Publications

This paper introduces a new configuration of parallel manipulator call the Rotopod which is constructed from all revolute type joints. The Rotopod consists of two platforms connected by six legs and exhibits six Cartesian degrees of freedom. The Rotopod is initially compared with other all revolute joint parallel manipulators to show its similarities and differences. The inverse kinematics for this mechanism are developed and used to analyze the accessible workspace of the mechanism. Optimization is performed to determine the Rotopod design configurations which maximum the accessible workspace based on desirable functional constraints.

A capacitive sensing technology has been applied to develop a Standoff Sensor System for control of robotically deployed tools utilized in Decontamination and Dismantlement (D and D) activities. The system combines four individual sensor elements to provide non-contact, multiple degree-of-freedom control of tools at distances up to five inches from a surface. The Standoff Sensor has been successfully integrated to a metal cutting router and a pyrometer, and utilized for real-time control of each of these tools. Experiments demonstrate that the system can locate stationary surfaces with a repeatability of 0.034 millimeters.

A non-contact capacitive sensing system has been developed for guiding automated welding equipment along typical v-groove geometries. The Multi-Axis Seam Tracking (MAST) sensor has been designed to produce four electric fields for locating and measuring the v-groove geometry. In this system, the MAST sensor is coupled with a set of signal conditioning electronics making it possible to output four varying voltages proportional to the electric field perturbations. This output is used for motion control purposes by the automated welding platform to guide the weld torch directly over the center of the v-groove. This report discusses the development of this capacitive sensing system. A functional description of the system and MAST sensor response characteristics for typical weld v-groove geometries are provided. The effects of the harsh thermal and electrical noise environments of plasma arc welding on sensor performance are discussed. A comparison of MAST sensor fabrication from glass-epoxy and thick-film ceramic substrates is provided. Finally, results of v-groove tracking experiments on a robotic welding platform are described.

This paper describes an application of Sandia`s non-contact capacitive sensing technology for collision avoidance during the manufacturing of rocket engine thrust chambers. The collision avoidance system consists of an octagon shaped collar with a capacitive proximity sensor mounted on each face. The sensors produced electric fields which extend several inches from the face of the collar and detect potential collisions between the robot and the workpiece. A signal conditioning system processes the sensor output and provides varying voltage signals to the robot controller for stopping the robot.

A sensor-based control approach for real-time seam tracking of rocket thrust chamber assemblies has been developed to enable automation of a braze paste dispensing process. This approach utilizes a non-contact Multi-Axis Seam Tracking (MAST) sensor to track the seams. The MAST sensor measures capacitance variations between the sensor and the workpiece and produces four varying voltages which are read directly into the robot controller. A PID control algorithm which runs at the application program level has been designed based upon a simple dynamic model of the combined robot and sensor plant. The control algorithm acts on the incoming sensor signals in real-time to guide the robot motion along the seam path. Experiments demonstrate that seams can be tracked at 100 mm/sec within the accuracy required for braze paste dispensing.

Abstract not provided.

This paper describes a collaborative effort between Sandia National Laboratories and the Rocketdyne Division of Rockwell International Corporation to develop an automated braze paste dispensing system for rocket engine nozzle manufacturing. The motivation for automating this manufacturing process is to reduce the amount of labor and excess material required. A critical requirement for this system is the automatic location of key nozzle features using non-contact sensors. Sandia has demonstrated that the low-cost Multi-Axis Seam Tracking (MAST) capacitive sensor can be used to accurately locate the nozzle surface and tube gaps.