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Integrated Vision System & Robot Streamline Production

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Integrated Vision System & Robot Streamline Production

  1. 1. Integrated Vision System and Robot Streamline Production of Lockheed Martin Aegis Weapon SystemRobotics “Best Practices” Users’ Conference at Penn State Presented by Bill Chesterson, Director - Manufacturing Automation
  2. 2. Aegis Weapon System• Naval Defense System• Integrated Radar and Missile System• Installed on 64 Navy Cruisers and Destroyers
  3. 3. Antenna Manufacturing• 12’ x 12’ Aluminum housing• 4,350 Receivers (phase shifters) are installed in housing• EF Connections are made• On-board electrical systems are installed• Windows and Buttons inserted• Face is coated with RTV
  4. 4. Array Face• 12’ x 12’ Aluminum Plate• Array of 4,350 receivers covered by ceramic windows• 1,600 small screw covers (buttons)• 500 large screw covers• RTV Adhesive
  5. 5. Manufacturing Method• Align array under bridge
  6. 6. Manufacturing Method• Align array under bridge• Place ceramic window / button into carrier
  7. 7. Manufacturing Method• Align array under bridge• Place ceramic window / button into carrier• Apply adhesive bead using cam driven adhesive dispensing system
  8. 8. Manufacturing Method• Align array under bridge• Place ceramic window / button into carrier• Apply adhesive bead using cam driven adhesive dispensing system• Transfer part to bridge via magnetic conveyor
  9. 9. Manufacturing Method• Align array under bridge• Place ceramic window / button into carrier• Apply adhesive bead using cam driven adhesive dispensing system• Transfer part to bridge via magnetic conveyor• Align insertion head over pocket
  10. 10. Manufacturing Method• Align array under bridge• Place ceramic window / button into carrier• Apply adhesive bead using cam driven adhesive dispensing system• Transfer part to bridge via magnetic conveyor• Align insertion head over pocket• Flip Carrier and eject window into array
  11. 11. Manufacturing Method• Align array under bridge• Place ceramic window / button into carrier• Apply adhesive bead using cam driven adhesive dispensing system• Transfer part to bridge via magnetic conveyor• Align insertion head over pocket• Flip Carrier and eject window into array• Wipe excess adhesive
  12. 12. Problems• Supportability - 17 years old• Ergonomics• Messy• Labor Intensive• Buttons inserted manually• Supportability - critical components no longer available
  13. 13. Design Constraints• Use existing bridge & array indexing mechanisms• RTV Adhesive• Could not change product to ease automated assembly – chamfers on parts and pockets• Implementation had to coincide with manufacturing schedule• Quality
  14. 14. Design Concept• Transport System – drives everything else in system concept – usually cannot be changed
  15. 15. Existing Transport System• Dial – Cam driven adhesive dispensing system
  16. 16. Existing Transport System• Dial – Cam driven adhesive dispensing system• Asynchronous Conveyor – transfer pallets to bridge
  17. 17. Existing Transport System• Dial – Cam driven adhesive dispensing system• Asynchronous Conveyor – transfer pallets to bridge• Linear Rail – Hard tooled window placement head
  18. 18. Robotic Transport System• Adaptability – limits development risk – 1 transport device
  19. 19. Robotic Transport System• Adaptability• Retoolable / Programmable – adaptability to future products
  20. 20. Robotic Transport System• Adaptability• Retoolable / Programmable• Agility – eliminated separate glue deposition system – eliminated part handoff
  21. 21. Robotic Transport System• Adaptability• Retoolable / Programmable• Agility• Dependability – good support – High MTBF
  22. 22. Robotic Transport System• Adaptability• Retoolable / Programmable• Agility• Dependability• Control – adhesive dispensing algorithms were canned subroutines – easy tie in / use of vision for inspection and arm positioning
  23. 23. End-of-Arm Vision System• Fine position locating in x-y of pocket to robot (didn’t have to teach 6,000 points)• Eliminated fine alignment of array for Skew & Level• Didn’t have to worry about repeatability of array face
  24. 24. Because of Vision System...• Ability to use camera to scan face to find next open window or button pocket• Provided coarse position coordinates for next empty pocket and determined type (window, large button or small button) – didn’t have to predefine a table with coarse position of each pocket / type• Made system adaptable to different pocket configuration on face• Eliminated synchronization between data table and reality
  25. 25. Cart Mount Vision System• Inspect ceramic window before bead placement• Inspect bead after adhesive deposition
  26. 26. Because of Vision System...• Fine alignment of part to gripper after picking improved part placement accuracy
  27. 27. Major System Components• Bridge• Array Indexing System• Cart – Robot – End-of-Arm Vision System – Cart Mount Vision System – End of Arm Depth Sensor – Adhesive Dispensing System – Part Magazines
  28. 28. Adhesive Dispensing System
  29. 29. Part Magazines
  30. 30. Cart
  31. 31. System Synopsis• Scan array to determine pocket type• Coarse alignment• Pick appropriate part• Inspect part• Fine position of part to end-effector• Dispense adhesive• Inspect adhesive bead• Fine alignment (x-y-z)• Place window / button into pocket• Final Inspect
  32. 32. Lessons Learned• Teach points or use sensing device to position robot• Tying in sensors depends on accuracy of robot which is much less precise than repeatability
  33. 33. Lessons Learned• Lighting – white adhesive on white part – tool tip mounted lighting • no shadows • consistent lighting pocket to pocket – Had to upgrade to increase intensity – Added skirts around cart to block unwanted light

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