Robotic polishing of large optical components

Lightweight space mirrors have been widely used in earth observation and astronomy applications. Many organizations and companies, such as NASA in America, ESA in Europe, SSTL in UK as well as CASC in China, have spent a lot of money and effort on researching new materials for larger size space mirrors to meet both the payload weight constraints of launch and the increased advanced manufacturing process demanded for higher observations quality. This project is aimed at robot neutral polishing of lapped, ground and polished optical substrates using an industrial FANUC robot system. The project focused on three main fields which were: robot polishing with polyurethane tool and cerium oxide, pitch polishing with pitch tool and cerium oxide, as well as polishing of a 400mm ULE component. The polishing process targets were to achieve: 1) a surface roughness (Ra) of 10 nm and a surface profile (Pt) of 6 µm and 2µm on lapped and ground substrates respectively with polyurethane based tools and 2) a surface roughness (Ra) of 2nm with a surface profile (Pt) unchanged on robot neutral polished substrates using pitch based tools. This thesis comprises four main sections: a literature review, an experimental implementation, metrology and analysis, and the final conclusions. The experiment results measured with the metrology equipment selected were analysed. Conclusions of the relationship between the polishing performance of a specific sample and the selected polishing tool, polishing slurry, tool pressure, polishing time and other parameters were drawn. Results obtained from robot neutral polishing were surface roughness (Ra) of 8-10nm and surface profile (Pt) of 6µm for 100mm square lapped and ground parts. The process scalability was demonstrated from robot neutral polishing in 45hours, a 400mm square ground component from a surface roughness (Ra) of 200nm to 10nm. There is additional work to be implemented in the future, such as the development of robot pitch polishing of robot neutral polished parts to achieve 2nm Ra

Micro-manufacturing : research, technology outcomes and development issues

Besides continuing effort in developing MEMS-based manufacturing techniques, latest effort in Micro-manufacturing is also in Non-MEMS-based manufacturing. Research and technological development (RTD) in this field is encouraged by the increased demand on micro-components as well as promised development in the scaling down of the traditional macro-manufacturing processes for micro-length-scale manufacturing. This paper highlights some EU funded research activities in micro/nano-manufacturing, and gives examples of the latest development in micro-manufacturing methods/techniques, process chains, hybrid-processes, manufacturing equipment and supporting technologies/device, etc., which is followed by a summary of the achievements of the EU MASMICRO project. Finally, concluding remarks are given, which raise several issues concerning further development in micro-manufacturing

Robotic processes to accelerate large optic fabrication

The manufacture of metre-scale optics for the next generation of extremely large telescopes (and many other applications) poses a number of unique challenges. For the primary mirror of the European Extremely Large Telescope, each of its 1.45 m segments will need to be completed with nanometre scale accuracy. This demands an unprecedented combination of hybrid fabricating technology to process nearly 1000 segments before the year 2024. One important aspect in improving the current state-of-the-art manufacturing developments is adding an efficient smoothing process that can achieve a faster, and less expensive, manufacturing process-chain. The current process to finish a prototype segment using CNC grinding and CNC polishing takes approximately 1-2 months, and a significant contributing factor in this is the excessive processing times needed to correct the local grinding marks. In this study, therefore, grolishing, an intermediate process between grinding and polishing, is adopted to smooth the part and reduce the overall manufacturing time. This PhD work serves to advance the development of effective robotic grolishing processes (RGP) by the following achievements: (1) to propose the specification and achieve the requirements; (2) to design tools and establish a mechanism for grolishing; (3) to investigate and propose experimental methods to reduce process times while still achieving high performance, reliability and quality surfaces; (4) to establish the RGP and demonstrate that this process can smooth the errors from grinding and provide superior surfaces for polishing to speed up the current process; (5) to develop prototype metrology systems and algorithms to measure grolished surfaces; and, (6) to investigate an innovative proposed method to control mid-spatial frequencies on complex surfaces by using rotating rigid tools. These novel achievements describe the newest fabrication technology, and anticipate the evolution of the process-chain for future high-quality imaging systems for use in astronomy, space-research and laser physics

The simulation of automated leading edge assembly

Aircraft manufacturers are experiencing a fierce competition worldwide. Improving productivity, increasing throughput and reducing costs are influencing aircraft manufacturer’s future development. In order to improve competitiveness and provide sufficient and high quality products, it should reduce operations of aircraft assembly,majority of which are still in manual process, which limit production output. In contrast, these processes can be automated to replace manual operations. Much more attention should be placed on automated application. This project aims to propose a methodology to develop the automated assembly based on robotics and use this methodology to develop a new concept of Automated Leading Edge Assembly. The research selects an automated assembly process for further evaluation and brackets assembled on the front spar of Leading Edge are chosen to be automated assembly with robot assistant. The software DELMIA is used to develop and simulate the automated assembly process of brackets based on 3-D virtual aircraft Leading Edge models. The research development is mainly divided into three phases which are: (1) The state of art on Manual Leading Edge Assembly; (2) Automated Leading Edge Assembly framework development; (3) Automated Leading Edge Assembly framework evaluation including automated assembly process simulation based on DELMIA robotics workbench and automated assembly cost estimation. The research has proposed a methodology to develop the automated assembly based on robotics, proposed a new concept of Automated Leading Edge Assembly: using robots to replace workers to finish the assembly applications in the Leading Edge, and proposed a new automated bracket assembly process with laser ablation, adhesive bonding, drilling, riveting, and robot application. These applications can attract more and more engineers’ attention and provide preliminary knowledge for further study and detail research in the future

From Concept to Market: Surgical Robot Development

Surgical robotics and supporting technologies have really become a prime example of modern applied information technology infiltrating our everyday lives. The development of these systems spans across four decades, and only the last few years brought the market value and saw the rising customer base imagined already by the early developers. This chapter guides through the historical development of the most important systems, and provide references and lessons learnt for current engineers facing similar challenges. A special emphasis is put on system validation, assessment and clearance, as the most commonly cited barrier hindering the wider deployment of a system

Англійська мова загальнотехнічного спрямування: Sensors and control

Практикум для студентів другого курсу факультету авіаційних і космічних систем укладено відповідно до чинної програми з дисципліни “Іноземна мова”, яка передбачає формування у студентів комунікативної компетенції, необхідної для ефективної участі в процесі навчання та в різноманітних ситуаціях професійного спілкування. Мета практикуму – розширення та закріплення студентами загальнотехнічної термінологічної лексики та опанування граматичними конструкціями, що дозволяють розуміти автентичні тексти, пов’язані з навчанням та спеціальністю. Розроблений практикум сприяє систематизації іншомовного навчального матеріалу, формуванню навичок, розвитку та удосконаленню вмінь у читанні, говорінні, письмі, аудіюванні та перекладі.The practicum for the 2nd year students of Faculty of Airspace Systems was designed according to the recommendations of the current curriculum that implies the students’ professional language competence formation. The objective of the practicum is to widen students’ technical thesaurus, to broaden students’ knowledge of specialty, to improve reading, writing, listening and speaking skills. The practicum helps to develop a broad understanding of international socio-cultural issues in order to operate appropriately in professional and cultural environment. The practicum highlights the requirements to students’ knowledge on different types of language activity.Практикум для студентов второго курса факультета авиационных и космических систем отвечает действующей программе дисциплины «Иностранный язык», которая предполагает формирование у студентов коммуникативных компетенций, необходимых для эффективного участия в процессе обучения. Цель практикума расширить и закрепить у студентов знание терминологической лексики, овладение грамматическими конструкциями, которые позволяют понимать аутентичные тексты. Данное учебное издание поможет систематизировать обучающий материал, сформировать навыки, развить и усовершенствовать умения в чтении, говорении, письме аудировании и переводе общетехнических текстов

Modelling and Calibration Technique of Laser Triangulation Sensors for Integration in Robot Arms and Articulated Arm Coordinate Measuring Machines

A technique for intrinsic and extrinsic calibration of a laser triangulation sensor (LTS) integrated in an articulated arm coordinate measuring machine (AACMM) is presented in this paper. After applying a novel approach to the AACMM kinematic parameter identification problem, by means of a single calibration gauge object, a one-step calibration method to obtain both intrinsic—laser plane, CCD sensor and camera geometry—and extrinsic parameters related to the AACMM main frame has been developed. This allows the integration of LTS and AACMM mathematical models without the need of additional optimization methods after the prior sensor calibration, usually done in a coordinate measuring machine (CMM) before the assembly of the sensor in the arm. The experimental tests results for accuracy and repeatability show the suitable performance of this technique, resulting in a reliable, quick and friendly calibration method for the AACMM final user. The presented method is also valid for sensor integration in robot arms and CMMs

An implementation of a versatile camera calibration technique for high-accuracy 3D machine vision metrology using off-the-shelf TV camera and lenses

This thesis studies and implements a new versatile camera calibration technique for high-accuracy 3D machine vision metrology using off-the-shelf TV camera and lenses developed by Roger Tsai [1]. This technique builds up a unique relationship from the world coordinate system to the computer image coordinate system of calibration points by using a radial alignment constraint. The technique has advantage in terms of accuracy, speed, and versatility over existing techniques. The fundamental knowledge for using this technique is presented in this thesis first, followed by an overview of the existing calibration techniques, and a detailed description of the new technique. The implementation is then presented step by step and is algorithm-oriented. Finally, the experimental results using real data are reported. A precise calibration pattern, a CCD camera with zoom lens and a DADACUBE image acquisition system are used for the implementation of the calibration technique. This thesis supplies the calibrated parameters for researchers who will use the CCD camera in their research, and may pave the way for future research in camera calibration

Uncertainty Modelling of High-precision Trajectories for Industrial Real-time Measurement Applications

Within the field of large volume metrology, kinematic tasks such as the movement of an industrial robot have been measured using laser trackers. In spite of the kinematic applications, to date most research has focused on static measurements. It is crucial to have a reliable uncertainty of kinematic measurements in order to assess spatiotemporal path deviations of a robot. With this in mind an approach capable of real-time was developed, to determine the uncertainties of kinematic measurements