1 April 1987

N INDUSTRIAL TECHNOLOGYMODERNIZATIONI C

Phase II Final ReportProject 12

Mechanical Inspection Cell

II .INDUSTRIALTECHNOLOGY MODERNIZATIO

PROGRAM

I "DTICELECTE Prepared for

SEPO6 1989 GENERAL DYNAMICS

S DFort Worth, TomaContract No. F33657-82-C-2034

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C0 OperationsDELCO ELECTRONICS CORPORATION

Goleta, Caltfornia 93117'DU' -x'""-r nc

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6c. ADDRESS (City, State, and ZIP Code) 1b. SOURES OFty FUNDING anUMIPCeRS

PROGRAM PROJECT TASK WOK UNITELEMENT NO. NO. NO. ACCSON NO

Dayton, OH 45433 rCESO O

11. TITLE (include Security Classification)Phase 2 Final Project Report -Project 12 -Mechanical Inspection Cell

12. PERSONAL AUTHOR(S)

TP O REOT 13b. Ti E 0 E D4. DATE OF REPORT (Year, Month, Day) 15. PAGE COUNT

Ih1 FROM~ - -4 TO 1-31-87F 87,04,01 12716. SUPPLEMENTARY NOTATION

CDRL ITM-004

-17, COSATI CODES 18. SUBJECT TERMS (Continue on reverse if necessary and identify by block number)-FIELD GROUP SUB-GROUP Robotic Inspection

19 ,BSTRACT (Continue on reverse if necessary and identify by block number)

!Tsis a semiautomatic vision system to inspect part dimensions, combined with roboticgauging of threaded holes. The project is complete but never implemented due to a lackof F-16 business. ... ,.

DJOTMUrON STAUTEMEMr XApproved tot public telga~g,

20. DISTRIBUTION /AVAILABILITY OF ABSTRACT 21. ABSTRACT SECURITY CLASSIFICATIONQIUNCLASSIFIED/UNLIMITED 0 SAME AS RPT. COTIC USERS unclassified

22a. NAME OF RESPONSIBLE INDIVIDUAL Z2b. TELEPHONE (include Area Code) 22c. OF;ICE SYMBOLCaptain Curtis Britt 513-258-4263 1 YT

DO FORM 1473, 84 MAR 83 APR edition may be used until exhausteo. SECURITY CL-ASSIFICATION OF THIS PAGE

All other editions are obsolete, unclassified)

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1 April 1987

IIg INDUSTRIAL TECHNOLOGY

MODERNIZATION: IPhase II Final Report

I Project 12Mechanical Inspection Cell

INDUSTRIA.'. TECHNOLOGY MODERNIZATIONI PROGRAM

Prepared for M-LS y' ., L

GENERAL DYNAMICS I : TAdLFort Worth, Texas uo,. .,, - D

Contract No. F33657-82-C-2034 - - - _-

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PDelco Ds pCa3 Systems 1,I10h Operations

I OELCO ELECTRONICS CORPORATIONGoleta, California 93117

I

TABLE OF CONTENTS PAGEI

1.0 Introduction 1

1 .1 Background 1

20 Objective 2

3.0 A Comparison of Present and Proposed Methods 3

1 3.1 Present 33.2 Proposed

4.0 Proposed Technical Approach 6

4.1 nspection Ce 2c n n

4.1.1 Dimensional Measurement Station 9

4.1.2 Threaded Hole Inspection 9

4.1.3 System Supervisiory Computer 9

4.1.4. Material Handling Robot 9

4.1.5. Safety System I

4.2 Operational Inspection Sequencing 9

4.3 System Options 12

5.0 Equipment Selection

5.1 Dimensional Inspection Machine 165.2 Robot 185.3 Six-Axs Force Sensor 18

5.4 System Supervisory Computer 19

6.0 Equipment Specifications

6.1 Dimensional Inspection Machine 20

6.2 Robot 206.3 Six-Axis Folle Sensor 24

I 7.0 Enabling Technology Developmenmt 28

7.1 Thread Inspection 28

I 7.1.1 Background 28

7.1.2 Testing 29

7.2 Material Handling ?q

7.2.1 Design 55

7.2.2 Testing 55

8.0 Proof-ot-Concept Design 60

8.1 Statement-of-Work Definition 60

8.2 System Supervisory Computer Control Design 60

£ 8.2.1 View 1200 60

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q2.2 Karel Controller

8.3 Thread Inspection EOAT Design 62

8.3.1 Mechanical Hardware 628.3.2 Control Electronics/Software (Karel) 63

8.4 Lab Layout 64

9.0 Areas for Future Concern/Development 70

I0.0 Final Design 71

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ILLUSTRATTONS

FIGURE DESCRIPTION PAGE

1 Typical Mechanical Parts 42 Cell Concept 73 System Breakbown 84 EOAT-Thread Inspection 105 Inspection Sequence 136 Go Gaging Sequence !47 No-Go Gaging Sequence i58 Dimensional Inspection Comparison Matrix 179 View Engineering Model 1200 2110 Accuracy Specifications 211 GMAF S100 Robot 23

12 JR3 Force Sensor 2513 Torque Test Setup 3014 Operator Test Data #1 3115 Operator Test Data #2 3716-24 Individual Torque vs. Gage Size (Aluminum) 33-4125-33 Individual Torque vs. Gage Size (Steel) 42-5034-35 Average (Steel-Aluminum) 51-5216 Torque Threshold Guideline 5337 4th Axis with Robotic Gripper 5438 Part/Gripper/Pallet Cross Reference 5639 Test Part/Pallet 5740 Test Part/Pallet 5841 Test Part/Pallet 5942 EOAT Cross Section View 6543 a,b,c Thread Inspection Sequence 66-6844 Labortory Layout 6945 4th Axis with Tooling Plate 7246 a,b, c, d As-is Idef Model 73-76

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1 1.0 € INTRORICTTON

This report- -f-he- - presents program efforts9durin the ri-d ti-Ja-nuary--33 1987 in support

of Phase II of the Industrial Technology Modernization (ITM)program sponsored by General Dynamics%.under contract No. F33657-82-C-2034.' Phase II is dedicated to demonstration of enablingI technologies for the factory modernization projects. ... ' , *

.1 ACKGROUND

A Phase I Technology modernization program was performed at Delcofrom October 1982 through September 1983. Objectives were toconduct an analysis of manufacturing processes and facilities toI be used in th' production of DOD deliverable hardware, and toevaluate and identify new technology modernization projects thatcould, if implemented, significantly reduce deliverable unitcosts. Both direct (i.e, Manufacturing Operations) activities andindirect (i.e., Manufacturing Management) activities wereconsidered.I

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2.0 ORIECTIVE .

As a result of the Phase t efforts conducted under the Tech ModProgram, Delco proposed to,'General Dynamics a continuation of theManufacturing Modernizatio Proaram, under Phase II, A MechanicalInspection Cell (Project 12) This project deals with the designof a work cell to automatically inspect mechanical components as areceiving inspection operation. Specific functions of this workcell were dimensional inspection, thread aaqinq, and material

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3.0 A COMPARISON OF PRESENT AND PROPOSED METHODG

3.1 PRESENT

The present method of inspecting mechanical components is tomanually verify each dimension using vernier calipers. Thosedimensions that can not be checked with vernier calipers arechecked using the appropriate gaging, such as threads/thread gage,radiuses/radius gage, center-to-centers distances ofholes/coordinated measuring machine, and depths/depth micrometers.

The parts examined are primarily cast or machined aluminum andrange in size from 0.375 inches to 22 inches. The Parts are

I primarily used in military products and require thoroughinspection. See Figure 1 for typical mechanical parts. A nre-selected quantity of parts from a manufacturing lot are subjectedto first article examinations. These first article carts are 100%inspected for part-to-drawing conformance. The remainder of theparts from the manufacturing lot are checked for predetermineddimensions, specifically those dimensions critical to the functionor assembly of the parts or those dimensions frequentiy not heldduring the machining operations. An inspection record is main-tained for each part to permit quality trend reporting.

3.2 PROPOSED

3.2.1The proposed method of dimensional inspection is to use a semi-automatic vision sysstem whereby all part dimensions would bechecked using vision system principles. This method utilizes anX-Y servo-motor-driven table with a camera mounted in the Z-axis.Since the X and Y dimensions are in the same plane, the Planardimensinrn is establc!hed by he distance the i-able travels plusthe camera's interpretation of the edge of the surface featurebeing inspected. A built-in algorithm establishes the planardimension that has been checked. The dimension along the Z-axis

is a function of the focal length of the camera. One plane isestablished as the zero or reference point, with the depth being anew plane requiring a new focal length. The distancp the fixedfocal length camera moves along a Z axis determines the Z dimen-sion of the part feature being examined.

3.2.2 The proposed method of thread inspection will use a robotic systemequipped with an end effector capable of driving a Go or No-Gogage into a tapped hole while monitoring torque. When a predeter-mined torque threshold, based on thread size, is attained thesystem will discontinue driving the gage into the part. Duringgage extraction revolutions will be counted allowing the depth ofthe threaded hole to be determined. The end effector would alsocontain a tool changer to accomodate differences between Go andNo-Go gages.

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3.2.3 T- maximize the Workcell's throughput a material handling systemwould also be utilized. This. system would be comprised of a robotand the necessary quick change end-effectors to handle the varietyof parts the workcell would see.

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4.0 PROPOSED TECHNICAL APPROACH

Based on an initial mechanical inspection cell definition, ex-tpected results from such a system, and information gathered on

existing inspection equipment identified during Phase I of the ITMProgram, the following scenario was generated to further define afinal system's approach and design criteria. A concept layout ofthe inspection cell and system breakdown are shown in Figures 2and 3.

4.1 INSPECTION CELL DEFTNITTON

The inspection cell shall consist of: 1) 3-dimensional visionsystem station to be used for measuring features of a part; 2) arobot station that would utilize modified go/no-go thread gages toinspect tapped holes; 3) a system supervisory computer to control,transfer, and store data; 4) a material handling robot system toautomatically load and unload each station as required; and 5) asafety system.

The inspection cell shall have a working envelope (X,Y, Z) of 18 x24 x 6 inches and a maximum inspected part weight of 12 lbs.

Part fixturing requirements will want to be semi-dedicated, allow-ing for common usage between several classes of Parts to beinspected. All fixturing will also be manually loaded andunloaded.

4.1.1 DIMENSTONAL MEASUREMENT STATTON

The 3-dimensional vision system chosen is a View Engineering Model1200. It consists of: 1) A System Control Unit (SCU), 2) A DataGathering Unit (DGU), and 3) part position monitor.

4.1.1.1 The SCU handles overall control of the vision measurement system.It includes a TV monitor, keyboard, two floppy disk drives (638Keach), one 10-megabyte hard disk, and an 8086/8087 16 bit CPU.Data is downloaded to it from the primary computer and suppliedsoftware along with built-in algorithms instruct the DGU to per-form all required inspections.

4.1.1.2 The DGU accomplishes the actual data measurement. It utilizes ahigh resolution video camera system mounted in the Z-Axis and anX-Y servo-motor-driven table onto which the part to be inspectedis mounted. Since the X and Y dimensions are in the same plane,the planar dimension is established by the distance the tabletravels plus the camera's interpretation of the edge of the sur-face feature being inspected. A built-in algorithm establishesthe planar dimension that has been checked. The dimension alongthe Z-axis is a function of the focal length of the camera. One

I plane is established as the zero or reference point, with the

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4.1.2 THREADED HOLE INSPECTION

Threaded hole inspection will be accompllished using roboticthread gaging, This system consists of a robot, robot controller,and end effector tooling that will inspect threaded holes (#2through 1/4 inch) for correct size, class and thread length, perFED-STD-H28/6.

4.1.2.1 End effector tooling (see Figure 4) contains a motorized spindlecapable of driving the thread gage, a rotational measurementdevice (Resolver/Potentiometer), a 6-axis force sensor containinga microprocessor capable of torque monitoring and force feedbackto facilitate fine robot positioning, and thread gage toolingcapable of automatic tool changing.

4.1.2.2 Alignment of the end effector tooling to the tapped hole shall beadequate enough to guarantee that 95k of any torque monitored willrepresent true torque values and not be due to side loading.

4.1.3 SYSTEM SUPERVISORY COMPUTER (SSC)

The SSC handles overall cell control. It provides for operatoroverride, processes data, acts as a functional/maintenance/safetymonitor, and stores and controls all internal and external dataflow. The computer's inspection data base would be manuallypreprogrammed and upon completion of an inspection sequence itwould store all results and print out any inspections reports asinstructed.

4.1.4 MATFRIAL HANDLING ROBOT

A material handling robot system will be utilized for parts trans-fer between the in/out station, dimensional inspection, and threadinspection stations. This robot system will also be required toact as a parts platform for the thread inspection station minimiz-ing the requirement for dedicated worksurface tooling.

4.1.5 SAFETY SYSTEM

The inspection cell shall have a safety system that will automati-cally shut down all operations in areas accessible by operatingrobots when entered by any person.

4.2 OPERATIONAL INSPECTION SEOUENCING

During the initial development phase it will be assumed that allpart fixturing will be manually loaded into each station of theinspection cell. Typical sequence of events for a part requiringboth dimensional and tapped hole inspection is summarized belowand presented in the flow charts of Figure 5,6 and 7.

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Inspection sequence:

4.2.1 Primary computer is loaded with a program (via CAD or manually).

4.2.2 Application program required for dimensional inspection isdownloaded to the dimensional inspection station System ControlUnit. The part is transferred to the X-Y platform part fixturingby the material handling robot.

4.2.3 The dimensional inspection sequence is started.

4.2.4 Prompting of the material handling robot by the computer will bedesired if part orientation changes are required.

4.2.5 After inspection of the part is complete, data is transferred backto the primary computer. Actual measurements, not desiredmeasurements, for center-to-center distances of tapped holes maybe transferred to the thread inspection station controller.(Actual dimensions will minimize control loop feedbackrequirements.)

4.2.6 Parts are then transferred from the dimensional inspection stationand refixtured onto the thread inspection working surface (or heldby material handling robot).

4.2.7 The tapped hole inspection sequence is started.

4.2.8 Robot will select proper thread gage per downloaded applicationprogram.

4.2.9 Robot will center tooling with tapped hole. Robot may utilizeactual measured values from the dimensional station to minimizepositional corrections. Located on the hand of the robot is a 6-axis force sensor which in addition to measuring torque can sensethe required compliance (see Figure 4 insert) to reposition therobot. This will minimize any binding experienced by the toolingand thereby give truer torque measurements.

4.2.10 When centering of the thread gaging and tapped hole is ac-complished, the drive motor will be commanded to reverse rotatefor 1.5 turns. This will insure that the gage and the part beinginspected are not cross-threaded.

4.2.11 Thread gaging beings. Gage is driven into part while torque ismonitored.

4.2.12 Should gage meet resistance (increase torque), motor would becommanded to stop. Depending on whether the gaging is "go" or "no-go" a decision would have to be made. If a "go" gage is used thesystem would reverse and count the number of revolutions it takesto extract the tooling, thus determining the thread lenqth. If a"no-go" gage is used, it should meet resistance by the third entryrevolution. (The system will be required to inspect eight stan-dard and helicoil thread sizes per part E#2,#4,#6,#8, 2 @ #10, 2

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4.2.13 Material handling robot prompting by the controller will bedesired if part orientation changes are required.

4.2.14 After completion of a particular gage size inspection sequence thecontroleer will command a tool change and the inspection processcontinues until the part is fully inspected.

4.2.15 After part inspection is complete, all data is transferred fromthe controller to the primary computer, and an inspection reportprintout for the part is then made.

4.3 SYSTEM OPTIONS

The operational sequence previously presented assumes a part to be100% inspected for both dimensions and tapped holes. The oc-curance may arise where only a dimensional inspection or tappedhole inspection will be required, or only a percentage of thatoperation will want to be executed. For this reason partdimensions/tapped holes will want to be coded or characterized soas to facilitate this type of inspection procedure.

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5.0 EoUIPMENT SELECTTON

Based on the proposed technical approach equipment requirementsof euipent erenecssar toiniiatethepro e.uineetwere next addressed. It was determined that four specific piecesof equipment were necessary to initiate the project. Since afinal cell configuration would be dependent upon testing of thisequipment, and integration of any hardware purchased into thefinal concept was desireable, all hardware was required to meetthe most stringent specifications. These initial equipment re-quirements were:

1. Dimensional Inspection Machine

2. Robot

3. Six Axis Force Sensor

4. System Supervisory Computer

5.1 DIMENSIONAL INSPECTION MACHINE

At the time this survey was performed only two vendors weremanufacturing equipment meeting the requirements of the project:

Rank Videometrics411 Jarvis Ave.Des PlainesIll. 60018312-297-7720

View Engineering1650 N. Voyager Ave.Simi Valley, Ca. 93063805-522-8439

Primary considerations regarding equipment selection were:

1. Operation Envelope: 18 x 18 x 6 (X,Y, Z)2. Menu Driven3. Accuracy - ± .0025 inches (All Axes)4. Supplier Support5. Price6. Peripheral Options

Based on available information and vendor communications a matrixcomparing options and support was generated. See Figure 8. Afinal decision to select the View Engineering Model 1200 non-contact 3-dimensional measuring system was justified primarilly onits thermal compensation, maturity of the product line (4 years)and the fact that GM is a partial owner in the company. It wasfelt that View's relationship with GM would gain additionalleverage should modification of the equipment be required.

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52 ROBOT

At the time this survey was performed only two vendors manufac-tured a robot with an advanced controller design: GMF Robotics andADEPT. Unlike other manufacturers controllers these featuredself-diagnostics, full program and edit capability, menu drivensoftware, analog and digital I/O capability, and high levelprogramming languages. At the time the robot selection was beingaddressed there existed two applilcations. One for materialhandling, and the second for thread inspection. ADEPT'S designlent itself only to thread inspection while GMF'S product linecould support both. (ADEPT built only one robot at that time.)

If thread inspection were to become a reality it would be desire-able to have common equipment. For this reason GMF'S S-100 robotand Karel controller were selected. This robot was designed foruse as a material handling platform. However, for developmentpurposes it could be used on an interim basis for determining ifthread inspection end-of-arm-tooling was robot compatible.

5.3 SIX-AXIS FORCE SENSOR

At the time this survey was performed only three vendors weremanufacturing six-axis force sensors. These were:

Barry Wright Corp.700 Pleasant St.WatertownMass. 02172Model FS6-120A

Lord Corp.407 Gregson Dr.CaryN. Carolina 27511919-469-2500Model F/T-15/50

JR INC22 Harter Ave. #13WoodlandCA. 95695Model VFS-3A15

All these devices are similar in construction and are specificallymade for robctic applications. They are based on strain technol-ogy and allow the user to monitor force and torque reactions in +or - X,Y and Z directions, hence six axes. Generally all unitsare available in varying levels of sensitivity, however for ourapplication, due to the delicate nature of thread gaging, aresolution of .05 in -oz in torque was desired. At the time allvendors were advertising a .15 - .20 in-oz resolution. Anotherfeature absolutely required for laboratory testing was an analog

18

output capability. Ater reviewing these requirements with sun-pliers, all felt they could fine tune an otf-the-sheif unit tomeet the torque sensitivity requirements. However, only JR3 couldsupply the analog output at no extra charge. For this reason theJR3 force/torque sensing system was selected.

5.4 SYSTEM SUPERVISORY COMPUTER (SSC)

Selection of the SSC was facilitated through use of an evaluationmatrix, which was designed to aid in the comparison of severalcandidate systems. The selection issues used for comparisonincluded:

- system bus standard- system CPU type

- type of system memory- operation systems supported- available programming languages- data communications interfaces- DSO experience with candidate system- type and availability of training- availability of maintenance support- price- vendor's ability to deliver- overall match with project needs

The vendors considered were:

- Digital Equipment Corporation- Hewlett Packard- Intel- Motorola- International Business Machines

Additionally, it was required that the hardware and softwaresolutions be implemented by using of-the-shelf products. Anintangible factor, best described "as the perceived abililty andwillingness of the vendor" to help satisfy project goalsthroughout the life of the project, also entered into the finalselection. The system selected was the Intel 310 microcomputer.

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6.0 EOUIPMENT SPECIFICATIONS

6.1 DTMENSIONAL INSPECTION MACHINE

3 The View Engineering Model 1200 (Figure 9) is a 3 - dimensional- non-contact measuring system. It has a working envelope of 18 x

24 x 6 (X,Y, Z) inches in addition to a fourth rotational axisthat was orginally designed to mount and turn symetricallymanufactured (Lathed) parts. The system is delivered with four

5 lenses (16mm, 38mm,50mm,75mm) allowing the user to select anoperating accuracy depending on the application involved. Usingthe system's most accurate lens a system accuracy of .0004 inches

- in X,Y and Z axes can be attained. See Figure 10 for other avail-able accuracy specifications.

The system utilizes an X - Y servo-motor-driven table with acamera mounted in the Z-axis. Since the X and Y dimensions are inthe same plane, the planar dimension is established by the dis-tance the table travels plus the camera's interpretation of theedge of the surface feature being inspected. A built-in algorithmestablishes the planar dimension that has been checked. Thedimension along the Z-axis is a function of the focal length ofthe camera. One plane is established as the zero or referencepoint, with the depth being a new plane requiring a new focallength. The distance the fixed focal length camera moves along aZ axis determines the*Z dimension of the part feature beingexamined. Lens selection is determined by part feature tolerancesto be inspected. Because each lens has a different field-of-view(.01 to .20 in.) and the system is preprogrammed to move to anominal location to acquire an image (edge of feature), it isnecessary to match the field-of-view with the allowable partvariance (due to part tolerance). Search routines do exist, to alimited degree, to "look" for the feature outside the field-of-view. Since the vast majority of mechanical parts produced atDelco are more critically toleranced, all testing performed usedthe most accurate lens (16mm.)

S6.2 ROBOT

The GMF S100 Robot selected is a six-axis anthropomorphic devicemanufactured for material handling and medium accuracy assemblyapplications (see Figure 11 for Illustration: ManufacturersSpecifications). It's unique human-like configuration allows itto operate in both spherical and cartesian coordinate systems.Optional equipment included a 16 channel A/D converter card foruse in digitizing force sensing electronics.

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6.3 SIX-AXIS FORCE SENSOR

The JR3 Force Sensor selected (Model UFS-3A15, see Figure 12) wasa specially modified off-the-shelf device. Modifications made atthe factory enhanced the system's resolution from 0.15 in-oz to.05 in-oz. otherwise, the system's specifications are as follows:

- JR3 monolithic six-degree-of-freedom force sensor- sensor cable (connects JR3 sensor to JR3 electronicsenclosure)- JR3 Intelligent Support System (JR3 sensor to JR3electronics enclosure which contains):- signal conditioning board- data acquisition board- processsor board

Foil strain gages on the JR3 sensor body are excited by voltagethrough the sensor cable from the electronics enclosure.Millivolt analog signals from the sensor are carried back to theelectronics enclosure via the sensor cable. The sensor cable'sfoil shielding is driven at a guard voltage to increase noiserejection.

The JR3 signal conditioning board amplifies and filters the raw

analog signals, then transmits them to the JR3data acquisitionboard where the signals are digitized (12 bit A/D1. Digital data

is then transmitted to the JR3 processor board, processed (crosssensitivity removal, digital filtering, load envelope monitoring,tare weight removal, etc.) and made available for output. Theprocesssor board also watches for, and acts upon, input commands.The six channels of un-decoupled analog signals are also outputthrough a nine-pin port.

Onboard shunt resistors combined with full scalechecking/calibration software offer automatic drift compensationupon the receipt of the proper command.

The JR3 sensor requires the power supplies listed below. Each isshown with the particular portion of the electronics it powers.

+5V 2A digital power (microprocessor, etc)+15V 300mA analog power (bridge amplifiers,

reference voltages, etc.)-15V 300mA analog power+12V 75mA serial communication, shunt relays-12V 75mA serial communication

The six channels of analog outputs are in the +10 volt range with+10 volts at +100% of full scale load and -10 volts at -100% offull scale load. Within a certain range, the user may set thedesired full scale values via gain adjust. Setting the full scale

24

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for larger loads allows the user to read overloads; setting thefull scale for smaller loads enhances resolution.

The discrete 1/0 port consists of:- eight discrete bits of input: four are used to enable load

envelopes; one triggers a soft reset; one resets the offsets;and one is not currently used.

- eight bits of output - seven user-definable flags for loadenvelope trip points and error flag plus the safety strobe.

- hard reset - hardware reset of processor.- digital ground.

Two RS232 serial ports are provided (port A & B) which can be usedfor inputting commands, data transmission, error monitoring,threshold monitoring, etc. Data format through each serial portis controlled by commands entered through that port. The onlydifference between ports A & B is that port B will begin a baudrate detection routine upon receipt of a "break" signal; port Aignores the "break" signal. Default serial communicationparameters (from factory) on powerup are: 9600 baud, 8 data bits,no parity, 1 stop bit.

6.4 SYSTEM SUPERVTSORY COMPUTER (SSC)

6.4.1 SSC HARDWARE

The system selected to function as the system supervisory computeris an Intel system 310 microcomputer. Its characteristicsinclude:

- a seven slot card cage, suitable for addition ofvarious data communications controller boards

- an 80286 based, 16 bit processor- multi-user and multi-tasking capability- priority interrupt logic- hardware system clock- 1 megabyte of RAM storaqe- 1 parallel port connector- 2 serial port connectors- 1 flexible 5-1/4 inch double sided, double density

disk drive- 1 40 megabyte Winchester disk drive

The Intel system 310 has proven to be compatible with all SSCoriented project requirements.

* 6.4.2 SSC SOFTWARE

The operating system selected was Intel's iRMX 86. It's majorfeatures include:

- real-time capability- concurrent running of multiple tasks- priority-based scheduling- interrupt-driven processing- device-independent I/O capability

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The iRMX 86 operating system is configurable through use of a

supplied interactive configuration utility program. Various

programming languages were available, and PL/M-86 was selected for

project use. PL/M-86 is a high-level, block structured language

which has many useful features.

27

7.0 ENABLING TECHNOLOGY DEVELOPMENT

This section of the report will primarilly address testing asrelated to thread inspection and material handling. Because thevision system used for dimensional inspection was an off-the-shelftechnology no enabling technology testing was required in thisarea. Some material handling concepts were tested as related togroup technology and will be discussed in lesser detail. Theresults of these experiments would be used to further solidify theinspection cell's final configuration.

7.1 THREAD INSPECTION (INTERNAL)

7.1.1 BACKGROUND

Gaging of internal screw threads is the process of investigatingthe extent to which they conform dimensionally to prescribedlimits of size. This inspection process is accomplished using goand no go gaging that is physically threaded into the productthread.

The maximum-material-limit, or go gage, verifies the extent of thetolerance as applied to a specific thread in the direction of thelimit of maximum material and represents the minimum limit ofinternal threads. The ideal go gage is a threaded counterpart ofthe internal thread, made exactly to its prescribed dimensions.These gages most nearly duplicate the assembly conditions ofthreads.

The minimum-material-limit gages, or no go, control the extent ofthe tolerance in the direction of the maximum limit of internalthreads. Again it is a threaded counterpart of the internalthread, however does not represent assembly conditions.

The application and maintenance of thread gaging is defined inFED-STD-H28. In short the usage of thread gaging to verifyproduct conformance is very subjective. Because it is not practi-cal, or possible, to control nor limit the torque applied byoperators, or even that used by a specific operator at varioustimes and under varying conditions, the following standard prac-tice has been adopted with respect to permissible gage entry:

Go gages must completely enter the product internal threadprovided a definite drag from contact with the productmaterial does not result.

No Go Gages acceptability is applied to the product internalthread if it does not enter, or if a definite drag fromcontact with the product material results on or before thethird turn of entry. Obviously the term "Definite Drag" issubjective and will vary from operator to operator.

2 f.

7.1.2 TESTING

In order to develop an automated thread inspection process, it wasnecessary to determine quantitatively what the "Definite Drag"limit would be for each thread size. Using internally threaded

samples (steel and aluminum) mounted to the JR3 force/momentsensor, inspection operators normally assigned thread inspectiontasks were tested. Each operator "inspected" three samples eachof 2-56, 4-40, 6-32, 8-32, 10-32, 1/4-20 and 1/4-28 size threads(see Figure 13). Class III threads were chosen to obtain a worstcase situation and all testing was conducted with go gaging only.It was assumed that definite drag limits would be independent ofgage type. During each sample test. running torques as well as

stall torques were obtained using the JR3 sensor analog output anda strip chart recorder. In all 27 samples for each thread sizeand material type were tested. Running torque data from a typicaltest run is shown in Figure 14 and variations in technique areapparent. Some operators continually turn the gage with bothhands while others use only one hand. This can be observed bycomparing running torque applitude variations. It is also ap-parent from the data (Figure 15) that stall torque (Definite Drag)differences did exist between operators. Averaged Torque valuesvs. gage size are represented in Figures 16 thru 24 for aluminumand Figures 25 thru 33 for steel, for each of the participatingoperators. 'A summary of these curves is presented in Figures 34and 35. From this data desireable torque thresholds required torautomating Go/No Go Gaging proceedures were derived. This data ispresented in Figure 36 and served as a guideline throughout thethread inspection end-of-arm-tooling design phase.

7.2 MATERIAL HANDLING

Efforts concentrated on designing and testing end-of-arm tooling(EDAT) concepts capable of holding and/or transporting families ofsimilar parts from input stations to the View 1200 where dimen-sional inspection would occur. The object was to identifyconcepts and designs that would minimize tooling requirementsprimarilly at the View 1200 thereby further increasing the costpayback of the proposed automated system.

As mentioned earlier the View 1200 is equipped with a fourthrotational axis. Though it was intended by the manufacturer tohold and orient lathed parts, the concept of adding a roboticgripper capable of fixturing a part seemed a more desireablesolution. (See Figure 37). To successfully implement the transportand fixturing concept on an open-loop basis (no feedback) twoconditions had to be met. First the gripper must be capable ofhandling a family of parts, not a unique part, and second it musttransport them to the View 1200 with sufficient accuracy to placethe part within the vision systems field of view (+.005).

29

O TORQUE THRESHOLD TEST SETUP

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7.2.1 DESIGNIThree parts were chosen from Delco's F-16 Product Line as can-didate sample parts for end effector development. (Bracket,7561002; panel, 7565015; plate, 7566938; See Attached). TheseIcomponents were very representative of large volume hardwarerequiring thorough inspection at the time of selection. Figure 38cross references gripper and part pallet designs necessary toaccomodate the above sample parts. Figures 39 thru 41 illustratepallet concepts.

In short, gripper designs were kept simple. A parallel jaw grip-per (P/N FLAT-PG-284) for both robot and fourth axis werepurchased from Mechanotron, Minneapolis, Mn. They were thenmodified with rack and pinion gearing (see drawing No. SK005340)to insure each gripper jaw acted synchronously. Gripper fingerswere fully adjustable to accomodate various width parts by incor-porating a sliding dovetail mount onto the gripper jaw. Range ofmotion was controlled by installing adjustable stops into the rackand pinion mechanism. Typical clearances between sample parts andgripper fingers, when open, ranged from .10 - .15 inches.

7.2.2 TESTING

During initial testing it was quickly found that all sample partsrequired accurate fixturing within their pallets in order topredictively place them iiLo the fourth axis gripper system. Dueto inaccuracies of robot motion this caused part/pallet binding asthey were removed and collisions during pallet loading afterinspection was complete.

To eliminate these effects parts were loaded loosely into theirpallets. The robot gripper would then aquire a part and transportit to a staging area which consisted of nothing more than agranite surface plate. At the staging plate the robot wouldorient an edge of the part parallel to the staging plate within.005 inches, release, and then regrip it. Much like squaring offa deck of cards. The robot would then reorient the sample part toanother known edge and again release and regrip. After repeatingthis cycle twice it was found that the robot could place thesample part within the fourth axis gripper with sufficient ac-curacy without requiring the use of search routines by the visionsystem. Based on this testing we attained the confidence levelnecessary to implement a material handling system for the View1200 inspection process.

55

II!

PRODUCT/GRIPPER/PALLETPART NO. CROSS REFERENCE

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80 PROOF-OF-CONCEPT DESIGN

U 8.1 STATEMENT OF WORK DEFINITION

Based on the successful enabling technology development and test-ing it was determined that the automated mechanical inspectioncell concept employing both dimensional and robotic thread inspec-tion was technically feasible. The next step was to identify theIi"[ specifications and standards required to construct a complete

cell. Though the intent at this time was to develop only thosesubsystems that would represent a proof-of-concept design, it wasfelt that an overview of a total cell concept was necessary. Formthe proof-of-concept cell additional subsystems and capabilitiesneed only be added minimizing any potential redesign. Attached isa Statement of Work (E41-001) identifying the final cell design.

8.2 SYSTEM SUPERVISORY COMPUTER (SSC) CONTROL DESIGN

The primary function of the control program is to cause the execu-tion of a series of View 1200 programs and Karel programs to takeplace in a specific sequence. The result of executing theseprograms is the inspection of the selected part (Attached is anexample of A typical inspection report) according to the stepscontained in these 'station programs'.

The names of programs to be executed at the stations are stored,in sequence of execution, in a file on disk. Through a series ofmenus (attached) presented on the system console, the operatormakes selections which ultimately result in the use of the ap-propriate list of station programs. These programs are downloadedto and executed at the appropriate station, and results of theinspection process are uploaded to the SSC and stored on disk.When the end of a station program is sensed, the next program is

5 processed in a similar fashion. This process continues until thelist of station programs is exhausted. At this point, thespecified inspection is complete and the operator is once againpresented with the initial menu which began the process justdescribed.

The station programs to be executed can reside on either mountableflexible disk, or permanently mounted Winchester disk. Theoperator specifies their location as part of the menu orienteddialog prior to part inspection.

The operator is kept abreast of inspection progress through aseries of informational and explanatory messages. In certaincases, when an operator selection error has been detected by thecontrol program, such messages are followed by repetition of themenu selection or prompt requiring correction.

8.2.1 EXCHANGING MESSAGES WITH THE VIEW 1200

Station programs and inspection results are transferred betweenthe View 1200 and SSC through control program implementation of a

60

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message exchange protocol compatible with the protocol supplisd aspart of the View 1200. Capabilities include transfer of stationprograms in both directions, receipt of inspection results at theSSC and transmission of control commands to the View 1200.

8.2.2 EXCHANGING MESSAGES WITH THE KAREL CONTROLLER

Station programs and inspection results are transferred betweenthe Karel and the SSC through the use ot Digital DataCommunications Message Protocol (DDCMP) and Manufacturing MessageFormat Specification (MMFS). DDCMP is widely used, and wasdeveloped by Digital Equipment Corporation. MMFS is part of theManufacturing Automation Protocol (MAP) originated by GeneralMotors. The Karel provides a subset of the full MMFS; it and theportion implemented for use on the SSC provide sufficientcapability for transfer of station programs, transmission ofinspection results and SSC control of the Karel.

6

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8.3 THREAD INSPECTTON EOAT DESTGN

The thread Inspection End-of-Arm-Tooling is comprised of: 1) aMotorized Drive System with positional encoding, 2) a gage holdingmechanism with built in compliance, 3) Control Electronics, and 4)Control Software. The system was designed to operate on commandfrom a GMF Karel Controller, however, is fully adaptable to any

other robotic controller provided it has discrete and RS232 withread/write I/O capability.

8.3.1 MECHANICAL HARDWARE

The mechanical end-of-arm-tooling consists of two basic units (seeFigure 42). The upper drive section contains a 20 inch-oz DC

Servomotor, 1000 count encoder, and 40 conductor slip ring. TheAencoder is used for speed control and positional feedback to a

motor controller while the slip ring supplies power and sensoraccess to the rotating tool section. The lower tool section con-sists of a telescoping gage tip, bellows joint for lateralcompliance, 12 VDC Solenoid drive to extend the tool tip, and ahome sensor.

When the gage is positioned over the tapped hole the solenoiddrive extends the gage off it's seat and mildly preloads itagainst the tapped hole opening. This action also allows tae gageto improve its oientation laterially over the tapped hole due tothe bellows linkage above. As the gage is drawn into the hole,solenoid power is no longer required and it is de-energized. Whenthe programmed threshold torque, specific to the thread size, isattained rotational motion is stopped. A counter within the motorcontroller is zeroed and counter-rotation, to extract the gage, isstarted. As the gage is extracted the robot moves in a positivedirection .25 inches at the same exit feed-rate as the gage. Thisallows the gage to snap out of the tapped hole into its homeposition. When the sensor output is detected motor motion isstopped and a total exit revolution count can be determined.Knowing the thread pitch, the depth of the tapped hole can becalculated.

By trial and error it was determined that the robot could positionthe gage over the hole within t .015 inches without any noticeableeffects on torque thresholding. This allows usage of this EOAT onjust about any robot without effecting its performance and allowedus to delete the requirement of closing a force loop with therobot in X and Y directions to guarantee gage-to-threaded holealignment.

62

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During the initial testing phase we asssumed that threshold torquemeasurements would have to be monitored by the force/momentsensor. However, it soon became apparent that due to mechanicalnoise contributed by the robot that the sensor could not resolvethe required torques. Attempts were made to mount the sensor inthe rotating frame as well as the stationary frame to no avail.It was then determined that by scaling motor current, thresholdtorques could be measured at their desired resolution. The systemby which this was achieved will be discussed in greater detail inthe following section.

8.3.2 CONTROL ELECTRONICS/-SOFTWARE (KAREL)

The controlling elements of the thread inspection EOAT include amotor controller, digital torque detection electronics, and theKarel Controller.

Operationally the system has two modest Calibration and Running.During the Running Mode Programming specific to hardware requiringinspection positions the EOAT over the first threaded hole to begaged. At this time a standardized subroutine (Attached) isrecalled from memory and commands are downloaded via R'_'3 anddiscrete I/0 from the Karel Controller to the Motor Controller andTorque Detection Electronics, respectively.

The Motor Controller requires information defining direction otrotation and maximum number of entry revolutions. The TorqueDetection Electronics receives an 8-bit discre'e signal definingthe threshold at which gage rotation stops. After setup informa-tion is received a 'start' command is sent to motor controller.When the Torque Threshold, specific to thread size, is attained adiscrete signal is returned to the Karel whereupon it transmits a"stop motion" command to the Motor Controller. At this time, therotational counter register in the Motor Controller is also set tozero. This allows exit revolutions to be counted duringextraction. When the gage exits the tapped hole the home sensorwithin the EQAT acts similarily to the thresholding circuit. Itnotifies the Karel Controller that a "gtov motion" command needsto be transmitted to the Motor Controller.

As indicated earlier, torque is determined by scaling motorcurrent. To account for motor current required to drive the EOAT(without thread engagement) a calibration mode was added. Duringsystem initialization at power up, software (attached) at theKarel commands the motor to rotate ten revolutions. During thistime current is monitored, averaged, digitized and stored intomemory located on the torque detection electronics board. Duringthe remainder of the "work shift" this value is added to thedesired torque threshold downloaded from the karel thereby compen-sating the system for inherent frictional effects.

Also, during calibration user specific parameters required by themotor controller are set. For our application these included

63

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motor speed, acceleration, pole and zero locations (contol feed-back parameters) and operational mode(velocity, position ortorque). This application required the motor to work in a velocitymode. Reference figures 43 A,B,C for a block diagram repre-sentation of the above described process.

8.4 LABORATORY LAYOUT

The laboratory layout used during the Proof-of-Concept phase isshown in Figure 44. Robot location was chosen to facilitatematerial handling concept tests with the View 1200.

64

EOAT CROSS SECTION VIEW

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9.0 AREAS FOR FJTURE CONCERN/DEVELOPMENT

To complete the thread inspection system, gaging quick-changeconcepts in addition to drive system redesigns need to beaddressed. Presently, Go and No Go Gaging is mechanically fas-tened to the end-of-arm-tooling. Conversion to a quick changetooling concept requires an electro-magnetic quick design toreplace the existing tool holder. Regarding drive systemredesign, the existing assembly utilized design configurations

originally intended to meet a broad range of test requirements orperformance standards. Selection of the 40 conductor slip ringwas based on unknown electronics that potentially may have beenplaced in the rotating frame. A redesigned assembly would need nomore than 7 conductors (3 for home sensor, 2 for solenoid and 2

i for proposed electromagnetics). The designed bearing configurationutilizes a duplexed bearing set in the lower housing section and asingle bearing in the upper. Again, due to unknown payloads atthe time of design an overly rigid structure was concepted.Redesign would eliminate one bearing from the lower section andreconfigure the bearing style to a spaced duplex set.

The benefits of the drive system redesign would decrease the freerunning torque. This torque is approximately .7 - .9 in-oz. andis presently compensated for during the claibration mode.Depending of the final design and subsequent testing it may bepossible to eliminate the calibration mode all together.

IIIUIII!1|7

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10.0 FTNAL DESTGN

At approximately halfway through the proof-of-concept developmenteffort it became apparent that thread inspection would not beutilized in a production capacity as initially expected. Programsinvolving large volumes of "bare" tapped holes have been completedand anticipated programs did not materialize. The bulk of Delco'sfuture programs involving mechanical assemblies have been out-sourced and rely heavily on source inspection. Also, thoseassemblies that will be fabricaed in house utilize locking insertsfor which this inspection cell was not designed. For thesereasons the study effort regarding thread inspection was com-pleted, however final designs to implement this system on aproduction basis were not pursued. The original intended user ofthe inspection cell was the Delco Milwaukee Manufacturing Group.However, due to product and inspection outsourcing the installa-tion location has changed to Delco Systems in Goleta.

The final system configuration also reverted to the stand aloneView 1200 without material handling and thread inspection. TheView 1200 Fourth Rotational Axis was modified to include a toolingplate onto which adapter plates product-specific could be mounted(see Figure 45). This minimized dedicated tooling while allowingmultiple part orientations.

Due to inherent limitations of the View 1200 it will supportinspection activities normally assigned to our resident coordinatemeasuring machine, not replace it. These limitations are basi-cally due to programming vs. Quantity tradeoffs ana physicallimitations of the equipment (ie; it s ability to place the lensat the required location to aquire an image without interferingwith a part feature such as a web or wall). Because this equipm-ent in effect becomes support to the existing receiving inspectionfunction no chanqe to the IDEF Model is realized. The as-is IDEFModel is shown in Figure 46.

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TITLE S MNMECHANICAL INSPECTION CELL - ITM PROJECT 12 E41-001 AM

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PREPARED BYD A Eqk SHEET /OF 1',tNT T -5365 7-80)-

APPROVED BY I CONTRACT r 3)- -

NO.G-0007

APPROVED BY CODE IDENT NO 13160

AMENDMENT LCG

AMEND DESCRIPTION AUTHORITY DATE APVD

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II

I TABLE OF CONTENTS

1.0 GENERAL

1.1 PURPOSE1.2 DOCUMENTS

1 2.0 DESCRIPTION OF ARTICLES AND SERVICES TO BE FURNISHED2.1 GENERAL

2.1.1 SYSTEMS OBJECTIVES2.1.2 INSPECTION CELL SUBSYSTEM DEFINITION2.1.3 SEQUENCE OF OPERATIONS2.1.4 SYSTEM CYCLE TIME AND THROUGHPUT2.1.5 EXPANSION CAPABILITY

2.2 OPERATING SYSTEM SOFTWARE

2.2.1 GENERAL REQUIREMENTS2.2.2 SYSTEM INITIALIZATION2.2.3 MEASUREMENT OF CONFIGURATION2.2.4 SYSTEM CALIBRATION2.2.5 MEASUREENT DATA STORAGE2.2.6 INSPECTION REPORTS

2.3 SYSTEM HARDARE

2.3.1 GEERAL REOUIREMENTS2.3.2 ENVIRONMENTAL REQUIRMETS

'II

t Pace 2

1.0 SCOPE

1.1 PURPOSE

This specification outlines equipment requirements for an automated mechani-cal inspection cell to be used in a Receiving and Inspection department (seeFigure 1). This inspection cell shall utilize machine vision and robotictechnologies to accomplish this task.

1.2 DOCUMENTS

The following government standards, specifications, and regulations, issuedin effect on the date of this contract, or as otherwise stated herein, shallform a part of this statement of work to the extent specified.

Sound Level Specification GM spec SLl.0Robotic Safety Standards Section 28Basic Electrical Standard ESIScrew Thread Standard FED-STD-428/6GM Manufacturing Automation Protocol MAPEngineering Exhibit EE-75-S-989

2.0 DSCRIPTION OF ARTICLES AND SERVICES TO BE FURNISHED

2.1 GENERAL

2.1.1 SYSTEM OBJECTIVES

2.1.1.1 The mechanical inspection cell shall use automatic vision androbotic svstems to inspect a part for all features normallyaccomplished manually in a receivina/inspection department.Part features would include lengths, widths, heights, featurelocations, hole size and depths, tapped hole sizes and depth, angularity, pockets, slots, grooves and any other featurewithin he capability of the proposed equipment.

2.1.1.2 The inspection cell shall consist of 1) 3-dimensional visionsystem station to be used for non-contact gaging of mechanicalpart features; 2) a robot station that would utilize standardgo/no-go thread gages to inspect tapped holes; 3) a systemsupervisory computer to control, transfer, and store data; 4)a material handling robot system to automatically load andunload each station as required; and 5) a safety system.

2.1.1.3 The inspection cell shall have a working envelope (X, Y, Z) of18 x 24 x 6 inches and a maximum inspected part weight of 12lbs.

2.1.1.4 Part fixturinq recuirements shall be semi-dedicated, allowingfor common usaae between several classes of parts to beinspected. All fixturip- shall be manually loaded andunloaded. Detailed fixturing requirements shall be developedduring the final systems development.

VAX EC44EAI] CRAWFORD- ZURLINDN/CELL

i Pace 3

2.1.1.5 The system shall provide prompting routines for each functionwhich are easily understood without extensive trainina. Theseroutines must provide the operator with stev by step guidancethrough all phases of system operation includina startup,calibration, limit settina, fault recovery, and maintenance.

2.1.1.6 The inspection cell system shall provide for operator over-ride, data processing, act as a functional/maintenance/safetvmonitor, and store and control all internal and external dataflow. Upon completion of an inspection sequence it wouldstore all results and print out any out-of-tolerance partfeatures and make acceptance or rejection decisions.

2.1.2 INSPECTION CUL SUBSYSTEMS DEFINITION

2.1.2.1 DIMENSIONAL MEASUREMENT STATION

2.1.2.1.1 The 3-dimensional vision system that adequately fulfills therequirements of this inspection cell is a View EncineerinaModel 1200. It consists of 1) a System Control Unit (SCU),2) a Data Gathering Unit (DGU), and 3) a part postionmonitor. A vision system equivalent to the View 1200 may beused.

2.1.2.1.2 The SCU handles overall control of the vision measurementsystem. It includes a TV monitor. keyboard, two floppy diskdrives (638K each), one 10-megabyte hard disk, and an8086/8087 16-bit CPU. Data is downloaded to it from theprimary computer and supplied software along with built-inalgorithms instruct the DGU to perform all requiredinspections.

2.1.2.1.3 The DGU accomplishes the actual data measurement. It utilizesa high resolution video camera system mounted in the Z axisand an X-Y servo-motor-driven table onto which the part to beinspected is mounted. Since the X and Y dimensions are in thesame plane, the planar dimension is established by the dis-tance the table travels plus the camera's interpretation ofthe edge of the surface feature being inspected. A built-inalgorithm establishes the planar dimension that has beenchecked. The dimension along the Z axip 4 a function of thefocal lenath of the camera. One plp- established as thezero or reference point, with the _ Deinq a new planerequirina a new focal length. The distance the fixed focallenath camera moves along a Z axis determines the Z dimensionof the part features being examined.

j VAX EC44EAW] CRAWFORD - ZURLINDEN/CELL

Page 4

2.1.2.1.4 System accuracy reauirement shall be + .00025 inches minimumin all axes.

2.1.2.2 THREAD INSPECTION STATION

2.1.2.2.1 Tapped hole inspection will be accomplished by using RoboticThread Gaging. This system consists of a robot, robot con-troller, and end effector tooling that will use co/no-gothread gages to inspect threaded holes (#2 through 1/4 inch)for correct size, class and thread length.

2.1.2.2.2 End effector tooling shall contain a motorized spindle (if notsupplied with robot) capable of drivina thread gage toolino, atorcue sensor, and a rotational measurement device. The endeffector shall be capable of sensing go/no-go torque condi-tions consistent with standard tapped hole inspectionprocesses per FED-STD-428/6.

2.1.2.2.3 Alignment of the end effector tooling to the tapped hole shallbe adequate enough to guarantee that 95% of any toraue

monitored will represent true torque values and not be due to

side loading.

2.1.2.2.4 The end effector shall have a rotational position accuracy of+450.

2.1.2.2.5 The end effector shall have automatic tool chanqina

capability.

2.1.2.3 SAFETY SYSTEM

2.1.2.3.1. The inspection cell shall have a safety system that willautomatically shut down all operations in areas accessible byoperating robots when entered by any person. Alarm an-nuciators shall be provided to indicate the occurrence of asafety violation.

2.1.2.3.2 A flashing indicator light will be on when the system isoperating.

VAX rC44EAW3 CRAWFORD - ZURLIND/CELL

Page 5

2.1.2.4 MATERIAL HANELING ROBOT

2.1.2.4.1 A material handling robot system shall be designed into theinspection cell to accomodate parts transfer between thein/out, Thread Inspection, and Dimensional InspectionStations. Durina an inspection sequence, it will alsofacilitate part reorientation when commanded by the system'scontroller. This robot system will also be required to act asa parts platform for the Thread Inspection Station minimizingthe requirement for worksurface toolina.

2.1.2.4.2 The material handling robot system shall consist of arobot(s), controller, and end-of-arm toolina (EOAT). Thissystem shall be capable of delivering a part (12 lbs. maximum)to worksurface tooling with sufficient positional accuracy toinsure that a smooth and non-binding condition occurs.

2.1.2.4.3 The EDAT shall have an automatic tool chance capability andwill be designed to handle a family of parts minimizing anyunique part handling conditions.

2.1.2.5 SYSTEM SUPERVISORY COMPUTER (SSC)

2.1.2.5.1 A computer shall be integrated into the inspection cell andwill provide for overall cell control. It will be capable ofinteracting with all other equipment listed within thisspecification without adversely effecting the inspection cellperformance or intended functions.

2.1.2.5.2 The SSC shall provide for operator override, act as afunctional/maintenance/safety monitor, and store and controlall data entering or leavina the inspection cell. The com-puter's inspection data base will also have a manualprogramming capability.

2.1.3 SEOUENCE OF OPERATIONS

During the initial development phase it will be assumed that all part fix-turing will be manually loaded into each station of the inspection cell.Typi.al sequence of events for a part requiring both dimensional and tappedhole inspection is summarized below. Detailed part transfer requirementsshall be developed during final systems development.

2.1.3.1 SSC is loaded with a program.

2.1.3.2 Application program required for dimensional inspection isdownloaded to the dimensional inspection station SystemControl Unit. The part is transferred to the X-Y platformpart fixturing by the material haniling robot.

2.1.3.3 The dimensional inspection sequence is started.

2.1.3.4 Prompting of the material handling robot by the computer willbe desired if part orientation changes are required.

VAX C44EAWJ CRAWFORD - ZURLINEEN/CELL

Page 6

2.1.3.5 After inspection of the part is complete, data is transferredback to the SSC.

2.1.3.6 Parts are then transferred from the Dimensional Inspectionstation and refixtured onto the Thread Inspection Station worksurface (or held by material handling robot).

2.1.3.7 The tapped hole inspection is started.

2.1.3.8 Robot w-11 select proper thread gage per downloaded applica-tion program.

2.1.3.9 Robot will center tooling wih tapped hole. Located on thehand of the robot is a 6 axis force sensor which in additionto measuring torque can sense the required compliance toreposition the robot. This will minmize any binding ex-perienced by the tooling and thereby give truer torauemeasurements.

2.1.3.10 When centering of the thread gaging and tapped hole is ac-complished the drive motor will be commanded to reverse rotatefor 1.5 turns. This ill insure that the gage and the partbeing inspected are not cross threaded.

2.1.3.11 Thread gaging begins. Gage is driven into part while torqueis monitored.

2.1.3.12 Should gage meet resistance (increased toraue), motor would becommanded to stop. Depending on whether the gaging is "co" or"no-go", a decision would have to be made. If a "go" gage isused the system would reverse and count the number of revolu-tions it takes to extract the tooling, thus determining thethread length. If a "no-go" gage is used, it should meetresistance by the third entry revolution. (The system will berequired to inspect as many as eight standard and helicoilthread sizes per part [#2, 04, #6, #8, 2 @ #10, 2 @ 1/4"3 witheach possibly of being a Class 2 or Class 3 thread. A "co"and "no-go" gage is required for each condition r64 gagestotal3).

2.1.3.13 Material handling robot prompting by the controller will berequired if part orientation changes are required.

2.1.3.14 After completion of a particular gage size inspection sequencethe controller will command a tool chan4e and the inspectionprocess continues until the part is fully inspected.

2.1.3.15 After part inspection is complete, all data is transferredfrom the robot to the SSC and an inspection report printoutidentifying all discrepancies for the part is generated.

VAX EC44EAHJ CRAWFORD - ZURLINDEN/CELL

Page 7

I2.1.4 SYSTE CYCLE TIME AND THROUGHPUT

The system throughput must be sufficient to complete each inspection cycleon a continuous basis. The inspection cycle shall include the following:

a. Sensor Image Formation and Transmissionb. Image Processingc. Feature Measurement and Associated Calculationsd. Tapped Hole Gaging Datae. Storaae of Measurement Dataf. On-Line Reports: Individual Inspection Reports cener-

ated (printed) at a sufficient throughput to maintainreport synchronization (real time) with the parts asthey exit from the inspection cell or substations.

2.1.5 EXPANSION CAPABILITY

2.1.5.1 The inspection system shall be designed to include an expan-sion capability. This expansion shall be accomplished throughthe addition of dimensional inspection, vision, robotic threadinspection and/or material handlino robots. The expansionshall not involve the replacement of existing computers orinspection ecuipment.

2.1.5.2 The inspection system shall be capable of receiving opera-tional data from an intraplant network and returningmeasurement data to that network. The electrical standardshall be IEEE-802 token passing bus or as minimum RS-422. Theprotocol shall be the GM MAP standard which is based on cur-rent ISO, IEEE and NES standards for local area networks.

2.2 OPERATING SYSTEM SOFTWARE

2.2.1 GENERAL REQUIRE TS

2.2.1.1 The system software shall include an interactive operatinasystem which guides the operator through each of the inspec-tion station functions. The operating system shall provide amenu of selectable system functions. Promptino routines whichare easily understood shall be used to direct the operator ina step by step manner through the completion of each systemfunction.

VAX EC44EAW3 CRAWFORD - ZURLINVN/CELL

Page 8

2.2.2 SYSTEM INITIALIZATION

2.2.2.1 The system shall perform diagnostic checks on all computerand processing equirment including CPU boards, memory devices,I/O interfaces (discrete, analog and serial ports), powersupplies, sensors and peripheral devices (reference section2.2.7).

2.2.2.2 A prompting routine shall be provided to direct the operatorthrough the initialization process.

2.2.3 MEAS UREENT CONFIGURATION

2.2.3.1 Configuration data must be stored on a non-volatile memorydevice that is readily available for alteration and can beloaded directly during system initialization reference section2.2.2.

2.2.3.2 Dimensional measurement programs required per section 2.1.2.1dimensional measurement station.

2.2.3.3 Tapped hole measurement programs required per section 2.1.2.2tapped hole inspection station.

2.2.4 SYSTEM CALIBRATION

2.2.4.1 The manpower and level of technical expertise to performsystem calibration must be plant personnel compatible andshall not require assistance. Calibration procedures shall beautomatic and must be designed for easy implementation underthe limited time constraints associated with productionconditions.

2.2.4.1 Set up and system calibration data must be stored on a non-volatile memory device that is readily available foralteration, can be loaded directly during system initializa-tion (reference section 2.2.2) and can be accessed forverification, replacement or recalibration functions.

2.2.5 MEASUREENT DATA STORAGE

The measurement data produced by the inspection station must be stored in adata base which meets the following system requirements.

2.2.5.1 Capacity for 150 dimensioned features per part, at an inspec-tion rate of 100 parts per day over a five day period.

VAX [C44EAK3 CRAHFORD - ZURLINDEN/CELL

Page 9

2.2.5.2 Part number, aerial number, title, lot number and vroaram codeshall identify each part inspected. Each of these identifiersshall not exceed a 25 alpha/numeric character.

2.2.5.3 Date and time of system operation.

2.2.5.4 Upon completion of an inspection sequence, a data field shallbe created that contains all the necessary information forreport qeneration.

2.2.6 INSPECTION REPORTS

2.2.6.1 The generation of inspection reports for each part shall besufficient to maintain report printing synchronization (realtime) with each part as it indexes from the inspection cell.Reports shall also be made available if requested manually.

2.2.6.2 All reports shall be available for output in either the svs-tems console (CRT) or printer.

2.2.6.3 Individual inspection reports shall contain:

# OF ALPHAMET.RTCSa. Identifier 19b. Program Number 10c. Serial Number 7d. RIP Number 7e. Defect Code 10f. Date and Time 11g. Inspection point discrepancies (sec. 2.2.5.1)

VAX rC44EAW3 CRANFORD - ZURLINlENIJELL

Page 10

2.3 SYSTEM HARDWARE

2.3.1 GENERAL REQUIREMNTS

2.3.1.1 The system shall conform to Delco Systems electricalspecifications and workmanship standards.

2.3.1.2 Readily available (off the shelf) materials and componentsshall be used wherever possible. Any sinale source items usedin the system must be clearly identified and a statement ofavailability supplied.

2.3.1.3 Troubleshooting shall be facilitated by the followingconsiderations.

a. Self-diaonostics that provide fault detection andreporting down to the major component level.

b. Easy access to all mechanical and electrical components.

c. Minimization of unique board proliferation.

d. Attention to modular design

2.3.1.4 The system console (CRT) and printer must be mounted inenclosures which meet all of the environmental conditionsstated in this specification.

2.3.1.5 All enclosures must have an automatic disconnect feature whichdisengages power when the internal enclosure temperaturereaches the manufacturer's specified limit of the device mostsensitive to elevated temperature. The power disconnectionfeature must be designed to provide a controlled power shut-down, which maintains the intearity of the inspection cyclethat is in process at the time the power failure occurred.

2.3.1.6 On power up and power down conditions, all outputs shallhardware default to a safe off state and remain so untilcommanded differently from the controlling processor.

2.3.1.7 All dc power supply outputs shall have short circuit, overvol-tage protection and adequate filtering.

2.3.1.8 There shall be an additional 120 VAC, 10 amp rated wall duplexreceptacle for powerine test equipment, etc., fused separatelyfrom the main circuit breakers, noise isolated from thecomputer/processing equipment and mounted inside the maincontrol enclosure.

2.3.1.9 All receptacles, fuses, indicators, modules, circuit boardsand test points shall be permanently labeled.

IV AX EC44EAKJ CRANFORD - ZURLIN b/CELL

I Page 11

' I2.3.1.10 All PROM based comnuter/processors shall have on-line PROM

checksum error detection.

2.3.1.11 Provisions shall be made to attach 4 AWG around strap betweenif all panels and subpanels to earth ground.

2.3.1.12 The main operating system computer must have a hardware realtime clock.

2.3.2 ENVIRONMENTAL REQUIREMENTS

2.3.2.1 The inspection system must operate at full accuracy unaer theenvironmental conditions of the Receiving/InspectionDepartment, including the followina.

a. Ambient temperature range of 620F to 90,F.b. Humidity levels from 30% to 100% (non-condensing).c. Airborne contaminants such as dust and oils.d. RFI and EMI electrical noise both conducted and

radiated.

2.3.2.2 Plant power source supplying standard 120 VAC AND 220 VAC.

I

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PROGRAM TI_V2

* VARTAPSIZE:INTEGER -- CURRENT TAP SIZEPATHLEN:INTEGER -- CURRENT PATH LENGTH

£ PITCH:INTEGER -- THREAD PITCH

DEPTH:REAL -- DEPTH OF THREAD T'0 BE TESTEDPI:POSITION -- DUMMY POSITION VARIABLEPFLAG:INTEGER -- PFLAG=l INSPECT A TAPPED HOLE, PFLAG=O:MOVE ONLY

D:INTEGERCLOCK:INTEGER

X, Y, Z, W, P, R, E, F, T: REALXX:REALYY:STRING[22]VAR1:STRING[4]MS:REAL -- MS IS THE NUMBER OF ROTATIONS/SEC OF EOAT MOTORPERCH:POSITION

-- THIS ROUTINE SETS THRESHOLD IN TORQUE COMPARATOR CIRCUITROUTINE SETTHRESH(TAPSIZE:INTEGER) FROM TI_V2EXT

ROUTINE CHANGETAP -- CHANGES EOAT TAP. CALLED FROM MAINBEGIN-- NOT YET IMPLEMENTED

-- WRITE F5 ('CURRENT TAP SIZE: ',TAPSIZE,CR)-- WRITE F5 ('CURRENT PATH LEN: ',PATHLEN,CR)-- WRITE F5 ('THREAD DEPTH: ',DEPTH,CR)-- WRITE F5 ('E: ',E,CR)-- WRITE F5 ('THREAD PITCH: ',PITCH,CR)

END CHANGETAP

ROUTINE CALLMC -- ISSUES EOAT MOTOR CONTROLLER

-- COMMANDS TO INSERT AND EXTRACT TAP. CALLED FROM INSPHOLEBEGINDOUT[12]=ONDELAY 250PULSE DOUT[1O] FOR 8DELAY 250DOUT[8]=OFFDOUT[7]=OFF

WRT GAGE INSERTIONWRITE F2 (';')DELAY 250WRITE F2 ('PR',XX::6::0,';')DELAY 250OPEN HAND 2DELAY 500WRITE F2 ('DH;')DELAY 250PULSE DOUT[IO) FOR 8DELAY 500-- FIND TIME REQUIRED TO THREAD HOLECLOCK=O

CONNECT TIMER TO CLOCKWRITE F2 ('PG;')DELAY 5000CLOSE HAND 2WHILE DIN1)]=OFF DO

HOLDENDWHILEI

WRITE F2 (IST;")DELAY 250DISCONNECT TIMER CLOCK

-- GAGE EXTRACTION

DOUT[12]=OFFWRITE F2 (' ;)

DELAY 250WRITE F2 ('VM;')DELAY 250WRITE F2 ('DH;')DELAY 250WRITE F2 ('DF;')DELAY 250

PULSE DOUT[IO] FOR 8DELAY 250WRITE F2 ('BG;')DELAY 1000UNHOLDIF (CLOCK/IOQO. < PITCH*0.0787/MS) THEN

T = 0.0175*MS*CLOCK/PITCHSHIFT (P1,VEC(0. , 0. , T))

ELSESHIFT (P1, VEC (0. ,O. ,2.0))

ENDIFWITH $SPEED=E MOVE TO P1WHILE DINCIJ=OFF DO

HOLDENDWHILEWRITE F2 ('ST;')DELAY 250PULSE DOUT1IO] FOR 8DELAY 250WRITE F2 ('TP;')READ F2 (YY)WRITE F5 (YY,CR)UNHOLD

END CALLMC

ROUTINE INSPHOLE -- INSPECT THREADED HOLEBEGIN

-- WRITE F5 (PF1,CR)XX=PITCH*DEPTH* (-4000. 0)DOUT[9]=OFF -- MOTOR CONTROLLER HARD RESET INITIALIZATIONSET THRESH (TAPSIZE)SHIFT (P1, VEC(0. 0, 0. 0, 5. C))MOVE TO P1SHIFT (P1, VEC (0.0,0.0,-5. 0))WITH $SPEED=500./$PRGOVERRIDE MOVE TO PlCALLMCSHIFT (P1, VEC(0. 0, 0. 0, 5. 0))MOVE TO P1END INSP_HOLE

BEGIN-- OPEN DATA FILES AND INITIALIZE PERTINATE VARIABLESFOR D=l TO 13 DO -- CLEAR SCREEN

WRITE (CR)ENDFOR

VAR1-'PS~$MOTYPE=LINEAR,STERMTYPE=F INE

$SPEED=200MS = 0.25 -- INLAND MOTOR TURNS AT 1/4 RPSOPEN FILE F2 ('RW,IA','CO:')OPEN FILE F5 (I RW' ,'IDATA. DT')OPEN FILE F6 ('RO','TAP..DATA.DT')KCL ('COMM SET BAUD CC) 30)01)PERCH=POS(1030.0, 105.0,650.0,-180.0,O.0,-180.0, 'N')MOVE TO PERCH

-SCAN DATA FILE TO OBTAIN EACH TAP SIZE AND CORRESPONDING HOLESREAD FS (TAP _SIZE1 PITCH, DEP-TH, PATHLEN, D)WHILE NOT EOF(F6) DO

$PRGOVERR IDE=DE = MS*2540)./(FITCH*D)CHANGETAPFOR D=l TO PATH LEN DO

READ F6 (PFLAG,X,Y,Z,W,.P-,R)P1 = POS (X, Y,Z, W, P,R,'IN')IF (PFLRG=l) THEN

INSP HOLEELSE

MOVE TO PiENDIF

ENDFORREAD F6 (TAPSIZE, PITCH, DEPTH, PATHLEN,))

ENDWHILE

MOVE TO PERCHCLOSE FILE F5VARI=' ERDY'WHILE (VAR1 'FDON') DOENDWHILEVAR 1=' PDON'END TI VE

PROGRAM TIV%2EXT

ROUTINE SETTHRESH(TAPSIZE: INTEGER)BEG INSELECT TAF'SIZE OFCASE (14) 5- .1 IN-OZ

DOUT Cl -OFFDOUTE83- OFFDOUT C3J 0NDOUTt43-ONPOUT CS) OFFDOUrTE63OFF

CASE (10) : -- :3.5 IN-OZ

DOUTL13=OFFDOUT ra) OFFDOUT C33=0NPOUT L4) 0NDOUT ES) ONPOUT E6)-OFF

CASE (8) -. -- 3.OIN-OZDOUT[i)-ONDOUT E12)-OFFPOUT L3) OFFDOUT E4J -FFDOUT[53) OFFDOUT C6) ON

CASE (6) : -- 2.5 IN-OZDOUT[13=OFFDOUT[21=ONDOUT[C3J 0NDOUT C4) OFFDOUT CS) OFFDOUT16S)=ON

CASE (4) : -- 2.0 IN-OZDOUTL13=DNPOUT123)=ONPOUT C3)=OFFDOUT CA) ONDOUT CS)-OFFDOUT CS)=ON

CASE (2) : -- 1.5 IN-OZDOUT[13=OFF

Dour C2J OFFPOUT C33=OFFDOUT C4) OFFI Dour CSJ ONPOUT1CS) ON

ELSE:j ENDSELECTEND SET-THRESH

BEGINI END TIV,2EXT

IPROGRAM TI_CALVARK:STRING[22]BEGINK = 'COMM SET BAUD CO 300' --- MOTOR CONTROLLERKCL (K)

DOUTE13=ONDOUT 12J =ONDOUT 13]=ONDOUT C4] =ONDOUT [5]=ONDOUT (6] =OFFDOUTC7]=OFF -- ENABLE BUFFERDOUT[8]=OFF ---- CLEAR BUFFERDELAY 250

OPEN FILE Fl ('RW, IA','CO:')WRITE Fl (';')DELAY 250WRITE Fl ('VM;')DELAY 250WRITE Fl ('PL 0;')DELAY 250WRITE Fl ('ZR 254;')DELAY 250WRITE Fl ('GN 3;')DELAY 250WRITE F1 ('SP 1000;' )DELAY 250WRITE Fl ('AC 500;')

DELAY 250WRITE Fl ('DH;')DELAY 250WRITE Fl ('PR -12000;')

DELAY 250PULSE DOUT[IO] FOR 8WRITE Fl ('BG;')DELAY 8000DOUT [8]=ON---CLEAR BUFFER

DELAY 250

DOUT E8] =OFFDELAY 500DOUT[7]=ON --- ENABLE BUFFERDELAY 250DOUT[7]-OFF --- DISABLE BUFFERDELAY 4000WRITE Fl ('ST;')PULSE DOUT[8] FOR 8

DELAY 250WRITE Fl ('DH;')END TICAL

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