ROBOTICS/MACHINE VISION

The technologies of Robotics and Machine Vision can be used separately, but are often used to complement each other. Successful application of these technologies requires a thorough understanding of their capabilities.

I have extensive experience in the application of industrial Robotics, including the development of work cell architecture, software development and design of end of arm tooling. I have implemented a variety of robotic work cells to perform assembly, machine loading, and packaging. I have hands on experience with Adept, Seiko, ABB and Unimation robots.

I also have extensive experience in the application of Machine Vision for inspection and robot guidance. I possess a fundamental understanding of most techniques for vision measurement and analysis. I am knowledgeable in the area of optics and lighting. I have hands on experienced with Convex, Acuity and Adept , View and DVT vision systems. I developed several unique optic systems including a coaxial camera lens/laser beam delivery apparatus on a moving platform. I was guest lecturer on several occasions for the University of St. Thomas Master of Manufacturing Engineering program on the topic of Machine Vision Technology.

The following section provides information on some of the robotic and machine vision projects I have implemented.

MACHINE VISION GUIDED ROBOTIC ASSEMBLY SYSTEMS

• Executed a retrofit project to retool and reprogram a Seiko SCARA robot to perform precision microscopic epoxy dispensing on a hermetic feedthough assembly that is part of a medical energy device. The cylindrical feedthrough assemblies are approximately 1/10 inch in diameter. Conductive epoxy is used to provide an electrical connection within the assembly while non-conductive epoxy seals the assembly and provides mechanical strength. Each epoxy must be accurately dispensed to prevent electrical short circuits and contamination of wire bond surfaces. The assemblies are processed in batches of up to 5 fixtures with each fixture containing 275 assemblies. The assemblies are securely held in the fixtures with vacuum. The precise X-Y location of each feedthough assembly is determined by a DVT 542C Color Vision Sensor programmed using DVT's Framework Machine Vision software. The Z height of each feedthrough is determined to within .001 inch by a Keyence Laser Displacement Transducer. Using the X-Y-Z information, the Seiko robot precisely manipulates a dispensing tip in order to accurately apply epoxy in several different configurations of rings and dots. The dispensing process is monitored using the DVT color vision sensor. The DVT sensor differentiates between several different colored non-conductive epoxies, and also can reliably detect the silver colored conductive epoxy against the gold feedthrough body. The system performs periodic process control checks to monitor and adjust for viscosity changes of the epoxy.

• Developed and installed a surface mount assembly system used to populate a microwave circuit. This system dispenses solder paste and reel feeds and places surface mount components to +/- .002 inches of artwork defined locations on a flexible substrate. This machine uses a vision guided Seiko Accusembler Cartesian robot.

• Developed and installed an micro assembly system using a vision guided Seiko Accusembler Cartesian robot and precision X-Y-theta translation stage. This system is used to place microscopic (.008” by .008” ) beam leaded Gallium Arsenide components to +/- .001 inch of a location defined by a micro strip artwork. 3 separate cameras with high resolution optics are used to determine orientation of components and artwork. A patented component handling tool is used to manipulate the delicate components. This tool also facilitates the use of a laser soldering process, which employs a NdYAG laser to reflow solder the components to the micro strip. An Adept XGS Vision system performs all vision functions and acts as the work cell controller.

• Developed and installed a fully automated two part urethane potting and curing system for encapsulation of magnetometer coils. A machine vision guided PUMA robot was used for parts handling. Precision metering, mixing and dispensing of two part urethane potting material was required.

• Developed and installed a machine that dispenses a pattern of brazing paste on stainless steel sheets. This machine employs a vision guided Adept 550 robot using Adept AIM software. A triangulation laser is used to accurately measure the precise height of the work piece to enable accurate dispensing.

ROBOTIC ASSEMBLY AND MATERIAL HANDLING

• Developed and installed a robotic parts handling system which feeds metal components to a 12 cavity injection molding system and transfers the molded assemblies to a shipping container. Several ABB six axis robots were used.

• Developed V+ software to direct an Adept robot to apply a pattern of adhesive to a thermoformed tray. A V+ version of Adept's "Dispense" software was used to provide a smooth stream of very thin liquid adhesive uniformly around the tray perimeter.

• Developed and installed a system using an Adept robot to load radar transceivers to a variety of tuning/testing systems. This included the building of an infrared testing station.

• Developed and installed an assembly system using two asynchronously operated dial index tables to perform product assembly. An Adept multi-tasking system controller controls the system. An Adept SCARA robot is used to feed additional components from cartons. Machine vision is used to verify assembly and gage a critical feature. An Eddy current tester is used to inspect a critical component for internal cracks.

MACHINE VISION INSPECTION

• Developed VisionWare programs to perform a multi camera inspection of optical discs, measuring run out to the micron level. Special strobe electronics were used to simultaneously acquire images from 3 different cameras. Special software was developed to provide geometric analysis required for run out correction and also to provide statistical information required for calculation of hardware calibration parameters.

• Developed feeding techniques and equipment to singulate, orient, and inspect ring shaped rubber components at 300 units per minute with equipment conforming to FDA GMP. A critical element of this system was machine vision, which was used to inspect a feature on the inside surface of the ring to determine "right side up". Machine vision systems from Acuity were used to inspect for this feature as well as inspect for roundness of the ring. Structured strobe lighting was employed to capture images of the parts moving at over 100 feet per minute. Fiber optic sensors were used to control shift registers to accurately time the pulsing of air jets that were used to manipulate the moving product.

• Developed a number of inspection programs and inspection techniques to inspect components and assemblies using a View Voyager video inspection system from View Engineering.