Automated System to Assist in Gauge Block Calibration

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 laboratory’s computer network via Ethernet or other communications protocols.