SBIR-STTR Award

New Scale Robotics (NSR) www.newscalerobotics.com will develop a metrology robotic system to automatically calibrate gauge blocks. This new system will automate block handling and data collection and eliminate temperature changes caused by human hands. A new six-axis metrology robot and gripper, with active thermal isolation, will prevent laboratory temperature changes greater than 0.2 F. The flexible collaborative robotic system will have sufficient load capacity, range, precision and fit to place and remove gauge blocks inside the measurement instruments used by the Navy. The gauge block calibration instruments use by the Navy are: (1) the Labmaster Universal Measuring System Model 175 manufactured by Pratt and Whitney Measurement Systems (PWMS) and (2) the Precimar Models 130B-24 or 16 manufactured by Mahr. These calibration instruments require multiple manual operating steps, in addition to handling the gauge blocks. A collaborative robot (cobot) solution operates safely, side-by-side, with the calibration technician. However, the goal of achieving 100%, hands-free calibration, is desirable and this project will also investigate requirements and solutions that automate all manual calibration steps. To create a new metrology robot, the significant heat generated at each motorized joint and gripper must be isolated from the temperature-controlled laboratory. The proposed solution adds an isolation shroud to a commercial six-axis cobot. Sensors will monitor air and shroud temperature and verify less than 0.2 F laboratory temperature rise is achieved. The robot drive and control electronics will be placed outside the room. The gripper that touches the gauge blocks will have fingertips that minimize thermal conduction and are non-marring to the block surfaces. The anticipated automated system will be an extension of the Q-Span workstation produced by NSR. The operating system is the cobot controller and teach pendant. Special digital communication between the cobot controller and the calibration instruments will be managed by a custom electronics and firmware. The script-based cobot software application seamlessly integrates commands to the six-axis arm and gripper with send-and-receive data from the measurement instrument. Containers of gauge blocks will be independently calibrated using unique and validated programs. Programs for different combinations of gauge block sizes, locations, and quantity are easily taught and saved in the teach pendant for future use. Measurement results are sent to the quality management software in the laboratorys computer network via Ethernet or other communications protocols.

Benefit:
NSRs goal for this development project is to significantly improve the overall process of gauge block calibration and elevate the productivity and competitiveness of calibration laboratories. More broadly, the goal is to improve manual calibration processes for all metrology standards that require temperature stability. The potential improvements include: Automate block handing, measurement, and data logging and eliminate temperature changes caused by human hands. Automate all manual calibration steps for 100% hands-free operation. Minimize staff time in the metrology room and disturbances to laboratory temperature. Increase calibration speed and department productivity. Elevate staff engagement, lessen turnover, and reduce costs of recruiting and training replacements. Gauge blocks are a primary day-to-day metrology tool for modern manufacturing quality control. In addition to orders from the Navy, NSR anticipates significant commercial potential for Q-Span Metrology Robotic Workstations that achieve repeatable and reliable calibration of gauge blocks and other metrology standards without human intervention and achieve much lower uncertainty due to temperature changes. Automation also provides a critical improvement in labor productivity as organization struggle to recruit and train new staff. Additional potential customers include calibration facilities in other DOD branches, other government organizations, universities, and industrial laboratories worldwide. NSR estimates the global served market for Q-Span Metrology Workstations is greater 1000 facilities. If only a few percent of these metrology laboratories adopt automation each year, this represents millions of dollars revenue growth.

Keywords:
metrology, metrology, Collaborative, Cobot, Robot, Calibration, temperature control, Automation, Gauge Blocks