CAD-driven microassembly and visual servoing

This paper describes current research and development on a robotic visual servoing system for assembly of LIGA (Lithography Galvonoforming Abforming) parts. The workcell consists of an AMTI robot, precision stage, long working distance microscope, and LIGA fabricated tweezers for picking up the parts. Fourier optics methods are used to generate synthetic microscope images from CAD drawings. These synthetic images are used off-line to test image processing routines under varying magnifications and depths of field, They also provide reference image features which are used to visually servo the part to the desired position

Parallel Assembly of LIGA Components

In this paper, a prototype robotic workcell for the parallel assembly of LIGA components is described. A Cartesian robot is used to press 386 and 485 micron diameter pins into a LIGA substrate and then place a 3-inch diameter wafer with LIGA gears onto the pins. Upward and downward looking microscopes are used to locate holes in the LIGA substrate, pins to be pressed in the holes, and gears to be placed on the pins. This vision system can locate parts within 3 microns, while the Cartesian manipulator can place the parts within 0.4 microns

Knowledge assistant: A sensor fusion framework for robotic environmental characterization

A prototype sensor fusion framework called the {open_quotes}Knowledge Assistant{close_quotes} has been developed and tested on a gantry robot at Sandia National Laboratories. This Knowledge Assistant guides the robot operator during the planning, execution, and post analysis stages of the characterization process. During the planning stage, the Knowledge Assistant suggests robot paths and speeds based on knowledge of sensors available and their physical characteristics. During execution, the Knowledge Assistant coordinates the collection of data through a data acquisition {open_quotes}specialist.{close_quotes} During execution and post analysis, the Knowledge Assistant sends raw data to other {open_quotes}specialists,{close_quotes} which include statistical pattern recognition software, a neural network, and model-based search software. After the specialists return their results, the Knowledge Assistant consolidates the information and returns a report to the robot control system where the sensed objects and their attributes (e.g. estimated dimensions, weight, material composition, etc.) are displayed in the world model. This paper highlights the major components of this system

Kinematically optimal robot placement for minimum time coordinated motion

This paper describes an algorithm for determining the optimal placement of a robotic manipulator within a workcell for minimum time coordinated motion. The algorithm uses a simple principle of coordinated motion to estimate the time of a joint interpolated motion. Specifically, the coordinated motion profile is limited by the slowest axis. Two and six degree of freedom (DOF) examples are presented. In experimental tests on a FANUC S-800 arm, the optimal placement of the robot can improve cycle time of a robotic operation by as much as 25%. In high volume processes where the robot motion is currently the limiting factor, this increased throughput can result in substantial cost savings

Probability of Detection for Cooperative Sensor Systems

In this paper, the authors quantify how communication increases the effective range of detection of unattended ground sensors. Statistical analysis used to evaluate the probability of detection for multiple sensors using one, two, and infinite levels of cooperation. levels of cooperation are defined as the levels of communication between sensors. One level of cooperation means that one sensor passes its state information to several other sensors within a limited communication range, but this information is not passed beyond this range. Two levels of cooperation means that the state information received by this first set of sensors is relayed to another set of sensors within their communication range. Infinite levels of cooperation means that the state information is further percolated out to all sensors within a communicating group. With large numbers of sensors, every sensor will have state information about every other sensor regardless of communication range. With smaller numbers of sensors, isolated groups may form, thus lowering the probability of information transfer

A capacitance-based proximity sensor for whole arm obstacle avoidance

This paper addresses the issue of collision avoidance in unknown or partially modeled environments using a capacitive sensor. An eight channel capacitance-based sensor system which can detect obstacles up to 400 mm (16 inches) away has been developed. This sensor can detect both conductive and non-conductive obstacles of arbitrary color and shape. The sensor hardware is reliable and inexpensive, and it may be fabricated using flexible printed circuit boards to provide whole-arm and joint protection for any robot or manipulator. Simple collision avoidance control algorithms have been implemented on a two-link robot arm. The sensor and control system enable the robot arm to avoid a conductive post and a concrete block. 13 refs., 9 figs

Assembly planning at the micro scale

This paper investigates a new aspect of fine motion planning for the micro domain. As parts approach 1--10 {micro}m or less in outside dimensions, interactive forces such as van der Waals and electrostatic forces become major factors which greatly change the assembly sequence and path plans. It has been experimentally shown that assembly plans in the micro domain are not reversible, motions required to pick up a part are not the reverse of motions required to release a part. This paper develops the mathematics required to determine the goal regions for pick up, holding, and release of a micro-sphere being handled by a rectangular tool

Ultra-Precise Assembly of Micro-Electromechanical Systems (MEMS) Components

This report summarizes a three year effort to develop an automated microassembly workcell for the assembly of LIGA (Lithography Galvonoforming Abforming) parts. Over the last several years, Sandia has developed processes for producing surface machined silicon and LIGA parts for use in weapons surety devices. Some of these parts have outside dimensions as small as 100 micron, and most all have submicron tolerances. Parts this small and precise are extremely difficult to assembly by hand. Therefore, in this project, we investigated the technologies required to develop a robotic workcell to assembly these parts. In particular, we concentrated on micro-grippers, visual servoing, micro-assembly planning, and parallel assembly. Three different micro-grippers were tested: a pneumatic probe, a thermally actuated polysilicon tweezer, and a LIGA fabricated tweezer. Visual servoing was used to accuracy position two parts relative to one another. Fourier optics methods were used to generate synthetic microscope images from CAD drawings. These synthetic images are used off-line to test image processing routines under varying magnifications and depths of field. They also provide reference image features which are used to visually servo the part to the desired position. We also investigated a new aspect of fine motion planning for the micro-domain. As parts approach 1-10 {micro}m or less in outside dimensions, interactive forces such as van der Waals and electrostatic forces become major factors which greatly change the assembly sequence and path plans. We developed the mathematics required to determine the goal regions for pick up, holding, and release of a micro-sphere being handled by a rectangular tool. Finally, we implemented and tested the ability to assemble an array of LIGA parts attached to two 3 inch diameter wafers. In this way, hundreds of parts can be assembled in parallel rather than assembling each part individually

Minimum-time trajectory control of a two-link flexible robotic manipulator

This paper analyzes the experimental and simulation results of a minimum-time trajectory control scheme for a two-link flexible robot. An off-line optimization routine determines a minimum-time, straight line tip trajectory which stays within the torque constraints of the motors and ends in a quiescent state, i.e., no vibrational transients. An efficient finite-element model is used in the optimization to approximate the flexible arm dynamics. The control strategy described here is used to determine the feedback gains for the position, velocity, and strain gage signals from a quadratic cost criterion based on the finite-element model linearized about the straight line tip trajectory. These feedback signals are added to the modeled torque obtained from the optimization routine and used to control the robot arm actuators. The results indicate that this combination of model-based and error-driven control strategies achieves a closer tracking of the desired trajectory and a better handling of modeling errors (such as tip payloads) than either strategy alone

Techniques for controlling a two-link flexible arm

The long length and relatively small cross sectional area of the robotic arms envisioned for use inside of the underground nuclear waste storage tanks will require the control of flexible structures. This will become an important problem in the characterization and remediation of these tanks. We are developing control strategies to actively damp residual vibrations in flexible robotic arms caused by high speed motion and abrupt external forces. A planar, two-link flexible arm is currently being used to test these control strategies. In this paper, two methods of control are discussed. The first is a minimum-time control approach which utilizes a finite element model and and optimization program. These tools plan the motor torque profiles necessary for the tip of the arm to move along a straight line, in minimum time, within the motors' torque constraints, and end in a quiescent state. To account for modeling errors in the finite element model, errors in joint angles, velocities, and link curvatures are added to the optimal torque trajectory. Linear quadratic Gaussian (LQG) regulatory design theory is used to determine the feedback gains. The second method of control is a teleoperated joystick controller which uses an input shaping technique to alter the commands of the joystick so as to reduce the residual vibration of the fundamental modes. Approximating the system as linear, the natural frequency and damping ratio are estimated on-line for the complete system, which includes the structure plus a lower level proportional derivative controller. An input shaping filter is determined from the estimated natural frequency, estimated damping ratio, and the desired transfer function of the system. 11 reps., 9 figs