SBIR Phase II: Force-Controlled Robotic Arm Capable of Sub-Millimeter Precision

这个小企业创新研究（SBIR）第二阶段项目提出了一种便携式交互式坐标测量机（CMM），用于收集与一系列零件统计抽样一致的几何数据。这项创新利用了电缆驱动的一个特点，即在铰接臂上支持精确的重复性。为了优化生产和避免废料的产生，必须及时进行制造工艺修正，但必须基于充分的测量数据。现有的计量系统抑制了这些首选的统计过程控制原则。大型机动三坐标测量机要么使用计算机辅助设计（CAD）模型离线教学，要么使用笨拙的操纵杆界面在线教学。手动移动臂测量机使用安全方便，但不支持教学和播放。提出的解决方案是一个电动铰接机器人，它结合了手动系统的安全性和回放精度，从而支持方便的统计过程控制（SPC）。研究目标是设计和建造一个机动三坐标测量机，并开发创建成功产品所需的算法、工具和程序。预期的商业化产品将是一种便携式的、用户友好的、具有成本效益的机械臂，它将统计过程控制的质量优势传播到广泛的产品和制造商，包括医疗外科等非传统制造业。这个项目的广泛影响/商业潜力有四个部分。首先是对美国经济的直接影响。美国工人将组装、测试和运输根据该SBIR开发的产品。零部件将从美国本土制造商和OEM供应商采购，这将提振美国经济并产生税收；其中一些产品将成为出口产品，从而减少美国的贸易不平衡。其次，目前可用的计量设备的缺点阻碍了统计过程控制的使用，从而破坏了制造质量。拟议的解决方案将通过更容易地采用统计过程控制来提高计量市场部门的制造业竞争力，从而提高质量并降低废料成本。第三，提议的解决方案邀请生产线工人回到他们必须最终理解和控制的过程中进行密切的身体接触。工人通过教设备了解每个新零件的几何形状来增强直觉，而回放功能避免了单调和重复的压力。企业经常将这些工人从他们的熟练工作中自动化，然后他们加入失业者，而公司失去了理解和创新流程的能力。最后，SBIR将支持与几所大学的正式实习项目，以保持多样性。

This Small Business Innovation Research (SBIR) Phase II project proposes a portable, interactive Coordinate Measuring Machine (CMM) for geometric data collection consistent with statistical sampling of a series of parts. The innovation exploits a characteristic of cable drives that supports precise repeatability in an articulated arm. To optimize production and avoid scrap generation, manufacturing process corrections must occur promptly and yet must be based on adequate measurement data. Existing metrology systems inhibit these preferred statistical process control principles. Large motorized CMMs are either taught offline using computer-aided design (CAD) models or online using awkward joystick interfaces. Manual-only portable-arm CMMs are safe and convenient to use, but teach-and-playback is not supported. The proposed solution is a motorized articulated robot that combines the safety of a manual system with playback precision thereby supporting convenient statistical process control (SPC). The research objectives are to design and build a motorized CMM and develop the algorithms, tools, and procedures needed to create a successful product. The anticipated commercialized product will be a portable, user-friendly, cost-effective robotic arm that spreads the quality advantages of statistical process control across a broad range of products and manufacturers including non-traditional manufacturing such as medical surgery.The broader impact/commercial potential of this project has four parts. The first is the direct impact on the US economy. US workers will assemble, test, and ship the products developed under this SBIR. Components will be sourced from local US fabricators and OEM suppliers, boosting the US economy and generating taxes; and some of these products will become exports, reducing the US imbalance of trade. Secondly, the shortcomings of metrology devices available today discourage the use of statistical process control, thereby undermining manufacturing quality. The proposed solution will improve manufacturing competitiveness in the metrology market sector through easier adoption of statistical process control, leading to higher quality and reduced scrap costs. Thirdly, the proposed solution invites production-line workers back into close physical contact with the process that they must ultimately understand and control. The worker strengthens intuition by teaching the device for each new part geometry, while the playback capability avoids tedium and repetitive stress. Corporations often automate these workers out of their skilled jobs who then join the unemployed while the company loses touch with the ability to understand and innovate processes. Finally, this SBIR will support formal internship programs with several universities in order to maintain diversity.