the Big Area Additive Manufacturing (BAAM) for polymer matrix composites was presented as the background motivation for the workshop. Following, the extension of underlying technology to low-cost metals was proposed with the following goals: (i) High deposition rates (approaching 100 lbs/h); (ii) Low cost (<$10/lbs) for steel, iron, aluminum, nickel, as well as, higher cost titanium, (iii) large components (major axis greater than 6 ft) and (iv) compliance of property requirements. The above concept was discussed in depth by representatives from different industrial sectors including welding, metal fabrication machinery, energy, construction, aerospace and heavy manufacturing. In addition, DOE’s newly launched High Performance Computing for Manufacturing (HPC4MFG) program was reviewed. This program will apply thermo-mechanical models to elucidate deeper understanding of the interactions between design, process, and materials during additive manufacturing. Following these presentations, all the attendees took part in a brainstorming session where everyone identified the top 10 challenges in large-scale metal AM from their own perspective. The feedback was analyzed and grouped in different categories including, (i) CAD to PART software, (ii) selection of energy source, (iii) systems development, (iv) material feedstock, (v) process planning, (vi) residual stress & distortion, (vii) post-processing, (viii) qualification of parts, (ix) supply chain and (x) business case. Furthermore, an open innovation network methodology was proposed to accelerate the development and deployment of new large-scale metal additive manufacturing technology with the goal of creating a new generation of high deposition rate equipment, affordable feed stocks, and large metallic components to enhance America’s economic competitiveness.
The Advanced Integrated Maintenance System (AIMS) is a remote maintenance system that uses a dual-arm teleoperator to control the Advanced Servomanipulator (ASM). Although, the ASM was designed for nuclear fuel reprocessing, it can provide a testbed for space telerobotics (space servicing and assembly). The objective of this project is to design and implement a generalized capability for automatic path-planning and obstacle avoidance during motion of the manipulator transporter (overhead crane and main manipulator shaft) from one work location in the hotcell to another. The work is to be accomplished in two phases. In the first phase, the transporter will move in a known world. In the second phase, sensor data will be used to update and verify the world model and the system will have the capability to avoid unexpected obstacles. This paper describes the design and initial development of a system for phase one. The phase one system will have three components: operator interface, navigation code, and hardware interface. The operator interface will be the most complex part of the system and will have three components: display, goal editor, and geometry editor. The display will allow the AIMS operator to view a three dimensional representation of the location of the ASM in the hotcell. The goal editor will allow the operator to define a goal for the ASM. The geometry editor will display the geometry of the hotcell and allow the operator to add or remove objects from the geometry. The navigation code will explore the geometry and define a clear path from the current position to the goal. The hardware interface will monitor the position of the ASM and send signals to the existing transporter control system and to the display.
The Selective Equipment Removal System (SERS) was previously developed under the Department of Energy`s Robotics Technology Development Program to demonstrate and evaluate mobile telerobotic concepts for performing selective dismantlement using the reconfigurable dual-arm work module (DAWM). DAWM was designed for overhead transporter, crane hook, and mobile vehicle deployment. The DAWM configuration provided two 6-degree-of-freedom (D.O.F.) hydraulic manipulators with a maximum capacity of 240 lbs in the elbows-up configuration and five additional D.O.F. supplying torso rotate for the entire positioning package, linear extension of each arm base, and base rotate for each arm (which added a seventh D.O.F. to the manipulator for elbows-up, elbows-out, and elbows-down operation). Hydraulic manipulators were selected to provide the payload capacity required for anticipated tooling and material handling needs that would be typical of heavy dismantlement tasks. The original design of the dual arm manipulation system was driven by the desire to provide maximum system versatility in the study of deployment options and orientation relative to specific task performance. In FY 1996, the program was directed to provide remote systems support for the dismantlement of the CP5 reactor at Argonne National Lab (ANL) beginning in FY 1997. A study of the tasks involved and the available deployment options led to a rework of the DAWM designated the dual arm work platform (DAWP), which was specifically designed around crane hook deployment, reduced the base D.O.F.`s to four instead of five, and made use of the existing DAWM control system. This paper describes the evolution of the DAWM into the DAWP and the design philosophy involved.
Additive manufacturing (AM) offers a means of facilitating sensor placement within a larger complex component. AM is especially attractive for the manufacture of components from titanium. Titanium is a difficult material to use in the production of solid components, because of its brittle nature and its phase change properties. Weight is a critical concern in unmanned aircraft, and AM offers a feasible means of producing engine components out of titanium, which is much lighter than steel. AM, also known as three-dimensional (3D) printing, has gained notable attention as a means of rapid prototyping and manufacturing small quantities of specialized components. Aluminum and copper are more often suited to the ultrasonic AM process, but progress is being made in their use with other print processes. AM provided a cost- and time-effective means of producing this prototype head by eliminating the mold development step.
The Department of Energy`s (DOE`s) Robotics Technology Development Program (RTDP) is participating in the dismantlement of a mothballed research reactor, Chicago Pile Number 5 (CP-5), at Argonne National Laboratory (ANL) to demonstrate technology developed by the program while assisting Argonne with their remote system needs. Equipment deployed for CP-5 activities includes the dual-arm work platform (DAWP), which will handle disassembly of reactor internals, and the RedZone Robotics-developed `Rosie` remote work vehicle, which will perform size reduction of shield plugs, demolition of the biological shield, and waste packaging. Remote dismantlement tasks are scheduled to begin in February of 1997 and to continue through 1997 and beyond.
The development of an expert system for optimizing the controls tuning of a gear and shaft force-reflecting servomanipulator is discussed. Remote maintenance techniques have produced hot-cell manipulators that do not require hands-on-repair. However, these manipulators are difficult to tune owing to the conflicting priorities of maximizing operator sensation of force reflection and minimizing operator fatigue in combination with the complex nonlinear control algorithms and cross-coupled motions. Owing to the heuristic nature of this tuning problem and the emphasis on human perception of performance, an expert system has been developed as an alternative to algorithmic optimization of gains.< >
The dual arm work module (DAWM) was developed at Oak Ridge National Laboratory (ORNL) by the Robotics Technology Development Program (RTDP) as a development test bed to study issues related to dual arm manipulation, including platform cotilguration, controls, automation, operations, and tooling. The original platform was based on two Schilling Titan II manipulators mounted to a 5-degree-of- freedom (DOF) base fabricated by RedZone Robotics, Inc. The 5-DOF articulation provided a center torso rotation, linear actuation to change the separation between the arms, and arm base rotation joints to provide up, elbows down, or out orientation. A series of tests were conducted on operations, tooling, and task space scene analysis (TSSA)-driven robotics for overhead transporter- mounted and crane hook-deployed scenarios. A concept was developed for DAWM deployment from a large remote work vehicle, but the project was redirected to support dismantlement of the Chicago Pile #5 (CP-5) reactor at Argonne National Laboratory in fiscal year (FY) 1997. Support of CP-5 required a change in focus of the dual arm technology from that of a development test bed to a system focussed for a specific end user. ORNL teamed with the Idaho National Environmental ,Engineering Laboratory, Sandia National Laboratory, andmore » the Savannah River Technology Center to deliver a crane-deployed derivative of the DAWM, designated the dual arm work platform (DAWP). RTDP staff supported DAWP at CP-5 for one FY; Argonne staff continued operation through to dismantlement of the reactor internals. Lessons learned from this interaction were extensive. Beginning in FY 1999, dual arm development activities are again being pursued in the context of those lessons learned. This paper describes the progression of philosophy of the DAWM from initial test bed to lessons learned through interaction at CP-5 and to the present investigation of telerobotic assist of teleoperation and TSSA- driven robotics.« less
