integrated vision system & robot streamline production

Integrated Vision System and RobotStreamline Production of Lockheed

Martin Aegis Weapon System

Robotics “Best Practices” Users’ Conference at Penn StatePresented by

Bill Chesterson, Director - Manufacturing Automation

Aegis Weapon System• Naval Defense System• Integrated Radar and Missile System• Installed on 64 Navy Cruisers and

Destroyers

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

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

Manufacturing Method• Align array under bridge

Manufacturing Method• Align array under bridge• Place ceramic window / button into

carrier

Manufacturing Method• Align array under bridge• Place ceramic window / button into

carrier• Apply adhesive bead using cam driven

adhesive dispensing system

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

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

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

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

Problems• Supportability - 17 years old• Ergonomics• Messy• Labor Intensive• Buttons inserted manually• Supportability - critical components no

longer available

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 withmanufacturing schedule

• Quality

Design Concept• Transport System

– drives everything else in system concept– usually cannot be changed

Existing Transport System• Dial

– Cam driven adhesive dispensing system

Existing Transport System• Dial

– Cam driven adhesive dispensing system• Asynchronous Conveyor

– transfer pallets to bridge

Existing Transport System• Dial

– Cam driven adhesive dispensing system• Asynchronous Conveyor

– transfer pallets to bridge• Linear Rail

– Hard tooled window placement head

Robotic Transport System• Adaptability

– limits development risk– 1 transport device

Robotic Transport System• Adaptability• Retoolable / Programmable

– adaptability to future products

Robotic Transport System• Adaptability• Retoolable / Programmable• Agility

– eliminated separate glue deposition system– eliminated part handoff

Robotic Transport System• Adaptability• Retoolable / Programmable• Agility• Dependability

– good support– High MTBF

Robotic Transport System• Adaptability• Retoolable / Programmable• Agility• Dependability• Control

– adhesive dispensing algorithms werecanned subroutines

– easy tie in / use of vision for inspection andarm positioning

End-of-Arm Vision System• Fine position

locating in x-y ofpocket to robot(didn’t have to teach6,000 points)

• Eliminated finealignment of arrayfor Skew & Level

• Didn’t have to worryabout repeatabilityof array face

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

Cart Mount Vision System• Inspect ceramic window before bead

placement• Inspect bead after adhesive deposition

Because of Vision System...• Fine alignment of part to gripper after

picking improved part placementaccuracy

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

Adhesive DispensingSystem

Part Magazines

Cart

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

Lessons Learned• Teach points or use sensing device to

position robot• Tying in sensors depends on accuracy

of robot which is much less precise thanrepeatability

Lessons Learned• Lighting

– white adhesive onwhite part

– tool tip mountedlighting

• no shadows• consistent lighting

pocket to pocket– Had to upgrade to

increase intensity– Added skirts around

cart to blockunwanted light