I

NBSIR 88-3779

RECOMMENDED TECHNICAL SPECIFICATIONS

FOR PROCUREMENT OF SYSTEMS

FOR THE INSPECTION WORKSTATION

NBS PL*8

JUL 1 i 19* May 11, 1988

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Jay H. Zimmerman

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RECOMMENDED TECHNICAL SPECIFICATIONS

FOR PROCUREMENT OF COMMERCIALLY AVAILABLE SYSTEMS

FOR THE INSPECTION WORKSTATION

Jay H. Zimmerman

May 11, 1988

This publication was prepared by United States Government

employees as part of their official duties and is, therefore, a

work of the U. S. Government and not subject to copyright.

Certain commercial equipment, instruments, or materials are

identified in this paper in order to adequately specify the

experimental procedure. Such identification does not imply

recommendation or endorsement by the National Bureau of Standards,

nor does it imply that the materials or equipment identified are

necessarily the best available for the purpose.
.

,
TABLE OF CONTENTS

Page

I. INTRODUCTION 1

1. WHAT THIS MANUAL IS ABOUT 1

2. AUDIENCE 1

3. OVERVIEW 1

II. MAIN INSPECTION WORKSTATION EQUIPMENT

SPECIFICATIONS 3

1. COORDINATE MEASURING MACHINE SPECIFICATIONS ... 3

1.1. Machine Description 3

1.2. Dimensional Measurement 3

1.3. PH9 Measuring Probe 4

1.4. Machine Operation 4

1.5. Built-in Microprocessor-based Control 4

1.6. Remote Microprocessor Machine Control 4

1.7. General Coordinate Measuring Machine

Specifications 5

1.8. Machine Functionality 5

2. SURFACE ROUGHNESS INSTRUMENT SPECIFICATIONS ... 6

2.1. Instrument Description 6

2.2. Surface Roughness Measurement 6

2.3. Part Fixturing and Alignment 7

2.4. Instrument Operation 7

2.5. Built-in Microprocessor Instrument Control ... 8

2.6. Remote Microprocessor Instrument Control .... 8

2.7. General Surface Roughness Instrument

Specifications 8

2.8. Instrument Functionality 9

3. INSPECTION WORKSTATION ROBOT SPECIFICATIONS ... 9

3.1. Machine Description .... 9

3.2. Work Capacity 9

3.3. Workpiece Handling Gripper ... 10

3.4. Machine Operation 10

3.5. Built-in Microprocessor-based Control 10

3.6. Manual Robot Control ..... 10

3.7. Remote Microprocessor Robot Control 11

3.8. General Robot Specifications 11

3.9. Machine Functionality 12

III. COMPUTER SYSTEMS EQUIPMENT SPECIFICATIONS ...... 13

1. PRINCIPAL HARDWARE AND SOFTWARE COMPONENTS .... 13

1
Page

1.1. Main Inspection Workstation Computer System . . 14

1.2. Coordinate Measuring Machine Computer System . . 14

1.3. Surface Roughness Instrument Computer System . . 14

1.4. Robot Computer System 14

2. INTERNAL MEMORY (RAM) CAPACITY 15

3. NETWORK COMMUNICATIONS 15

4. INSPECTION WORKSTATION SOFTWARE DEVELOPMENT ... 15

IV. MISCELLANEOUS INSPECTION WORKSTATION EQUIPMENT

SPECIFICATIONS 17

1. AUTOMATIC DIAL INDICATOR SPECIFICATIONS 17

1.1. Instrument Description 17

1.2. Distance Measurement 17

1.3. Part Fixturing and Staging 17

1.4. Instrument Operation 18

1.5. Built-in Microprocessor-based Control 18

1.6. Remote Microprocessor Instrument Control .... 18

1.7. General Automatic Dial Indicator

Specifications ........ 18

2. SAFETY FENCE SPECIFICATIONS ........... 18

2.1. Device Description ..... 19

2.2. Safety Fence Configuration ...... 19

2.3. General Safety Fence Specifications 19

APPENDICES ..... 21

A. IWS DOCUMENTATION LIST 21

B. LIST OF REFERENCES .................. 23

C. GLOSSARY (and abbreviations) ............. 25

READER COMMENT FORM ........ .... 27

ii
RECOMMENDED TECHNICAL SPECIFICATIONS

FOR PROCUREMENT OF COMMERCIALLY AVAILABLE SYSTEMS

FOR THE INSPECTION WORKSTATION

I. INTRODUCTION

1. WHAT THIS MANUAL IS ABOUT

This manual furnishes technical specifications of the Inspection

Workstation (IWS) in the Automated Manufacturing Research Facility

(AMRF) at the National Bureau of Standards (NBS ) . These

specifications should be useful when procuring inspection and

computer equipment for an automated facility modeled after the

IWS

.

2 . AUDIENCE

This manual is targeted for technical personnel who wish to

procure inspection and computer equipment for an automated

inspection facility.

3 . OVERVIEW

Chapter II describes technical specifications of the main IWS

inspection equipment—a coordinate measuring machine, a surface

roughness instrument, and a part-handling robot.

Chapter III describes technical specifications of the computer

equipment which controls the main IWS inspection equipment.

Next, Chapter V describes technical specifications of the

miscellaneous IWS equipment—an automatic dial indicator and an

electronic safety fence.

The appendices consist of useful information. Appendix A lists

the entire IWS documentation set. References specific to the IWS

are listed in Appendix B. Appendix C contains a glossary of terms

used in this document.

Completing the document is a reader comment form. The reader is

encouraged to write down comments and mail the attached form to

the address specified.

1
IWS TECHNICAL SPECIFICATIONS

-

.
IWS TECHNICAL SPECIFICATIONS

II. MAIN INSPECTION WORKSTATION EQUIPMENT

SPECIFICATIONS

The main IWS inspection equipment is made up of a coordinate

measuring machine (CMM) , a surface roughness instrument (SRI) , and

an inspection (part-handling) robot.

1. COORDINATE MEASURING MACHINE SPECIFICATIONS

The CMM is a modified four-axis moving-table horizontal arm type

coordinate measuring machine. It is a displacement measuring

device which provides digital readout for the distance travelled

by a movable machine component. The travelling component, a gage

head with the mounted sensing probe, is guided along three

mutually perpendicular, straight-line paths contained in common

planes representing the X, Y, and Z axes of a Cartesian system of

coordinates

.

1.1. Machine Description

The CMM has three components that move along mutually

perpendicular guide ways. The measuring probe is mounted to a

cantilevered beam (horizontal arm) . The horizontal arm is

supported at one end only by a vertical support column and has the

capability to move up and down on its support column. The support

column may move from side to side on the base of the machine. The

support column and the horizontal arm provide positioning along

the CMM's X and Y machine coordinate axes, respectively. The

staging table is an airlifted rotary table that moves back and

forth on the machine base to provide positioning along the CMM's

machine coordinate Z-axis.

The machine column supporting the horizontal arm (ram) and probe

move along the X-axis on roller bearings. The Y-axis is the

vertical axis. The ram moves up and down the column on

recirculating ball bearings and is counterbalanced by means of a

dead weight supported by a steel cable. The Z-axis is the staging

table, or horizontal axis, of the machine. The table may be moved

to relocate the part instead of maneuvering the probe. Moreover,

the staging table rotates to permit 360-degree exposure of

workpiece (part) features to the measuring probe without

repositioning the part.

1.2. Dimensional Measurement

The CMM provides dimensional measurement by touching a workpiece

(part) at various points on the part with a measuring probe.

Dimensional measurement may be performed by moving the part to be

measured and/or the measuring probe along the three mutually

perpendicular axes. The outcome of the inspection will typically

3
IWS TECHNICAL SPECIFICATIONS

be a comparison of the measured geometry with the nominal

specified by the part design.

1.3. PH9 Measuring Probe

The principal measuring probe of the CMM is a motorized two-axis,

three-dimensional probe (Renishaw PH9 ) . This measuring probe is

force sensitive and sends a latch signal to the CMM microprocessor

upon touching a part. The adjustable touching force is maintained

at approximately 5 grams for normal IWS operation. When the probe

is displaced, the circuit is interrupted and at a set resistance

value the signal is sent to the processor to read the scales.

While the low force of 5 grams allows most parts to be measured

without being secured to the table, small parts should be secured

in a fixture or held in place with a magnetic or vacuum chuck.

The PH9 processor is programmable for sixty-four different tip

positions. This processor has a battery supported memory unit

that can retain the probe orientations for several hours in case

the machine is turned off or its power supply is interrupted.

1.4. Machine Operation

The CMM is equipped with servos for remote control or direct

computer control (DCC) of measuring probe positioning to meet

application requirements for operating in either manual or

automatic (computer-controlled) mode, respectively. The CMM

functions in the automatic mode for all IWS operations except for

the positioning of the probe to the 0,0,0 machine position and

the initial calibration of the probes.

1.5. Built-in Microprocessor-based Control

Microprocessor-based firmware furnished by the CMM manufacturer

provides fundamental machine operations—metric/inch conversion,

linear data display, part reference implementation, part

alignment, point handling, measuring probe positioning,

coordinate measurement data processing and calculations, and error

handling. Programmed servo positioning is not possible through

the firmware, but initial part setup, limited measurement

calculations, and manual servo positioning are available through

the remote control unit (RCU) machine controls. The RCU is

equipped with joysticks for operator control of machine movement.

1.6. Remote Microprocessor Machine Control

The CMM is controlled by an integrated, data-driven, hierarchical

control software system called the Coordinate Measuring Machine

Controller (CMMC) . The CMMC program is written in Hewlett-Packard

(HP) Pascal 3.0 Language System which provides a level of

4
IWS TECHNICAL SPECIFICATIONS

software control and flexibility necessary to implement essential

IWS software applications. This controller is an NBS product and

is, therefore, not commercially available.

Machine-related functions available in the CMMC function library

help the CMMC software system control the CMM. The library

includes software responsible for interfacing between the higher

level commands executed by the CMMC program and the corresponding

firmware level commands at the CMM's microprocessor level. The

CMMC function library was translated into HP Pascal 3.0 from the

Function Library BASIC (FLB) originally written in HP BASIC 2.0

and supplied by the CMM manufacturer.

1.7. General Coordinate Measuring Machine

Specifications

The CMM should be equipped with an acceptable level of technical

features, as outlined in Sections 1.1 through 1.6, to enable the

inspection facility to measure dimensional tolerances of machine

parts manufactured by the production facility. The CMM employed

in an automated workstation fashioned after the IWS could be able

to inspect a wide range of part sizes, shapes, and weights.

Next, the CMM should be designed with a standard communications

interface suitable (i.e., Hewlett-Packard Interface Bus (HP-IB)

,

General Purpose I/O (GPIO) , RS-232 (Serial), etc.) for connecting

to a host computer. The interface should permit both commands and

data to be transmitted from the host computer to the machine as

well as status information and data to be transmitted from the

machine to the host computer.

Perhaps, a two-axis measuring probe could be installed to permit

probe positioning in two axes and by that means minimize frequent

part refixturing.

1.8. Machine Functionality

The CMM should implement commercial functions that are initiated

remotely. These functions include:

(a) Initializing the CMM to a fixed position at system

startup and/or automatic (computer-controlled)

zero probe calibration;

(b) Moving the probe to a specified location in free

space

(c) Moving the probe and touching the part at a specified

location on the part and saving the location data

for the point touched;

(d) Setting the probe free space and touch speeds; and

5
IWS TECHNICAL SPECIFICATIONS

(e) Selecting PH9 probe tip orientations (for CMM models

equipped with a PH9 measuring probe)

.

The document Implementation of the CMM Controller [A. 3] describes

these functions in further detail.

2. SURFACE ROUGHNESS INSTRUMENT SPECIFICATIONS

The SRI is a photo-optical surface roughness instrument. This

portable, hand-held commercial device provides non-contact, realtime surface roughness inspection.

2.1. Instrument Description

The principal components of the SRI consist of an optical

scattering sensor and an electronic control unit. The sensor is

mounted to an NBS-designed and manufactured holder. As a safety

feature, the holder is seated directly on three ball bearings.

This feature enables the sensor to pitch in order to tolerate

inadvertent impacts sustained from the robot gripper or inspection

parts inspected during normal inspection cycles.

The SRI sensor consists of a light emitting diode (LED) and twenty

optical detectors (linear array of twenty photodiodes) mounted in

a tube. The LED emits radiation at a near infrared wavelength

frequency of 810 nanometers. This radiation is emitted first

through a collimating lens, then through one side of a special

measuring lens that focuses and redirects the radiation so that it

illuminates the surface to be measured at a slight angle of

incidence but very close to the optical axis. Typically, the

radiation reflected, or scattered, by the measuring surface then

passes through the other side of the measuring lens and is

redirected to a linear photodiode array which measures a line

sample of the scattered light beam to obtain an angular

distribution of light intensity. A root mean square (rms)

roughness value is estimated based on empirical analysis.

Inspection of the surface finish, or roughness, of parts

manufactured by the AMRF has typically required a straight-design

(type 40) measuring head having a measuring spot diameter of 1.8

millimeters. Special measuring spot diameters between 0.2 and 4.0

millimeters may be used for special applications.

2.2. Surface Roughness Measurement

The SRI provides surface roughness inspection by measuring the

angular distribution of light scattered from the surface of the

part. All measurements performed by the SRI are closely

coordinated with the IWS robot and the automatic dial indicator

(ADI) . Valid optical scattering readings are obtained when the

6
IWS TECHNICAL SPECIFICATIONS

robot properly aligns the surface of the part in a direction

essentially perpendicular to the plane of the SRI. The ADI is

used to help the robot position the part in front of the SRI for

its initial reading. Using the SRI optical signals as sensory

input, the robot properly aligns the surface of the part in front

of the SRI so that a valid optical scattering reading is obtained.

The SRI uniquely characterizes the surface roughness of machined

parts. If the surface is smooth, the pattern of scattered light

falling on the photodiode array is nearly the same as the circular

pattern of the incident beam leaving the collimating lens. On the

other hand, the scattered light pattern is broadened when the

surface is rough. If the pattern of marks (lay) left on the

surface by the finishing process is unidirectional, the scattered

light pattern is elongated along the roughness direction. Various

finishing processes, including milling, grinding, and turning,

leave unidirectional machining patterns on the surface of a part

and, therefore, yield elongated scattering patterns. Care must be

taken to align the part so that the elongated scattering pattern

is parallel to the long axis of the photodiode array.

Critical parameters of the optical system include the angle of

incidence of the light (a)

,

the angular resolution and angular

range (/?) of the detected scattering light pattern, the

illuminated spot size (y'), and the axial distance of the surface

from the measuring lens. The unitless light scattering parameter

(S N ) output by the optical sensor serves as a measure of surface

roughness. S N

is proportional to the variance of the intensity

distribution about the mean (M) of the data. As a result of

normalizing the integral of the intensity distribution, S Nis

independent of the reflectivity of the inspection part test

surface. The outcome of the inspection will typically be a

comparison of the measured roughness with the nominal specified by

the part design.

2.3. Part Fixturing and Alignment

The robot is exclusively accountable for part relocation and

alignment. The alignment of the part must coincide with the

axial orientation of the SRI sensor. Therefore, the approach for

proper axial alignment of the part surface requires taking

successive measurements of the part surface and subsequently

aligning the part with respect to pitch, yaw, and roll.

2.4. Instrument Operation

The coupling of SRI and IWS robot operations during remote or

automatic control of part positioning enables the IWS to meet

application requirements for operating in either manual or

automatic mode, respectively. The SRI functions in the automatic

7
IWS TECHNICAL SPECIFICATIONS

mode for all IWS operations except for the initial calibration of

the SRI sensor.

2.5. Built-in Microprocessor Instrument Control

Microprocessor-based firmware furnished by the SRI manufacturer

provides fundamental instrument operations—data display,

automatic self-testing, single and continuous measurement, surface

roughness data processing and calculations (statistics) , and error

handling. Complex surfaces and their microstructure may be

described by means of stand-off distance, tilt, surface curvature,

object movement, and/or contamination. Equipment functions can be

controlled through a standard interface from a remote computer.

2.6. Remote Microprocessor Instrument Control

The SRI is controlled by an integrated, data-driven, hierarchical

control software system called the Surface Roughness Instrument

Controller (SRIC) . The SRIC program is written in the HP Pascal

3.0 Language System which provides a level of software control and

flexibility necessary to implement essential IWS software

applications. This controller is an NBS product and is,

therefore, not commercially available.

Machine-related functions available in the SRI function library

help the SRIC software system control the SRI. The library

includes software responsible for interfacing between the higher

level commands executed by the SRIC program and the corresponding

firmware level commands at the SRI (machine) microprocessor level.

2.7. General Surface Roughness Instrument

Specifications

The SRI should be equipped with an acceptable level of technical

features, as outlined in Sections 2.1 through 2.6, to enable the

IWS to determine the surface roughness of machine parts

manufactured by the production facility. The SRI employed in an

automated workstation fashioned after the IWS should be able to

inspect a wide range of surface textures. The technical features

of the SRI should include rapid data collection, simple handling

and ease of use, high reliability and ruggedness, correlation of

measured values to standard values in specified production

processes, and capability of integrating in automatic testing

stations

.

Next, the SRI should be designed with a standard communications

interface suitable (i.e., Hewlett-Packard Interface Bus (HP-IB)

,

General Purpose I/O (GPIO) , RS-232 (Serial), etc.) for connecting

to a host computer. The interface should permit both commands and

data to be transmitted from the host computer to the machine as

8
IWS TECHNICAL SPECIFICATIONS

well as status information and data to be transmitted from the

machine to the host computer.

2.8. Instrument Functionality

The SRI should implement commercial functions that are initiated

remotely. These functions include initializing the SRI at system

startup and retrieving and transmitting scattering (S N )

,

intensity

(I)

,

and individual detector reading (1^) values. The document

Implementation of the SRI Controller [A. 4] describes these

functions in further detail.

3. INSPECTION WORKSTATION ROBOT SPECIFICATIONS

The IWS robot is a standard six-axis robot. The principal

applications of the robot consist of relocating inspection parts

throughout the IWS and working in concert with the SRI to position

a part in front of the SRI sensor as required.

3.1. Machine Description

The principal components of the robot consist of a six-axis

attachment (robot arm) , an NBS-designed and manufactured material

handling gripper, a computer numerical control (CNC) controller,

and a teach pendant. The robot arm is custom mounted upside down

on an overhead gantry. The gantry enables the robot arm to reach

essential areas in the IWS.

The robot has two asynchronous modes of movement—position and

track. In position mode, the robot can be moved at six axes, or

joints. The six axes of the robot arm are the waist axis, the

shoulder axis, the elbow axis, the wrist rotate axis, the wrist

flex axis, and the hand roll axis. In track mode, the robot can

be moved along the gantry track.

The material handling gripper is mounted on the hand faceplate of

the robot arm. The gripper is guided along three mutually

perpendicular, straight-line paths contained in common planes

representing the X, Y, and Z axes of a Cartesian system of

coordinates

3.2. Work Capacity

The defined work volume of the IWS robot is 72 inches by 40 inches

by 40 inches approximately three feet from the floor. When the

robot arm is fully extended, it has a maximum reach of 40 inches.

The gantry axis travel is 72 inches. The maximum load, or

lifting, capacity of the IWS robot arm is approximately 50 pounds.

9
IWS TECHNICAL SPECIFICATIONS

3.3. Workpiece Handling Gripper

The robot is equipped with a prototype (NBS-designed and

manufactured) robot gripper to meet the demands of the IWS for

relocating inspection parts manufactured by the AMRF. The twofingered gripper can secure a maximum part size of 5-3/4 inches.

Its stroke distance (e.g., maximum distance - minimum distance) is

6 inches. Its fingers move in straight-line paths to maintain

parallelism.

The gripper is actuated by compressed air adjustable up to a

recommended maximum air pressure of 60 pounds per square inch. At

the recommended maximum air pressure, a force of approximately 50

pounds is exerted by the fingers, which is adequate to handle the

tasks of relocating inspection parts. The air pressure is not

adjustable under automated control so fragile parts are likely to

be damaged.

3.4. Machine Operation

The robot is equipped with servos for remote control or direct

computer control (DCC) of robot and part handling gripper

positioning to meet application requirements for operating in

either manual or automatic (computer-controlled) mode,

respectively. The robot functions in the automatic mode for all

essential IWS operations except for teaching the robot and

initial calibration of the robot.

3.5. Built-in Microprocessor-based Control

Microprocessor-based firmware furnished by the robot manufacturer

provides fundamental machine operations—-robot arm alignment,

part handling gripper positioning, robot "teach" operations, robot

program implementation, and error handling.

Seven independent 6809 microprocessors are dedicated to single

tasks of controlling a single robot axis motor. All of the 6809

microprocessors are coordinated by a central Motorola 68000

microprocessor. This central microprocessor is responsible for

performing major computing tasks while coordinating the activity

of the 6809 systems.

The robot is equipped with a hand-held teach pendant/ j oystick for

operator control of robot activity.

3.6. Manual Robot Control

The fundamental manual control of the robot is a teach pendant.

The teach pendant includes a twenty key keypad with four different

modes, furnishing eighty available commands. On the same pendant

10
IWS TECHNICAL SPECIFICATIONS

is a joystick control for the robot, with three degrees of freedom

available at any one time. The joystick can regulate robot arm,

elbow, or gripper movement in X, Y, and Z axes, or it can control

pitch, yaw, and roll? the two modes "position" and "orientation"

are selected by a switch. Additionally, there is a motor "ON/OFF"

button and a program "RUN/STOP" rocker switch.

3.7. Remote Microprocessor Robot Control

The robot is controlled by an integrated, data-driven,

hierarchical control software system called the Inspection Robot

Controller (IRC). The IRC program is written in the HP Pascal 3.0

Language System which provides a level of software control and

flexibility necessary to implement essential IWS software

applications. This controller is an NBS product and is,

therefore, not commercially available.

Machine-related functions available in the IRC function library

help the IRC software system control the robot. The library

includes software responsible for interfacing between the higher

level commands executed by the IRC program and the corresponding

firmware level commands at the robot (machine) microprocessor

level

3.8. General Robot Specifications

The standard robot should be equipped with an acceptable level of

technical features, as outlined in Sections 3.1 through 3.7, to

enable the IWS to automatically relocate inspection parts.

The robot should be capable of positioning an inspection workpiece

to an accuracy of 0.25 inch within a defined working volume of

approximately 70 cubic feet. This working volume, or region,

includes three work areas—the delivery platform, the CMM table,

and the SRI measurement region. The motion in the latter region

requires a supplementary linear robot motion.

The robot should be equipped with a workpiece handling gripper

capable of spanning a pick-up dimension of all machined parts as

well as lifting and transporting these parts in a safe and

proficient manner.

The robot should be designed with a suitable interface for

connecting to a host computer permitting both commands and data to

be transmitted from the host computer to the robot and status

information to be transmitted from the robot to the host computer.

The control system of the robot should provide a teach mode, such

as teach-pendant programming, whereby robot positions may be

11
IWS TECHNICAL SPECIFICATIONS

precisely measured and recorded. The resolution of this mode

should be less than 0.005 inches.

The control system of the robot should include a programmable

microprocessor with normal utility programs to simplify routine

tasks such as writing robot programs, the storage and retrieval of

these programs, file management, and communication between

peripherals. This level of software sophistication allows the

user to write programs which interface to the robot controller

(IRC) . The controller program will have to be modified at the

machine module level to be interfaced to the robot.

3.9. Machine Functionality

The robot should implement commercial functions that are initiated

remotely. These functions include:

(a) Initializing the robot to a fixed position at system

startup ? (b) Automatic (computer-controlled) robot arm and

material handling gripper calibration;

(c) Moving the robot arm and/or gripper to a specified

location in free space?

(d) Moving the robot arm and/or gripper and retrieving a

part from a specified location?

(e) Moving the robot arm and/or gripper and relocating a

part from one specified location to another?

(f) Moving the robot arm and/or gripper and delivering a

part to a specified location? and

(g) Setting the robot arm and/or gripper "move" speed and

mode

.

The document Implementation of the Robot Controller [A. 5]

describes these functions in further detail.

12
IWS TECHNICAL SPECIFICATIONS

III. COMPUTER SYSTEMS EQUIPMENT SPECIFICATIONS

The IWS equipment and instruments are controlled by a integrated

network of four Motorola 12.5 megahertz MC 68000 microprocessorbased microcomputers with 16-bit internal architecture. Each

microcomputer is delegated specialized functions with respect to

the inspection facility. Their respective tasks include main

Inspection Workstation controller (WSC) , coordinate measuring

machine controller (CMMC) , surface roughness instrument

controller (SRIC) , and inspection robot controller (IRC) . These

microcomputer systems allow the IWS to operate in stand-alone and

integrated modes.

1. PRINCIPAL HARDWARE AND SOFTWARE COMPONENTS

Each of the four computer systems of the IWS consists of a

selection of the following hardware and software components:

(a) He'

(b) HP

(c) HP

(d) HP

(e) HP

(f) HP

(g) HP

(h) HP

(i) HP

(j) HP

(k) HP

(1) HP

(m) HP

(n) HP

/lett-Packard (HP) 9000 Series 200 Microcomputer

(Model No. 992 0U or Model No. 9836U) ; 12-inch Monochromatic Monitor (Model No. 82913A)

(applicable for HP 9000 Series 200 Microcomputers

(Model No. 992 0U) only) ; -HIL Nimitz Keyboard (Model No. 9820B) (applicable

for HP 9000 Series 200 Microcomputers (Model No.

992 0U) only) ; 16.7-Megabyte (MByte) CS/80 Winchester Disc (Model

No. 7908P) or 28.7 Mbyte CS/80 Winchester Disc

(Model No. 7 9 IIP) ; 286.72-Kilobyte (KByte) AMIGO Dual 3-1/2 Inch

Flexible Disc (Model No. 9121D)

1.0-MByte Random Access Memory (RAM) Card (Product

No. 98257A)

256-KByte RAM Card (Product No. 98256A)

Keyboard/HP-IB Interface Card (Product No. 9920A)

(applicable for HP 9000 Series 200 Microcomputers

(Model No. 992 0U) only) ; Composite Video Interface Card (Product No.

98626A)

Interface Bus (HP-IB) Interface Card (Product No.

98626A)

RS-232 Serial Interface Card (Product No. 98626A)

General Purpose Input/Output (GPIO) Interface Card

(Product No. 98622A)

Programmable Data Communication Interface Card

(Adds DCE (female, direct-connect) RS-232 cable)

(Product No. 98628A/98691A Option 002)

and

Pascal 3.0 Language System (Product No. 98615A

Option 630)

13
IWS TECHNICAL SPECIFICATIONS

1.1. Main Inspection Workstation Computer System

The principal hardware and software components of the main IWS

computer system include an HP 9000 Series 200 Microcomputer (Model

No. 9820U) , several RAM boards, one HP-IB interface board, one RS232 serial interface board, one GPIO interface board, three data

communications interface boards, and the HP Pascal 3.0 Language

System. The HP remote microcomputer contains an internal Random

Access Memory capacity of approximately 786 kilobytes. The remote

microcomputer has an HP AMIGO dual 3-1/2 inch flexible disc drive

unit and an HP 16.7-Megabyte CS/80 Winchester disc.

1.2. Coordinate Measuring Machine Computer System

The principal hardware and software components of the CMM computer

system include an HP 9000 Series 200 Microcomputer (Model No.

9836)

,

several RAM boards, one built-in HP interface bus (HP-IB)

,

one data communications interface board, and the HP Pascal 3.0

Language System. The HP remote microcomputer contains an

internal Random Access Memory capacity of approximately 1,901

kilobytes. The HP-IB interface provides the communications link

between the microcomputer and the CMM's built-in microprocessor.

The remote microcomputer has two built-in 5-1/4 inch flexible disk

drive units and an HP 65.6-Megabyte CS/80 Winchester disc.

1.3. Surface Roughness Instrument Computer System

The principal hardware and software components of the SRI computer

system include an HP 9000 Series 200 Microcomputer (Model No.

992 0U)

,

several RAM boards, one GPIO interface board, one data

communications interface board, and the HP Pascal 3.0 Language

System. The HP remote microcomputer contains an internal Random

Access Memory capacity of approximately 2,228 kilobytes. The RS232 serial port provides the communications link between the

microcomputer and the SRI's built-in microprocessor. The

communications link between the microcomputer and the ADI is

provided by the HP-IB interface port. The remote microcomputer

has an HP AMIGO dual 3-1/2 inch flexible disk drive unit and an HP

16.7-Megabyte CS/80 Winchester disc.

1.4. Robot Computer System

The principal hardware and software components of the robot

computer system include an HP 9000 Series 200 Microcomputer (Model

No. 992 0U)

,

several RAM boards, one HP-IB interface board, one

GPIO interface board, one data communications interface board, one

RS-232 serial interface board, and the HP Pascal 3.0 Language

System. The HP remote microcomputer contains an internal Random

Access Memory capacity of approximately 1,048 kilobytes. The

computer communication interfaces of the robot include sixteen

14
IWS TECHNICAL SPECIFICATIONS

bits of input and twelve bits of output controlled by the GPIO

(parallel) port and the serial port which uses RS232 protocol.

The remote microcomputer has an HP AMIGO dual 3-1/2 inch flexible

disk drive unit and an HP 28.7-Megabyte CS/80 Winchester disc.

2. INTERNAL MEMORY (RAM) CAPACITY

The HP 9000 Series 200 Microcomputer models 9920U and 9836U base

systems will support 3.07 and 2.05 MBytes internal RAM,

respectively. The microcomputer systems currently possess an

internal Random Access Memory capacity range between 750 KBytes

and 2.0 MBytes each. Although present IWS software applications

do not generally require greater internal memory capacities,

capacities of 1,048 kilobytes (1.0 megabytes) or greater are

recommended.

3 . NETWORK COMMUNICATIONS

In keeping with the integrated, data-driven, hierarchical control

strategy of the AMRF, programmable data communication interface

(Product No. 98628A/98691A Option 002) cards were installed in

each of the four microcomputers. These interface cards have

erasable-programmable read-only memory (EPROM) integrated circuits

to meet the specific AMRF-related data communication and serial

interfacing needs. NBS personnel programmed the EPROM circuits in

Z-8 0 assembly language and installed each circuit onto its

respective data communications interface card. Information passed

by these cards includes command and status information. The WSC

has four of these communication interface cards and the other

three controllers, the IRC, the CMMC, and the SRIC, each have one.

Integration of the IWS to the AMRF depends on a reliable and

effective network communications system. In keeping with the

strategy of the AMRF control system, inspection operations at the

IWS must foster its important role as one of the controlled

components of a fully integrated manufacturing cell. Other

workstations of the AMRF include the Cleaning and Deburring

Workstation (CWS) , the Horizontal Workstation (HWS) , the Material

Handling System (MHS) , the Turning Workstation (TWS)

,

and the

Vertical Workstation (VWS)

Refer to the AMRF Network

Communications document, written by S. F. Rybczynski, E. J.

Bakmeyer, E. K. Wallace, M. L. Strawbridge, D. E. Libes, and C. V.

Young, for specific characteristics of this network.

4. INSPECTION WORKSTATION SOFTWARE DEVELOPMENT

All IWS software applications approach specific goals in

accordance with AMRF hierarchical control strategy. Nonetheless,

local software development and implementation was influenced by

the constraints imposed by each microcomputer system, its

15
IWS TECHNICAL SPECIFICATIONS

operating system, and the available HP Pascal 3.0 Language System.

The high degree of software integration to the hardware may impede

transfer of the IWS software to other computer systems.

16
IWS TECHNICAL SPECIFICATIONS

IV. MISCELLANEOUS INSPECTION WORKSTATION EQUIPMENT

SPECIFICATIONS

The miscellaneous Inspection Workstation equipment includes an

automatic dial indicator (ADI) and a safety fence.

1. AUTOMATIC DIAL INDICATOR SPECIFICATIONS

The ADI is a digital dial gage. This instrument senses and

measures axial distance variations and displays the amplified

version of the sensed dimensional variation on a liquid crystal

display (LCD) digital readout.

1.1. Instrument Description

The ADI employs a sensing (gage) spindle that moves back and forth

in a supporting stem (measuring spindle guide) and a LCD digital

readout indicator. The travelling component, or removable contact

(gaging) point, attached to the anterior apex of the gage spindle,

is guided along a linear path. Distance variation sensing and

measuring is performed by the indicator. The mechanism of the

indicator converts the axial displacement of the measuring spindle

into rotational movement which is then amplified by mechanical

means and displayed by a LCD digital readout.

1.2. Distance Measurement

The ADI measures axial displacement when a part touches the gaging

point on the gage spindle. The distance between a reference plane

at a fixed position relative to the instrument and a gaging point

on the part is measured. This distance is then displayed on the

liquid crystal display (LCD) digital readout.

1.3. Part Fixturing and Staging

Since the ADI by itself is not a complete measuring instrument,

indicator measurements of length must be complemented with the

inspection robot. The ADI is mounted to an NBS-designed and

manufactured fixture mount.

The robot presents the part on a reference plane which is

coincident with one end of the distance to be measured (the datum

of the measurement) . The permanent affixation of the ADI to a

positive position from that reference plane allows the spindle to

adjust to different distances to be measured.

Typically, the axial alignment procedure in the IWS is performed

by way of the inspection robot moving the part to a position

approximately one inch in front of the ADI and then moving the

part toward the instrument in half inch steps until the part

17
IWS TECHNICAL SPECIFICATIONS

contacts the gaging point and a reading is made of the axial part

position. In Chapter III, Section 2 of the document

Implementation of the SRI Controller [A.4], this procedure is

called the axial calibration.

1.4. Instrument Operation

The ADI is equipped with a battery-backed microprocessor for

operating in either manual or automatic (computer-controlled)

mode. Typically, the ADI functions in the automatic mode for all

IWS operations except the initial zero adjustment of the

instrument.

1.5. Built-in Microprocessor-based Control

& The built-in microprocessor furnished by the ADI manufacturer

provides fundamental instrument operations—metric/ inch

conversion, linear data display, axial displacement measurement,

zero adjustment, and error handling.

1.6. Remote Microprocessor Instrument Control

The ADI is controlled by the SRIC software system, discussed in

Chapter II, Section 2.6, through the machine-related functions

available in the SRI function library. This library includes

software responsible for interfacing between the higher level

commands executed by the SRIC program and the corresponding

firmware level commands at the ADI (machine) microprocessor level.

1.7. General Automatic Dial Indicator

Specifications

The ADI should be equipped with an acceptable level of technical

features, as outlined in Sections 1.1 through 1.6, to enable the

inspection workstation to measure axial displacement. It should

conform to basic American Gage Design (AGD) specifications for

mounting in order to permit the same fixturing used for

conventional AGD indicators. The ADI should be designed with a

microprocessor-based electronic measuring system that allows the

instrument to be integrated into automatic (computer-controlled)

testing stations. Also, the ADI should be designed with a

computer interface port for communication between the host

computer and the instrument.

2. SAFETY FENCE SPECIFICATIONS

The safety fence is an electronically integrated system of two

transmitter and receiver units. These electronic sensing devices

promote safety in the IWS environment by protecting against bodily

injury to personnel and damage to equipment and parts. These

18
IWS TECHNICAL SPECIFICATIONS

devices monitor the space occupied by the inspection robot to

detect the infiltration thereof along electronically shielded

regions, particularly during intervals of on-going inspection

operations

2.1. Device Description

The safety fence of the IWS integrates two sets of Dolan-Jenner

Safescan IV 15 1/2 transmitter and receiver units, each separately

supported by mounting stands. The transmitter and receiver units

are housed in welded steel enclosures which meet the twelve NEMA

requirements. The units were designed with vibration pads to help

them withstand shock and vibration and thereby improve reliability

of operation.

Each transmitter and receiver unit has eighteen sets of light

emitting diode (LED) transmitters and receivers. The LED's can be

pulsed or modulated (rapidly switched on and off to provide brief

flashes of invisible light) to allow detectors or receivers to be

tuned to the repetition rate and duration of the pulse. This LED

pulse modulation technique of tuning out extraneous light makes

the Safescan IV immune to light sources other than its own

transmitter and allows the unit to extend its operating ranges to

45 feet. Sequential operation of the transmitters and receivers

permits full beam intensity for each pair without interference

from any other pair regardless of transmitter-receiver spacing.

2.2. Safety Fence Configuration

While the safety fence system is a part of the inspection robot

system, its operation is not controlled by the IRC. However, when

functioning in integrated mode, this system has the capability to

stop the operation of the robot upon detection of any object

coming across its electronic field. This inevitably halts IWS

operations

Safety in the inspection environment of the IWS is enhanced by the

design and physical layout of this safety system. The transmitter

and receiver units monitor two critical regions directly outside

the space occupied by the inspection robot. These critical

regions are deemed most accessible by personnel as well as

automated equipment.

2.3. General Safety Fence Specifications

The safety considerations of an inspection workstation environment

may prescribe integration of an electronic safety fence system.

Therefore, general safety fence equipment should exhibit features

such as highly-dependable operator protection, high stability and

noise immunity, ease of installation and alignment, adequate range

19
IWS TECHNICAL SPECIFICATIONS

(distance) of operation, and high reliability in semi-clean

inspection environments.

The safety fence equipment should be designed and constructed to

meet Occupational Safety and Health Administration (OSHA) 1910.217

and the American Society of Mechanical Engineers (ANSI) Bll. 1-1982

requirements for point-of-presence sensing devices.

20
IWS TECHNICAL SPECIFICATIONS

APPENDICES

A. IWS DOCUMENTATION LIST

1. H. T. Moncarz, Architecture and Principles of the

Inspection Workstation , to be published as an

NBSIR.

2. H. T. Moncarz, Implementation of the Execution

Control System of the Inspection Workstation , NBSIR 88-3787, May 19, 1988.

3. H. T. Moncarz and T. H. Hopp, Implementation of

the CMM Controller , to be published as an NBSIR.

4. H. T. Moncarz and T. V. Vorburger, Implementation

of the SRI Controller , to be published as an

NBSIR.

5. H. T. Moncarz and B. Borchardt, Implementation of

the Inspection Robot Controller . NBSIR 88-3772,

April 21, 1988.

6. S. A. Osella, Implementation of the Workstation

Controller . to be published as an NBSIR.

7. J. Zimmerman, Inventory of Equipment in the

Inspection Workstation . NBSIR 88-3375, May 5,

1988.

8. H. T. Moncarz, S. A. Osella, B. Borchardt, and R.

Veale, Operations Manual for the Inspection

Workstation . NBSIR 88-3766, April 21, 1988.

9. J. Zimmerman, Recommended Technical Specifications

for Procurement of Commercially Available Systems

for the Inspection Workstation . NBSIR 88-3779, May

11, 1988.

21
IWS TECHNICAL SPECIFICATIONS
IWS TECHNICAL SPECIFICATIONS

B. LIST OF REFERENCES

1. American Robot Corporation. Merlin Robot System

Operators and User Guide. SMT-2 . 0-0184 : 1982.

2. Bendix Corporation. Cordax Coordinate Measuring

System-Owner's Manual for the Bendix Cordax 2000

Series Horizontal Arm CMM . Dayton, Ohio;

42001276: January 1982.

3. Bendix Corporation. Cordax Coordinate Measuring

System-Overview Manual for the Merlin Cordax

Coordinate Measuring System: An Introduction . Dayton, Ohio? 58001727: November 1982.

c 4. Bendix Corporation. Cordax Coordinate Measuring

System-Technical Manual for the Cordax MP-10 & MP20 Measuring Systems . Dayton, Ohio; 58001733:

November 1982.

5. Bendix Corporation. Cordax Coordinate Measuring

System-User's Manual for the PH9 Probe Head

Expansion . Dayton, Ohio? 58000982: May 1982.

6. Farago, Francis T. Handbook of Dimensional

Measurement . New York, New York: Industrial

Press? 1982. 524 p.

7. Gilsinn, D. E. ? Vorburger, T. V.; Teague, E. C.

McLay, M. J.? Giauque, C. ? Scire, F. E. Surface

Roughness Metrology by Angular Distributions of

Scattered Light. Measurement and Effects of

Surface Defects and Quality of Polish . Bellingham, West Virginia: Proceedings from

Society of Photo-Optical Instrumentation

Engineers. 525: 2-15; 1985.

8. Gilsinn, David? Vorburger, Theodore? Cao, Linxiang; Giauque, Charles; Scire, Frederic? Teague,

E. Clayton. Optical Roughness Measurements of

Industrial Surfaces. Optical Techniques for

Industrial Inspection . Bellingham, West Virginia:

Proceedings from Society of Photo-Optical

Instrumentation Engineers. 655: 8-16? 1986.

9. Kennedy, Clifford W. ? Andrews, Donald E.

Inspection and Gaging . New York, New York:

Industrial Press; 1977. 598 p.

23
IWS TECHNICAL SPECIFICATIONS

10 .

11 .

Rodenstock Precision Optics, Incorporated.

Rodenstock Operating Manual . 1984.

Vorburger, T. V. ; Teague, E. C. ; Scire, F. E.

;

McLay, M. J. ? Gilsinn, D. E. Surface Roughness

Studies with DALLAS-Detector Array for Laser Light

Angular Scattering. Journal Of Research of the

National Bureau of Standards (U.S.). 89(1): 3-16;

1984 January-February

.

o

24
IWS TECHNICAL SPECIFICATIONS

c. GLOSSARY (and abbreviations)

ADI Abbreviation for the Automatic Dial Indicator.

automatic dial indicator

Instrument used to measure the distance that a spring

mounted stem is depressed.

CMM Abbreviation for the Coordinate Measuring Machine.

CMMC Abbreviation for the Coordinate Measuring Machine

Controller.

controller

Supervises the operation of a mechanism and/or another

controller,

coordinate measuring machine

Machine used to measure the dimensions of a part.

inspection robot

Robot used in the Inspection Workstation to retrieve

and/or relocate a part.

inspection workstation

AMRF workstation that inspects parts for dimensional

tolerance and surface finish.

IRC Abbreviation for the Inspection Robot Controller.

IWS Abbreviation for the Inspection Workstation.

Kbyte Abbreviation for kilobyte (1024 bytes)

Mbyte Abbreviation for megabyte (1,048,576 bytes).

RAM Abbreviation for Random Access Memory.

SRI Abbreviation for the Surface Roughness Instrument.

SRIC Abbreviation for the SRI Controller.

surface roughness instrument

WSC

Machine that measures the optical scattering from the

surface of a part. The scattering can be correlated with

its surface roughness.

Abbreviation for the Workstation Controller.

25
IWS TECHNICAL SPECIFICATIONS

.

•

‘

.

26
READER COMMENT FORM

RECOMMENDED TECHNICAL SPECIFICATIONS FOR PROCUREMENT OF

COMMERCIALLY AVAILABLE SYSTEMS FOR THE INSPECTION WORKSTATION

This document is one in a series of publications which document

research done at the National Bureau of Standards' Automated

Manufacturing Research Facility from 1981 through March, 1987.

You may use this form to comment on the technical content or

organization of this document or to contribute suggested editorial

changes

Comments

If you wish a reply, give your name, company, and complete mailing

address:

What is your occupation?

NOTE : This form may not be used to order additional copies of

this document or other documents in the series. Copies of AMRF

documents are available from NTIS.

Please mail your comments to: AMRF Program Manager

National Bureau of Standards

Building 220, Room B-lll

Gaithersburg, MD 20899
.
MBS-114A (REV. 2-80

U.s. DEPT. OF COMM.

BIBLIOGRAPHIC DATA

SHEET (See instructions)

1. PUBLICATION OR 2. Performing Organ. Report No. 3. Publication Date

REPORT NO.

NBSIR 88-3779 MAY 1988

4. TITLE AND SUBTITLE

"RECOMMENDED TECHNICAL SPECIFICATIONS FOR PROCUREMENT OF COMMERCIALLY AVAILABLE

SYSTEMS FOR THE INSPECTION WORKSTATION"

5. AUTHOR(S)

Jay H. Zimmerman, Precision Engineering Division, Dimensional Metrology Group

8. PERFORMING ORGANIZATION (If joint or other than NBS. see instructions)

national bureau of standards

DEPARTMENT OF COMMERCE

WASHINGTON, D.C. 20234

7. Contract/Grant No.

8. Type of Report & Period Covered

9. SPONSORING ORGANIZATION NAME AND COMPLETE ADDRESS (Street, City, State, ZIP)

National Bureau of Standards

Route 270 and Quince Orchard Road

Gaithersburg, Maryland 20899

10. SUPPLEMENTARY NOTES

j~ Document describes a computer program; SF-185, FlPS Software Summary, is attached.

11. ABSTRACT (A 200-word or less factual summary of most si gnificant information. If document includes a significant

bibliography or literature survey, mention it here)

This document furnishes the technical specifications of the Inspection Workstation

(IWS) in the Automated Manufacturing Research Facility (AMRF) at the National Bureau

of Standards. The IWS is a prototype automated inspection facility. The principal

commercial mechanical and electronic equipment and instruments of the IWS

include the horizontal arm coordinate measuring machine (CMM) , the inspection robot

(IRC), and the optical surface roughness instrument (SRI). The computer systems of

the IWS include the Main Workstation Controller (WSC)

,

the Inspection Robot Controller

(IRC), the Coordinate Measuring Machine Controller (CMMC) , and the Surface Roughness

Instrument Controller (SRIC)

Other equipment and instruments include the automatic

dial indicator (ADI) and the electronic safety fence.

12. KEY WORDS (Six to twelve entries ; alphabetical order; capitalize only proper names; and separate key words by semicolon s) Automatic dial indicator; controller; coordinate measuring machine; Inspection

Workstation; robot; surface roughness instrument; technical specifications

13. availability

|~~x"l Uni imited

j

! For Official Distribution. Do Not Release to NTIS

[ [ Order From Superintendent of Documents, U.S. Government Printing Office, Washington, D.C.

20402.

LKj Order From National Technical Information Service (NTIS), Springfield, VA. 22161

14. NO. OF

PRINTED PAGES

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15. Price

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