NASA-CR-205084 / ,/ / -

/

Semiannual Technical Progress Report

Aeromover Systems Corporation3045 Broad Street

Dexter, MI 48130

Contract # NAS1-20640

This report covers the third six month period of the subject contract from

January 26, 1997 to July 26, 1997. The contract statement of work covers four

specific applications of Aeromover's 'N'-output differential technology that

are being developed in cooperation with industry and NASA. A quantitative

description of work, project difficulties, proposed solutions, and a statement

of the work that will be performed during the next six months has been

included for each of the four projects.

Contract # NAS1-202640 development projects:

1. Robotic Gripper for industrial application

2. End-effector design for NASA application

3. Nut-runner for simultaneous torquing of multiple threaded fasteners

4. Multiple output drive for power auto seats

/ /'

1. Robotic Gripper for industrial application

A four output differentially powered end-effector has manufactured and

tested for use at our collaborating manufacture's facility (Variety Die and

Stamping). During the past six months, the prototype device has gone

through several small design adjustments and mechanical "tweaking" typical

for this type of first-iteration equipment. Strain gauges used to test the torque

at the output/fingers showed that drag coefficients at each differentiated

output were inconsistent when measured at angles of incidence not parallel

with respect to the ground plane. Our investigations revealed that this was

primarily due to deficiencies in precision in bushing and bearing supports.

Bearing supports were modified and these problems were overcome.

Because the chosen task for demonstrating our industrial end-effector does

not require a particularly precise differential mechanism it is possible that thefirst iteration would have been sufficient for the chosen tasks without

modification. However, the Principal Investigator, Mr. Srinivas Bidare' and

Aeromover personnel felt that design refinements were necessary to gain a

better hands-on understanding of ancillary issues effecting the performance

the differential driving mechanism. Investigation has revealed that several

specific areas where designers will need to focus attention if precision

performance is to be attained. These areas include the following:

https://ntrs.nasa.gov/search.jsp?R=19980213235 2020-06-17T07:27:46+00:00Z

Overcoming the inertial load of the gear train, while supported

at various angles. (Critical to driving motor/actuation).

2 Supporting bearings & bushings design/location (Necessary for

gaining nearly equivalent drag co-efficients at each

differentiated output).

. Design of consistent finger actuation mechanisms that are low

mass and not subject to excessive drag. (Slide mechanisms

designed for the current model are adequate, however, they

prove to bulky for more precision applications).

Eastern Michigan University (EMU) has received a refurbished PUMA robot,

which is being used to create a mock-up test sight that will simulate tasks in

the manufacturing environment. The EMU test site is being used so that any

unforeseen problems with the new robotic system can be resolved prior to

actual system installation. The test site will also offer the opportunity to

more easily collect cycling information. When the system has proven its

readiness in the laboratory it will be brought to the manufacturing facility and

installed. After installation the end-effector will be examined on a regular

basis to monitor for any potential problems. The manufacture will be given

the opportunity to evaluate performance of the new system for several

months, using the EMU robot, before deciding whether or not a system will

be permanently installed, at which time the EMU robot will be returned to

the University. By the end of the contract period the system will been

installed at Variety Die and they will be evaluating it's performance.

2. End-effector design for NASA application/design iterations

Discovering a specific NASA application for our differentially powered end-

effector was delayed due to difficulties in breaking through to program end-

users and designers and in receiving their specifications for automated tasks.

Lack of progress in this area resulted in Aeromover requesting that project

technical monitor, Walter Hankins, assist us in finding an appropriate contact

within NASA, that could supply Aeromover with appropriate design

specifications. Mr. Hankins supplied Aeromover with contacts at Johnson

labs in Houston, with whom a dialogue has begun. By the end of the contract

period Aeromover will supply a design to meet the design criteria of a specificNASA end-effector mission.

During the past six months, in lieu of having an actual specific application

from NASA, the Principal Investigator began designing a "lightest weight"

and "least massive" configuration of the "N-output" differential gear train.

This gear train is seen as an extremely promising for application in prosthetic

devices or in other applications where the miniaturization of

component/mechanisms is critical. NASA's Johnson lab is primarily

working with astronaut interface to specific "hand-like" functions being

carried out in space. Our flexible, compliant, durable, and light weight

mechanism could prove be very appropriate. The following drawing shows

our most recent design iteration for a miniature high-speed four outputdifferential.

L__ J J

The device shown is less than 1" in diameter and slightly more than 1" in total length.

The design shown here is capable of driving the four pounds of gripping force

necessary for our current industrial application presuming that gear

reductions are made at some point after the differentiated outputs. A generic

rule in designing differentially driven mechanisms is that the gear train can

be made smaller and lighter if the reduction is done at the end of the

differential rather than before it. Therefore, handling heavier payloads with a

small mechanism requires that greater gear reduction occur after

differentiation. In applications such as a prosthetic hand, there are several

opportunities to accomplish reduction after differentiation and this type of

mechanism would be ideal. Specific task work loads and product designconstraints will indicate whether or not the smaller scale differential will

prove practical. The following drawing illustrates how the miniature gear

train could be used to build an end-effector that could carry out our currentindustrial manufacturing task.

....................... It-

The drivetrain shown here offers a dramatic reduction in the size and weightvs. our current device. EMU Principal Investigator Prof. Max Kanagy has

been concurrently carrying out design calculations with Mr. Bidare' to

develop a slightly larger drivetrain, approx. 2" diameter and 2.5" height, that

would not require post-differentiation reduction to accomplish our 4 pound

workload requirement. Currently, Dr. Kanagy's work seems the most wellsuited to most industrial applications, while Mr. Bidare's seem best suited to

more specialized applications such as "high-end" prosthetic devices.

In the last six months Aeromover has been weighing the benefits of different

differential designs for potential applications at both Ford Motor Company

and for Delphi automotive. (Both companies advanced Robotics departments

have asked Aeromover to propose an end-effector developmental proposal).

In the next six months we will make proposals to both corporations based ontheir specific design criteria. Similarly we will also obtain an appropriate setof specific design requirements from NASA Johnson and apply the most

effective version of a differential mechanism to a their specific requirements.

3. Nut-runner for simultaneous torquing of multiple threaded fasteners

Designs for an eight output nut-runner have been completed for use atTecumseh products. A final design evaluation (outside engineering check) isbeing conducted by our design subcontractor, South Lyon Design.Tecumseh's existing nut-runner frame is being replicated, by Tecumseh, forAeromover to use in testing the new machine. We expect delivery of the

Tecumseh frame in from 6-8 weeks and completion of the differential drivemechanism within 10 weeks. Testing will then begin and take form 2-4weeks. We expect to deliver the machine to New Holstein, Wisconsin withinthe next 16 weeks. Drawings for the nut-runner are attached at the end of this

report.

4. Multiple output drive for power auto seats

Our originally proposed Industrial Collaborator for manufacturing a

prototype six-way seat drive mechanism, Johnson Controls Inc. (JCI), has not

responded to Aeromover proposals in a timely enough manner to meet the

demands of our STTR schedule. Therefore, a second seat-drive manufacture,

Delphi Automotive, has taken JCl's place as our industrial collaborator.

Delphi has offered to fund the development of the prototype seat drive,

contingent upon intellectual property agreements that would ensure that

they would not pay royalty on any findings made during prototype

developments which they help to fund, they also wish to hold exclusive

rights to any new technologies developed for the next three years.

Aeromover is planning to proceed with the Prototype development, but, has

taken several steps to better ensure that our product/technology can not be

"held-up" by our collaborator should they choose not to use the new

technology. We want to ensure that the technology has the best possible

chance of actually being implemented rather than being "sat-on"by a majormanufacturer.

Aeromover has therefore completed designs for a seat mechanism to the

industrial prototype level. Manufacturing p_ and sources have been

quoted and two votenlial manufachzrem amm:mcl_,ed. (Drawings for the ssat

drive mechanism and assembly plans are attached at the end of this report.)

Aeromover has now completed more work on this project than was

originally proposed under NAS1-20640. We have taken these extra steps to

ensure that the product we are developing actually has a reasonable chance

for wide spread use. We anticipate that within the next six months that

agreements will be finalized with Delphi and that a prototype device will be

tested. (Build of this prototype is not overly complex or time-intensive). If,

however, these developments would jeopardize our corporate position, we

will contact NASA contracting officers and attempt to get exceptions made to

the specific terms of the STFR.

SOUTH LYON DESIGN

RE'V,APR 12.,1997

AEROMOVER INC"--'3 OUTPUT SEAl" DRIVE

FOR FLEX SHAFT 6 OUTPUT

SOUTH LYON DESIGN

REV. APR 12,1997

AEROMOVER INC•.) OUTPUT SEAl" DRIVEFOR FLEX SHAFT 6 OUTPUT

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AEROMOVER INC,ASSEMBLY

FOR 3 OUTPUT SEAT ASSEMBLY

NOTES:RE'VISION RECIE'VED APR 9 l gg71 CHANGE GEAR 1 TO DOUBLE HUNG2 ELIMINATE LEFT SIDE ALUMINIUM SUPPORT PLATE, INTEGRATE BUSHING

INTO PLASTIC MOLDED HOUSING

3 BUSHING MADE OF HARDENED STEEL W/ GREASE PACKED DURING ASSEMBLY4 SUN GEAR IS MADE OF POWERED METAL, INTEGRATED SHAFT AND HAS SQUARE HOLE FOR

CABLE DRIVE5 RING fEAR IS I_a,DE OF POWERED METAL

6 PLANET GEARS MADE OF POWERED METALOR COLD HEADED STEEL OR INJECTION MOLDEDPLASTIC, SMAF-F IS INTEGRATED INTO GEAR

7 COVER PLATE OF PLANETARY CAN BE MADE OF HIGH CARBON STEEL STAMPING WITH HOLESTHICKNESS MAY HAVE TO BE INCREASED TO REDUCE BEARING STRESS ON RING GEAR

8 ARM TO BE MADE OF POWERED METAL WITH LIGHTING HOLES OR PROFILE.9 OLD PLATE 3 - SNAP FIT INTO MOLDED PLASTIC HOUSING10 BRAKE LE'v'ER MADE OF PLASTIC WITH INTEGRATED SHAFT AND SPRING - NO FASTENER11 SOLENOID CAPTURED SNAP FIT AND HOUSED IN HOUSING

12 NO RIVETS, SHAFTS ETC TO CAPTURE BRAKE OR LEVER

NOTES:

AEROMOVER TO VERIFY TORQUE AND RPM OF ALL OUTPUT SHAFTSAEROMOVER TO VERIFY GEAR SIZE AND CAPABILIIh' FOR PRODUCT REQUIREMENTS

SOUTH LYON DESIGN

REV. APR 12,1997

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5 LATCH

6 GEAR

7 RIVET8 GEAR RING

9 ARM INPUT10 BUSHING

11 SHAFT OUTPUT12 SHAFT OUTPUT

13 SHAFT OUTPUT

14 SPRING

15 INPUT ARM

16 PLATE RETAINER

QTY

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AEROMOVER INC0 OUTPUT SEAT DRIVEFOR FLEX SHAFT 6 OUTPUT

AEROMOVER INCPREIMINARY ASSEMBLY OF6 OUTPUT SEAT UNIT

OPER DESCRIPTION

10 ASSEMBLY DIFFERENTIAL(12 SEC PER ASSEMBLY)

20 ASSEMBLY LOWER HALF

30 ASSEMBLY UPPER HALF

40 JOIN HALF, PRESSS &GREASE

50 MOUNT MOTOR

60 TEST & MARK PART

70 PACKAGE FOR SHIPMENT

TOTAL LABOR TIME (SEC/UNIT)

PRODUCTION RATE (PC/HR)

ANNNUAL UNITS/SHIFT

MANPOWER @ PROD. RATE

LABOR RATE

LABOR COST PER PIECE

OPERATOR MACHINETIME TIME

28 28

18 *

12 *

8 10

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EQUIPMENT

MACH DESCRIPTION

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RIVET (3)BASEPLANETARY GEAR (3)COVER

TIME (SEC)

PRESS HALF & GREASELOAD HALVESPRESS TO POSITIONINJECT GREASE (8 PLACES)UNLOADTIME (SEC0

TEST PRODUCTLOAD ASSEMBLYCONNECT LEADSSTALL TESTSOL 1 TESTSOL 2 TESTSOL 3 TESTSOL 2&3 TESTREV TESTDISCONNECT LEADSUNLOAD

OPERATORTIME

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12.00

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2.006.00

2.002.00

2.002.008.00

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CAPITALCOST

OPER DESCRIPTION

10 2 STA DIAL INDEX PRESS & STAKE MACHINECONPONENTS

BASEINDEX UNIT

PRESS SLIDE WITH FORCE MONITORSTAKE RAM (3) WITH DISTANCE MONITORFIXTURE (2)PNEUMATIC SYSTEMELECTRIC CONTROLLER

TRACK SECTION (2) (6 F'T')ESTIMATEBUILDER MARKUPCAPITAL COST

$95,00030.00%

$123,500

20 TRACK SECTION (6 FT)ESCAPEMENT & LATCH

30 FIXTURE

40 ASSEMBLY PRESS & GREASECONPONENTSCONPONENTS

BASELOWER RAMUPPER RAMLOWER RAM TOOLINGUPPER RAM TOOLINGESCAPEMENT (2)

TRACK SECTION(6 F'r)PNEUMATIC SYSTEMFORCE MONITORPOSITION MONITORELECTRICAL CONTROLLER

ESTIMATEBUILDER MARKUPCAPITAL COST

$105,00030.00%

$136,500

50

AEROMOVERINCPREIMINARY ASSEMBLY OF6 OUTPUT SEAT UNIT

TRACK (6FT)ESCAPEMENT & LATCH

6O TEST MACHINECONPONENTS

BASELOWER SLIDESPEED OUTPUT DEVICES (4)

TEST MOTOR CURRENT & VOLTBASE ELECTRICAL CONNECTORTORQUE BRAKE (1)MARKING SYSTEMPNEUMATIC SYSTEMELECTRICAL CONTROLLERTRACK SECTION (6 F"I')

ESTIMATEBUILDER MARKUPCAPITAL COST

QUALITY CONTROL ITEMSPC, STORAGE BACKUP, SPC, SHIP,DATA HIGHWAY, ETC

CAPITAL COSTCAPITAL COST/UNIT

$125,00030.00%

$162,500

$30,000

$452,500$1.76

FLOOR SPACE

COST PER PIEC

TOTAL COST PER PIECE

40 X 60.002400.00

$12$28,800

$0.11

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