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Precision Non-Contact Measurement

Shift Gauging System

Optical sensors are widely used for dimensional measurement and quality assurance (QA). One SwRI design uses several laser distance gauges to automatically measure the run-out of shafts as they are rotated on a fixture. This sensor replaced a manual system using visual reading of contact dial indicators. The success of this system required consistent optical signals and computer analysis of the data to provide results that correspond with accepted QA practice.

Image-Based Precision Measurement

Displacement Mapping

High-resolution video cameras can be used as optical sensors. The DisMap© system was designed for precision measurement of strain. Normalized image correlation is used to determine the displacements at grid points when a specimen is loaded. The resulting displacement map provides information of material deformation that would be impossible to obtain by any other method.
 

		Click photo for larger image (264k)
The DisMap system was designed for precision measurement of strain.

Image Measurement Based Control

Microcapsule Manufacturing

We have used image-based optical sensing for measurement and feedback control of complex processes. In one case, it was necessary to measure the size and shape of microcapsules as they were formed in order to control the extruder parameters to maintain quality. This system included a high-speed video camera with high-magnification lens and strobe lighting to capture images of the capsules as they fell from the extruder. Image analysis determined the size and shape of the capsules, and control algorithms were used to adjust the extruder speed and pressure.

		Click photo for larger image (264k)
High-speed video camera with high-magnification lens and strobe lighting to capture images of the capsules as they fell from the extruder.

	Komax Wire Harness Transfer

Automated Wire Termination

SwRI designed a high-speed transfer device to transfer terminated wires from a Komax 50 to a carousel for use in an automated wire harness system. The device cycled every two seconds and had to perform 15 different operations to transfer completed wire circuits to the carousel. The transfer device had to maintain orientation and spacing for the completed wire circuits as well as allowing for the removal of faulty wire circuits.

Clean Room Robot Development

SwRI designed a 6-degrees-of-freedom robot to store reticules in a clean room environment. It was designed to store and retrieve reticules without human intervention to keep dust contamination down.

Canopy Polishing

Aircraft canopy transparencies become scratched and pitted in service, weakening the canopy and interfering with the pilot's vision. SwRI developed a system for the U.S. Air Force to automatically rework flawed canopies. This automated system, which has been in operation at Hill AFB since 1988, utilizes 3 commercial robots – 2 robots for polishing and 1 robot equipped with a machine vision system for inspecting the canopies.
 

	Using a stereo-based laser end effector and computer vision techniques, this robot locates and identifies flaws on the surface of canopy transparencies and removes them.

For more information about manufacturing systems services projects and capabilities at SwRI or how you can contract with SwRI, please contact Michael P. Rigney, Ph.D. at mrigney@swri.org or (210) 522-5104.
 

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Southwest Research Institute® (SwRI®), headquartered in San Antonio, Texas, is a multidisciplinary, independent, nonprofit, applied engineering and physical sciences research and development organization with 11 technical divisions.

September 30, 2008