Manufacturing processes have become increasingly sophisticated leading to greater usage of robotics. Sustaining successful manufacturing robotic operations requires a strategic maintenance program. Without careful planning, maintenance can be very costly. To reduce maintenance costs, manufacturers are exploring how they can assess the health of their robot workcell operations to enhance their maintenance strategies. Effective health assessment relies upon capturing appropriate data and generating intelligence from the workcell. Multiple data streams relevant to a robot workcell may be available including robot controller data, a supervisory programmable logic controller data, maintenance logs, process and part quality data, and equipment and process fault and failure data. These data streams can be extremely informative, yet the massive volume and complexity of this data can be overwhelming, confusing, and sometimes paralyzing. Researchers at the National Institute of Standards and Technology have developed a test method and companion sensor to assess the health of robot workcells which will yield an additional and unique data stream. The intent is that this data stream can either serve as a surrogate for larger data volumes to reduce the data collection and analysis burden on the manufacturer, or add more intelligence to assessing robot workcell health. This article presents the most recent effort focused on verifying the companion sensor. Results of the verification test process are discussed along with preliminary results of the sensor's performance during verification testing. Lessons learned indicate that the test process can be an effective means of quantifying the sensor's measurement capability particularly after test process anomalies are addressed in future efforts.
X-ray computed tomography (XCT) is a promising nondestructive evaluation technique for additive manufacturing (AM) parts with complex shapes. Industrial XCT scanning is a relatively new development, and XCT has several acquisition parameters that a user can change for a scan whose effects are not fully understood. An artifact incorporating simulated defects of different sizes was produced using laser powder bed fusion (LPBF) AM. The influence of six XCT acquisition parameters was investigated experimentally based on a fractional factorial designed experiment. Twenty experimental runs were performed. The noise level of the XCT images was affected by the acquisition parameters, and the importance of the acquisition parameters was ranked. The measurement results were further analyzed to understand the probability of detection (POD) of the simulated defects. The POD determination process is detailed, including estimation of the POD confidence limit curve using a bootstrap method. The results are interpreted in the context of the AM process and XCT acquisition parameters.
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