1. Integrated Vision System and Robot
Streamline Production of Lockheed
Martin Aegis Weapon System
Robotics “Best Practices” Users’ Conference at Penn State
Presented by
Bill Chesterson, Director - Manufacturing Automation

2. Aegis Weapon System
• Naval Defense System
• Integrated Radar and Missile System
• Installed on 64 Navy Cruisers and
Destroyers

3. Antenna Manufacturing
• 12’ x 12’ Aluminum housing
• 4,350 Receivers (phase shifters) are
installed in housing
• EF Connections are made
• On-board electrical systems are installed
• Windows and Buttons inserted
• Face is coated with RTV

4. Array Face
• 12’ x 12’ Aluminum Plate
• Array of 4,350 receivers covered by
ceramic windows
• 1,600 small screw covers (buttons)
• 500 large screw covers
• RTV Adhesive

5. Manufacturing Method
• Align array under bridge

6. Manufacturing Method
• Align array under bridge
• Place ceramic window / button into
carrier

7. Manufacturing Method
• Align array under bridge
• Place ceramic window / button into
carrier
• Apply adhesive bead using cam driven
adhesive dispensing system

8. Manufacturing Method
• Align array under bridge
• Place ceramic window / button into
carrier
• Apply adhesive bead using cam driven
adhesive dispensing system
• Transfer part to bridge via magnetic
conveyor

9. Manufacturing Method
• Align array under bridge
• Place ceramic window / button into
carrier
• Apply adhesive bead using cam driven
adhesive dispensing system
• Transfer part to bridge via magnetic
conveyor
• Align insertion head over pocket

10. Manufacturing Method
• Align array under bridge
• Place ceramic window / button into
carrier
• Apply adhesive bead using cam driven
adhesive dispensing system
• Transfer part to bridge via magnetic
conveyor
• Align insertion head over pocket
• Flip Carrier and eject window into array

11. Manufacturing Method
• Align array under bridge
• Place ceramic window / button into
carrier
• Apply adhesive bead using cam driven
adhesive dispensing system
• Transfer part to bridge via magnetic
conveyor
• Align insertion head over pocket
• Flip Carrier and eject window into array
• Wipe excess adhesive

12. Problems
• Supportability - 17 years old
• Ergonomics
• Messy
• Labor Intensive
• Buttons inserted manually
• Supportability - critical components no
longer available

13. Design Constraints
• Use existing bridge & array indexing
mechanisms
• RTV Adhesive
• Could not change product to ease
automated assembly
– chamfers on parts and pockets
• Implementation had to coincide with
manufacturing schedule
• Quality

14. Design Concept
• Transport System
– drives everything else in system concept
– usually cannot be changed

15. Existing Transport System
• Dial
– Cam driven adhesive dispensing system

16. Existing Transport System
• Dial
– Cam driven adhesive dispensing system
• Asynchronous Conveyor
– transfer pallets to bridge

17. Existing Transport System
• Dial
– Cam driven adhesive dispensing system
• Asynchronous Conveyor
– transfer pallets to bridge
• Linear Rail
– Hard tooled window placement head

18. Robotic Transport System
• Adaptability
– limits development risk
– 1 transport device

19. Robotic Transport System
• Adaptability
• Retoolable / Programmable
– adaptability to future products

20. Robotic Transport System
• Adaptability
• Retoolable / Programmable
• Agility
– eliminated separate glue deposition system
– eliminated part handoff

21. Robotic Transport System
• Adaptability
• Retoolable / Programmable
• Agility
• Dependability
– good support
– High MTBF

22. Robotic Transport System
• Adaptability
• Retoolable / Programmable
• Agility
• Dependability
• Control
– adhesive dispensing algorithms were
canned subroutines
– easy tie in / use of vision for inspection and
arm positioning

23. End-of-Arm Vision System
• Fine position
locating in x-y of
pocket to robot
(didn’t have to teach
6,000 points)
• Eliminated fine
alignment of array
for Skew & Level
• Didn’t have to worry
about repeatability
of array face

24. Because of Vision System...
• Ability to use camera to scan face to
find next open window or button pocket
• Provided coarse position coordinates for
next empty pocket and determined type
(window, large button or small button)
– didn’t have to predefine a table with coarse
position of each pocket / type
• Made system adaptable to different
pocket configuration on face
• Eliminated synchronization between
data table and reality

25. Cart Mount Vision System
• Inspect ceramic window before bead
placement
• Inspect bead after adhesive deposition

26. Because of Vision System...
• Fine alignment of part to gripper after
picking improved part placement
accuracy

27. Major System Components
• Bridge
• Array Indexing System
• Cart
– Robot
– End-of-Arm Vision System
– Cart Mount Vision System
– End of Arm Depth Sensor
– Adhesive Dispensing System
– Part Magazines

28. Adhesive Dispensing
System

29. Part Magazines

30. Cart

31. System Synopsis
• Scan array to determine pocket type
• Coarse alignment
• Pick appropriate part
• Inspect part
• Fine position of part to end-effector
• Dispense adhesive
• Inspect adhesive bead
• Fine alignment (x-y-z)
• Place window / button into pocket
• Final Inspect

32. Lessons Learned
• Teach points or use sensing device to
position robot
• Tying in sensors depends on accuracy
of robot which is much less precise than
repeatability

33. Lessons Learned
• Lighting
– white adhesive on
white part
– tool tip mounted
lighting
• no shadows
• consistent lighting
pocket to pocket
– Had to upgrade to
increase intensity
– Added skirts around
cart to block
unwanted light