in cooperation with KUKA Robotics, UK. © 2011 Taylor & Francis

A laser tracking dynamic robot metrology instrument

Research work over several years has resulted in the development of a laser tracking instrument capable of dynamic 3-D measurements of robot end-effector trajectories. The instrument characteristics and experiments to measure the static and dynamic performance of a robot in an industrial manufacturing environment are described. The use of this technology for space applications is examined

The design and characterisation of miniature robotics for astronomical instruments

Micro robotics has the potential to improve the efficiency and reduce cost of future multi-object instruments for astronomy. This thesis reports on the development and evolution of a micro autonomous pick-off mirror called the Micro Autonomous Positioning System (MAPS) that can be used in a multi-object spectrograph. The design of these micro-autonomous pick-off mirrors is novel as they are capable of high precision positioning using electromagnetic propulsion through utilising non-conventional components and techniques. These devices are self-driven robotic units, which with the help of an external control system are capable of positioning themselves on an instruments focal plane to within 24 μm. This is different from other high precision micro robotics as they normally use piezoelectric actuators for propulsion. Micro robots have been developed that use electromagnetic motors, however they are not used for high precision applications. Although there is a plethora of literature covering design, functionality and capability of precision micro autonomous systems, there is limited research on characterisation methods for their use in astronomical applications. This work contributes not only to the science supporting the design of a micro-autonomous pick-off mirror but also presents a framework for characterising such miniature mechanisms. The majority of instruments are presented with a curved focal plane. Therefore, to ensure that the pick-off mirrors are aligned properly with the receiving optics, either the pick-off mirror needs to be tipped or the receiving optics repositioned. Currently this function is implemented in the beam steering mirror (i.e. the receiving optics). The travel range required by the beam steering mirror is relatively large, and as such, it is more difficult to achieve the positional accuracy and stability. By incorporating this functionality in the pick-off mirror, the instrument can be optimised in terms of size, accuracy and stability. A unique self-adjusting mirror (SAM) is thus proposed as a solution and detailed. As a proof-of-concepts both MAPS and SAM usability in multi-object spectrographs was evaluated and validated. The results indicate their potential to meet the requirements of astronomical instruments and reduce both the size and cost

Development of a Robotic Positioning and Tracking System for a Research Laboratory

Measurement of residual stress using neutron or synchrotron diffraction relies on the accurate alignment of the sample in relation to the gauge volume of the instrument. Automatic sample alignment can be achieved using kinematic models of the positioning system provided the relevant kinematic parameters are known, or can be determined, to a suitable accuracy. The main problem addressed in this thesis is improving the repeatability and accuracy of the sample positioning for the strain scanning, through the use of techniques from robotic calibration theory to generate kinematic models of both off-the-shelf and custom-built positioning systems. The approach is illustrated using a positioning system in use on the ENGIN-X instrument at the UK’s ISIS pulsed neutron source comprising a traditional XYZΩ table augmented with a triple axis manipulator. Accuracies better than 100microns were achieved for this compound system. Although discussed here in terms of sample positioning systems these methods are entirely applicable to other moving instrument components such as beam shaping jaws and detectors. Several factors could lead to inaccurate positioning on a neutron or synchrotron diffractometer. It is therefore essential to validate the accuracy of positioning especially during experiments which require a high level of accuracy. In this thesis, a stereo camera system is developed to monitor the sample and other moving parts of the diffractometer. The camera metrology system is designed to measure the positions of retroreflective markers attached to any object that is being monitored. A fully automated camera calibration procedure is developed with an emphasis on accuracy. The potential accuracy of this system is demonstrated and problems that limit accuracy are discussed. It is anticipated that the camera system would be used to correct the positioning system when the error is minimal or notify the user of the error when it is significant

Analysing uncertainty contributions in dimensional measurements of large-size objects by ultrasound sensors

According to the ever-increasing interest in metrological systems for dimensional measurements of large-size objects in a wide range of industrial sectors, several solutions based on different technologies, working principles, architectures and functionalities have been recently designed. Among these, a distributed flexible system based on a network of low-cost ultrasound (US) sensors - the Mobile Spatial coordinate Measuring System (MScMS) - has been developed. This article presents a possible approach to assess the system uncertainty referring to the measured point coordinates in the 3D space, focusing on the sources of measurement uncertainty and the related propagation la

An investigation of highly accurate and precise robotic hole measurements using non-contact devices

Industrial robots arms are widely used in manufacturing industry because of their support for automation. However, in metrology, robots have had limited application due to their insufficient accuracy. Even using error compensation and calibration methods, robots are not effective for micrometre (μm) level metrology. Non-contact measurement devices can potentially enable the use of robots for highly accurate metrology. However, the use of such devices on robots has not been investigated. The research work reported in this paper explores the use of different non-contact measurement devices on an industrial robot. The aim is to experimentally investigate the effects of robot movements on the accuracy and precision of measurements. The focus has been on assessing the ability to accurately measure various geometric and surface parameters of holes despite the inherent inaccuracies of industrial robot. This involves the measurement of diameter, roundness and surface roughness. The study also includes scanning of holes for measuring internal features such as start and end point of a taper. Two different non-contact measurement devices based on different technologies are investigated. Furthermore, effects of eccentricity, vibrations and thermal variations are also assessed. The research contributes towards the use of robots for highly accurate and precise robotic metrology

Progress in industrial photogrammetry by means of markerless solutions

174 p.La siguiente tesis está enfocada al desarrollo y uso avanzado de metodologías fotogramétrica sin dianas en aplicaciones industriales. La fotogrametría es una técnica de medición óptica 3D que engloba múltiples configuraciones y aproximaciones. En este estudio se han desarrollado procedimientos de medición, modelos y estrategias de procesamiento de imagen que van más allá que la fotogrametría convencional y buscan el emplear soluciones de otros campos de la visión artificial en aplicaciones industriales. Mientras que la fotogrametría industrial requiere emplear dianas artificiales para definir los puntos o elementos de interés, esta tesis contempla la reducción e incluso la eliminación de las dianas tanto pasivas como activas como alternativas prácticas. La mayoría de los sistemas de medida utilizan las dianas tanto para definir los puntos de control, relacionar las distintas perspectivas, obtener precisión, así como para automatizar las medidas. Aunque en muchas situaciones el empleo de dianas no sea restrictivo existen aplicaciones industriales donde su empleo condiciona y restringe considerablemente los procedimientos de medida empleados en la inspección. Un claro ejemplo es la verificación y control de calidad de piezas seriadas, o la medición y seguimiento de elementos prismáticos relacionados con un sistema de referencia determinado. Es en este punto donde la fotogrametría sin dianas puede combinarse o complementarse con soluciones tradicionales para tratar de mejorar las prestaciones actuales