Abstract:
A robotically assisted flexible test and inspection system that is portable and adaptable to test and/or inspect products is described. The test and inspection system is a compact system that can be moved easily to different locations and includes a robotic arm which is used for testing and inspection of a unit-under-test (UUT). The robotic arm can be used to activate different controls in the UUT or cause different functionality of the UUT to be tested. The robotic arm can use different tools such as a switch activator tool, to accomplish its tasks. The test and inspection system in one embodiment is a movable test cart, wherein the robotic arm is located in one of the shelves of the test rack and the UUT is located in another shelf of the test rack which has an aperture that presents portions of the UUT to the robotic arm. Another shelf or shelves of the moveable test rack can accommodate a test system controller, testing and inspection components/instruments, etc.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application claims the priority benefit of U.S. Provisional Application Ser. No. 65/050,192, filed Sep. 14, 2014, which is incorporated herein by reference in its entirety. 
     
    
     FIELD OF THE INVENTION 
       [0002]    This invention relates in general to test and inspection systems and more specifically to a robotically assisted flexible test and inspection system. 
       BACKGROUND 
       [0003]    Test and inspection systems are used in manufacturing operations in order to test and/or inspect products that have been manufactured in order determine if the manufactured product is working to the product&#39;s design specifications. Most test and inspection systems tend to be designed for a particular product that will be tested/inspected, making them good for the particular test application they have been designed for, but inflexible when it comes to testing the same product if it has been modified or testing/inspecting other products or multiple products. Another problem with current testing and inspection system, especially those used to test industrial products such as aircraft products (e.g., systems, subassemblies, parts, etc.) is that the test/inspection systems tend to be large fixed systems that are located in a particular location, requiring the products that are to be tested and/or inspected to be brought to the test/inspection system in order for the testing to be performed. This presents issues for manufactures that want flexibility in their manufacturing operations. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0004]    The features of the present invention, which are believed to be novel, are set forth with particularity in the appended claims. The invention may best be understood by reference to the following description, taken in conjunction with the accompanying drawings, in the several figures of which like reference numerals identify like elements, and in which: 
           [0005]      FIG. 1  shows a drawing of a portable robotically assisted test and inspection system in accordance with an embodiment of the invention. 
           [0006]      FIG. 2  shows a picture of a top side view of a portable robotically assisted test and inspection system in accordance with an embodiment of the invention. 
           [0007]      FIG. 3  shows a picture of a side view of a portable robotically assisted test and inspection system in accordance with an embodiment of the invention. 
           [0008]      FIG. 4  shows a picture of a robotic arm in accordance with an embodiment of the invention. 
           [0009]      FIG. 5  shows another picture of a robotic arm in accordance with an embodiment of the invention. 
           [0010]      FIG. 6  shows a side view of a portable robotically assisted test and inspection system in accordance with an embodiment of the invention. 
           [0011]      FIG. 7  shows another side view of a portable robotically assisted test and inspection system in accordance with an embodiment of the invention. 
           [0012]      FIG. 8  shows a block diagram of a portable robotically assisted test and inspection system in accordance with an embodiment of the invention. 
       
    
    
     DETAILED DESCRIPTION 
       [0013]    While the specification concludes with claims defining the features of the invention that are regarded as novel, it is believed that the invention will be better understood from a consideration of the following description in conjunction with the drawing figures. 
         [0014]    Referring to  FIG. 1 , there is shown a drawing of a portable test and inspection system  100  in accordance with an embodiment of the invention. Test and inspection system  100  includes a portable test cart  102  having a set of wheels  122  for portability and movability. The test cart  102  includes a support member  104  used in holding a keyboard, mouse, scanner, etc. that is used by the test operator to control and monitor the testing process. A monitor support arm  106  is coupled to the support member  104  and supports a monitor  108  such as an LED or LCD monitor that can provide visual and/or touch screen interface capability for the test operator that is using the test and inspection system  100 . Monitor  108  allows the test operator to select to re-run any sub-tests within a particular test sequence. 
         [0015]    Although not shown in  FIG. 1 , a test system controller such as a computer is coupled to the monitor  108  and is used to control the functionality of the test and inspection system  100 . In one embodiment the computer is located in the bottom shelf  124  of the portable test cart  102  along with a power supply to provide power to the product being tested, switching and/or testing equipment and/or instruments (not shown) that can also be under the control of the computer and used for conducting tests of the product being tested. Depending on the particular design requirements, portable test cart  102  can have any number of shelves to accommodate different testing/inspection requirements. The computer (not shown) can be a personal computer or specialized test system controller such as a card based computer mounted onto a test rack slot with other electronic boards such as switching/testing boards being mounted on other slots of the test rack. 
         [0016]    Portable test cart  102  includes a top shelf  114  which is used to receive a product to be tested. The product to be tested which will be referred to as a unit-under-test (UUT)  118  can be anything from a single component, electronic board, sub-assembly, etc. In one embodiment, the UUT  118  comprises an Astronics PECO division aircraft Passenger Service Unit (PSU) which is an aircraft assembly that is typically located overhead above airline passenger seats in an aircraft and that includes the passenger reading lights, air vents, flight attendant call buttons, emergency oxygen mask door, etc. 
         [0017]    A computer controlled robotic arm  112 , such as one manufactured by Energid Technologies/Robai is located on a shelf  110  underneath of the top shelf  114 . Robotic arm  112  is capable of grasping numerous tools such as a button press tool in order to activate controls such as switches found on the UUT  118 . Besides switches/controls found on the UUT  118 , the robotic arm can close an emergency oxygen mask door when it is opened during testing, it can also toggle a switch which sends the attendant light to the front or back of the airplane. The robotic arm  112  is strong enough to pick up and use different types of tools for testing of different UUTs. 
         [0018]    The top shelf  114  tray has one or more apertures (openings) to allow for certain parts of the UUT  118  to be accessible to the robotic arm  112  which is located underneath the top shelf  114 . In one embodiment, there is a singular large opening that allows access to the majority of the UUT  118  to the robotic arm except for a small amount of the edge margin of the UUT which is required to support the UUT to the top shelf  114 . The top shelf  114  can include one or more blocks or retention members to fix and register the UUT  118  to a specific location on the top shelf  114 . One or more clamps or other type of fixating devices can also be included on the top shelf  114  in order for the UUT  118  to be securely fastened in place prior to the robotic arm  112  activating the controls found on the UUT  118  during the testing sequence. In one embodiment, the robotic arm  112  is under control of the test system controller and has been programmed to test the different controls such as the light switches (buttons) located on the UUT  118 . Since the UUT  118  is firmly fixed in place using clamps or other fastening techniques, the robot arm  112  uses predetermined movements and positional alignments under the control of software executed by the test system controller to activate these switches on the UUT  118 . 
         [0019]    Robotic test and inspection system  100  reduces the time for a human to inspect and test an electro-mechanical device such as UUT  118 , collecting the data, analyzing the data through statistical process control (SPC) techniques, developing traceability data, and archiving the data by generating quality inspection reports for a variety of consumer or industrial products, like the aircraft PSU mentioned above. The pass/fail data for the UUTs  118  that have been tested using test system  100  is compared to customer defined limits and the software can document and alert the test operator when results are outside of expected limits. The test operator alerts can comprise audio and/or visual alerts. This helps the test operator make an early detection of a production lot that is potentially defective before more are manufactured and/or tested. Since test system  100  is computer controlled and robotically assisted, it can determine if a UUT  118  has been built and operates to the manufacturers predetermined set of requirements. Test system  100  replaces human vision inspection, audio testing, and touch of buttons with a humanoid manipulator (robotic arm)  112  and computer hardware and software to perform the same tasks as a human tester with higher reliability, all in a small and portable form factor. 
         [0020]    Test system  100  also automates the image (e.g., photographic/video) capture of the UUT  118  to validate that the test/inspection was performed, and stores the information in a database along with the part number and serial number information to meet regulatory agency requirements such as the Federal Aviation Administration (FAA) for the collection and archiving of quality inspection reports. The serial number and/or part number of the UUT  118  can be scanned using a scanner or using digital camera  126  or camera  128 , depending on the particular design objectives of test system  100 . The database can be a local or remote database depending on the particular design requirements for the test system. 
         [0021]    Image capture in test system  100  is performed by a machine vision camera  128  located on shelf  110  which is used to take an images (pictures) of the UUT  118  on the side facing the robotic arm  118 . The picture(s) taken by camera  128  can be compared using vision compare software run by the computer to a UUT that has been properly manufactured. The vision compare software can detect if any switches, parts, etc. are missing. In one embodiment, the picture or pictures taken by the machine vision camera  128  are stored in a folder with a Log.csv file and is given a unique name (UUTID_YYYYDDMMHHmm.png). The file name is then saved to the database so that when loaded in Excel (and format the row as a link) the picture can be opened in one click. 
         [0022]    In test system  100  a second camera  126  is mounted onto support member  120  which is connected to support members  116  which are coupled to the test cart  102 . The second or top camera  126  takes a picture and sends it to the vision software found in the test system controller, which inspects the placement and existence of critical components such as screws, wires, lanyards, doors, etc. which make part of UUT  118 . Using both cameras  126  and  128  allows for the vision software to inspect both sides of the UUT  118  for any flaws, missing parts and the like. The cameras  126  and  128  and accompanying software can also perform edge detection, color comparison, objection comparison, scan barcodes, determine illumination strength of lights that are activated, etc. 
         [0023]    Although in the preferred embodiment, test system  100  is used to test an aircraft PSU, the test system  100  can be configured to test a wide variety of consumer or industrial electronic or electro-mechanical products. The top test shelf  114  can also be designed so that it is easily removable from the test cart  102  and replaced with another top test shelf that can accommodate a different UUT having different dimensions, etc. The new top test shelf can have different aperture(s) (openings) to allow different parts of the UUT to be accessible to the robotic arm  112 . The top shelf  114  can be designed to be easily removed using fast disconnect fasteners as known in the art, top support members  116  can be designed to connect to the sides of the test cart  102  so that they are not in the way when the top shelf needs to be replace to accommodate a different UUT. 
         [0024]    Referring now to  FIG. 2 , there is shown a top side view of the test system  100 . As shown, a digital camera (camera  126  shown in  FIG. 1 ) is located on the top bracket and is used to take images of one side of the UUT (UUT  118  shown in  FIG. 1 ). In this case, the camera  126  takes images of the back side of the UUT  118 , in order to verify the components are all there. As shown, the UUT  118  is placed in proper position by a series of support/registration members which hold and align the edges of UUT  118 . At the bottom of the picture are locking mechanisms that keeps the UUT  118  firmly positioned in place so that when the robotic arm  112  is actuating the switches, the UUT  118  does not move out of place. 
         [0025]    Shown in  FIG. 3  is a side view of the portable test system, showing several shelves, one holding the robotic arm, the other two supporting the test system controller (computer) and any necessary switching and test equipment needed to test and inspect the UUT Also shown in this view is a cable connected to the UUT on the lower left corner that is connected to a power supply, power converter, and any test/switching equipment which are used to test the UUT  118 . The switching equipment includes a switch card that allows the test system  100  to control power to different components of the UUT individually and use both AC and DC power. 
         [0026]    Referring to  FIG. 4 , there is shown a close up view of the robotic arm  112  which is located on shelf  110 . The vision camera  128  is also shown on shelf  110 . In this view a microphone  402  is shown which can be used to verify that any audio signals that the UUT  118  needs to produce are in fact produced during testing. Besides a microphone  402 , other equipment such as a light detector could also be added in order to check for any light emissions for other UUTs, temperature sensors, etc. can also be included if the UUT requires other types of performance tests. The camera  128  rests on shelf  110  and is used to take images of the side of the UUT which the robotic arm  112  is interacting with. In  FIG. 5  there is shown a close up view of the robotic arm  112  using the switch activation tool to activate (press) a light switch found in the UUT  118 . In  FIG. 5  there is also shown the opening in top shelf  114  which allows a good portion of the UUT  118  to be accessible to robotic arm  112 . The robotic arm is shown grasping a switch testing tool used for activating the switches found in the UUT. 
         [0027]    In  FIGS. 6  and  FIG. 7  there are shown side view drawings of the test system  100 . In  FIG. 6  there is shown a few of the support members  602  that are used to hold and register the UUT in proper position for testing. One of the lock down clamps  604  which is used to hold down the UUT for testing is also shown. 
         [0028]    Referring now to  FIG. 8 , a simplified block diagram of the test system  100  is shown in accordance with an embodiment of the invention. A controller  802  as previously mentioned which can take the form of a personal computer, test controller, or other known in the art control unit can be used to control and execute the software needed to run the test and inspection system  100 . Controller  802  executes the robotic arm and vision software needed to operate the robotic arm  804  and cameras  126  and  128 . The vision software for example can be used to determine if a light in the UUT  118  is operational by taking a picture with the camera  128  and sending the picture to the vision compare software that is executed by controller  802 . The vision compare software compares the picture that has been taken to a pre-programmed picture and determines if the light is on or off during testing. Controller  802  is also coupled to input/output devices such as monitor  108 , a keyboard, cameras  128  and  126 , a microphone, a scanner for scanning bar code or other information from the UUT  806 , etc. A database  812  is coupled to the controller  802  and is used to store the information collected from the test and inspection of the UUT. The database  812  can be located either locally or remotely. Database  812  can also have stored therein pictures of UUT&#39;s  806  which have been manufactured correctly so the portable test and inspection system  100  can take images with cameras  126  and  128  and compare those images to those stored in database  812  for correctly built UUT&#39;s  806 . If the image information do not match, for example a control switch is missing from the UUT  806 , a warning message can be provided to the test operator using monitor  108  and the problem noted in the test report which can be stored in the database  812  and/or controller  802 . Such as warning message can cause the UUT  806  to fail the test/inspection. Test system  100  in one embodiment stores in database  812  for each UUT  806  that is tested operator/user information, UUT serial number, UUT part number, pass/fail information for each test conducted, a picture file name for each picture/image associated with the particular UUT test. Controller  802  also provides control to any necessary power supply and test and switching equipment  808 , as well as the keyboard, scanner, cameras, microphone, etc.  810  used to test and inspect the UUT  806 . 
         [0029]    While the preferred embodiments of the invention have been illustrated and described, it will be clear that the invention is not so limited. Numerous modifications, changes, variations, substitutions and equivalents will occur to those skilled in the art without departing from the spirit and scope of the present invention as defined by the appended claims.