DEVELOPMENT OF A LOW COST PRECISION POLISHING MACHINE BASED ON PARALLEL KINEMATIC SYSTEM

The increasing demand on mass production of high precision parts, has pushed the precision manufacturing industry to develop reliable precision finishing processes such as Bonnet polishing to address market requirements. Indeed, the nature of the surface to be polished plays an important role in the design of a possible polishing machine. A gap within the research in polishing for precision industry needs has been identified. Small parts with <50mm x 50mm and possible freeform curvature containing small slopes cannot be polished with available bonnet polishing (BP) processes on market. This is caused by the tool head size and the tool holder being bigger than part curvature or the part itself. Although, the BP process has a huge potential for surface roughness improvement and form accuracy, it is generally seen in industry as an expensive solution for a non-deterministic finishing process. Therefore, this project has sought to develop a BP machine to cover the gap with an innovative and inexpensive design. In order to develop a machine which responded to the market expectations all possible requirements were listed from a customer point of view. Based on the requirement, a machine concept was produced. Market analysis helped to identify sub-systems of the machine. FEA analysis of the design was performed to check for stress distribution and displacement due to its own mass. Additional assembly parts are designed and a prototype of the machine was produced. The designed machine is tested for its ability as precision polishing machine. Flat surfaces of P20 tool steel were targets for polishing to nanometric surface finishes. Empirical experiments helped to identify parameters which influenced the surface roughness. Taguchi method were then used to optimise the parameters for better surface roughness. Optimum parameters conditions helped to reach less than 10 nm Ra systematically and repeatedly. The samples were also polished using re-circulating slurry techniques, and the obtained results were discussed. Further, pre polishing, Grolishing processes capable of improving surface roughness from ground finish to mirror like finish were developed for cost effective manufacturing procedures. The material removal was analysed to identify parameters capable of improving surface roughness over a step grolishing process. Two grolishing procedures were developed. Both processes produced nanometric range surface finishes. Other variations in results were compared and discussed. Although, machine axis has the ability to produce freeform movement, tool holders need to be improved to facilitate the identification of the distance between tool origin and workpiece origin. Therefore, a new spindle holder assembly is produced to hold the tool and an optical measurement device DRI used to evaluate accurately the distance separating the tool-workpiece origin and further align the workpiece inclination with respect to the machine axis. A CAD-CAM package is also developed to generate programme capable of performing freeform curvature

Developing a mixed reality assistance system based on projection mapping technology for manual operations at assembly workstations.

ABSTRACT Manual tasks play an important role in social sustainable manufacturing enterprises. Commonly, manual operations are used for low volume productions, but are not limited to. Operational models in manufacturing sisters cased of x-to-order paradigms (e.g. assembly-to-order) may require manual operations to speed-up the ramp-up time of new product configuration assemblies. The implications of manual operations in any production line may imply that any manufacturing or assembly process become more susceptible to human errors and therefore translate into delays, defects and/or poor product quality. In this scenario, virtual and augmented realities can offer significant advantages to support the human operator in manual operations. This research work presents the development of a mixed (virtual and augmented) reality assistance system that permits real-time support in manual operations. A review of mixed reality techniques and technologies was conducted, where it was determined to use a projection mapping solution for the proposed assistance system. According to the specific requirements of the demonstration environment, hardware and software components were chosen. The developed mixed reality assistance system was able to guide any user without any prior knowledge through the successful completion of the specific assembly task

Fast Glass: Modernity, Technology, and the Cinematic Lens

This dissertation tells a cultural history of how lenses became cinema lenses. While lenses are essential for film production, we know very little about the early history of cinema lenses. Rather than just focusing on which lenses were used on certain movies, I historicize how lens production became an industry. Between the 1880s and the 1920s, lens production shifted from an artisanal craft to a commercial industry. By looking at how companies created lenses for film production and projection, I expand early film history to account for the creative work of opticians, engineers, advertisers, and distributors. In more specifically focusing on how lenses became “cinema lenses,” I historicize how ideas central to film studies – perspective, objectivity, subjectivity, and realism – were considered in relationship to lenses. I examine four influential optical companies in Germany (Zeiss), France (E. Krauss), the United States (Bausch & Lomb), and England (Taylor-Hobson). By examining international optics alongside film history, we can see that lenses were not just the product of remarkable inventors or ever-improving designs. Ultimately, I argue that lenses were shaped by a wide range of social, cultural, and industrial debates about the role that technologies of vision played in 19th and 20th century life

Design of LCOS microdisplay backplanes for projection applications

De evolutie van licht emitterende diodes (LED) heeft ervoor gezorgd dat het op dit moment interessant wordt om deze componenten als lichtbron te gebruiken in projectiesystemen. LED’s hebben belangrijke voordelen vergeleken met klassieke booglampen. Ze zijn compact, ze hebben een veel grotere levensduur en ogenblikkelijke schakeltijden, ze werken op lage spanningen, etc. LED’s zijn smalbandig en kunnen een groterekleurenbereik realiseren. Ze hebben momenteel echter een beperkte helderheid. Naast de lichtbron is het type van de lichtklep ook bepalend voor de kwaliteit van een projectiesysteem. Er bestaan verschillende lichtkleptechnologieën waaronder die van de reflectieve LCOS-panelen. Deze lichtkleppen kunnen zeer hoge resoluties hebben en wordenvaak gebruikt in kwalitatieve, professionele projectiesystemen. LED’s zijn echter totaal verschillend van booglampen. Ze hebben een andere vorm, package, stralingspatroon, aansturing, fysische en thermische eigenschappen, etc. Hoewel er een twintigtal optische architecturen bekend zijn voor reflectieve beeldschermen (met een booglamp als lichtbron), zijn ze niet geschikt voor LED-projectoren en moeten nieuwe optische architecturen en een elektronische aansturing ontwikkeld worden. In dit doctoraat werd er hieromtrent onderzoek gedaan. Er werd uiteindelijk een driekleurenprojector (R, G, B) met een efficiënt LED-belichtingssysteem gebouwd met twee LCOS-lichtkleppen. Deze LEDprojector heeft superieure eigenschappen (zeer lange levensduur, beeldkwaliteit, etc.) en een matige lichtopbrengst

Content creation for seamless augmented experiences with projection mapping

This dissertation explores systems and methods for creating projection mapping content that seamlessly merges virtual and physical. Most virtual reality and augmented reality technologies rely on screens for display and interaction, where a mobile device or head mounted display mediates the user's experience. In contrast, projection mapping uses off-the-shelf video projectors to augment the appearance of physical objects, and with projection mapping there is no screen to mediate the experience. The physical world simply becomes the display. Projection mapping can provide users with a seamless augmented experience, where virtual and physical become indistinguishable in an apparently unmediated way. Projection mapping is an old concept dating to Disney's 1969 Haunted Mansion. The core technical foundations were laid back in 1999 with UNC's Office of the Future and Shader Lamps projects. Since then, projectors have gotten brighter, higher resolution, and drastically decreased in price. Yet projection mapping has not crossed the chasm into mainstream use. The largest remaining challenge for projection mapping is that content creation is very difficult and time consuming. Content for projection mapping is still created via a tedious manual process by warping a 2D video file onto a 3D physical object using existing tools (e.g. Adobe Photoshop) which are not made for defining animated interactive effects on 3D object surfaces. With existing tools, content must be created for each specific display object, and cannot be re-used across experiences. For each object the artist wants to animate, the artist must manually create a custom texture for that specific object, and warp the texture to the physical object. This limits projection mapped experiences to controlled environments and static scenes. If the artist wants to project onto a different object from the original, they must start from scratch creating custom content for that object. This manual content creation process is time consuming, expensive and doesn't scale. This thesis explores new methods for creating projection mapping content. Our goal is to make projection mapping easier, cheaper and more scalable. We explore methods for adaptive projection mapping, which enables artists to create content once, and that content adapts based on the color and geometry of the display surface. Content can be created once, and re-used on any surface. This thesis is composed of three proof-of-concept prototypes, exploring new methods for content creation for projection mapping. IllumiRoom expands video game content beyond the television screen and into the physical world using a standard video projector to surround a television with projected light. IllumiRoom works in any living room, the projected content dynamically adapts based on the color and geometry of the room. RoomAlive expands on this idea, using multiple projectors to cover an entire living room in input/output pixels and dynamically adapts gaming experiences to fill an entire room. Finally, Projectibles focuses on the physical aspect of projection mapping. Projectibles optimizes the display surface color to increase the contrast and resolution of the overall experience, enabling artists to design the physical object along with the virtual content. The proof-of-concept prototypes presented in this thesis are aimed at the not-to-distant future. The projects in this thesis are not theoretical concepts, but fully working prototype systems that demonstrate the practicality of projection mapping to create immersive experiences. It is the sincere hope of the author that these experiences quickly move of the lab and into the real world