integrated vision system & robot streamline production
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TRANSCRIPT
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