An automatic gore panel mapping system

The Automatic Gore Mapping System is being developed to reduce the time and labor costs associated with manufacturing the External Tank. The present chem-milling processes and procedures are discussed. The down loading of the simulation of the system has to be performed to verify that the simulation package will translate the simulation code into robot code. Also a simulation of this system has to be programmed for a gantry robot instead of the articulating robot that is presently in the system. It was discovered using the simulation package that the articulation robot cannot reach all the point on some of the panels, therefore when the system is ready for production, a gantry robot will be used. Also a hydrosensor system is being developed to replace the point-to-point contact probe. The hydrosensor will allow the robot to perform a non-contact continuous scan of the panel. It will also provide a faster scan of the panel because it will eliminate the in-and-out movement required for the present end effector. The system software is currently being modified so that the hydrosensor will work with the system. The hydrosensor consists of a Krautkramer-Branson transducer encased in a plexiglass nozzle. The water stream pumped through the nozzle is the couplant for the probe. Also, software is being written so that the robot will have the ability to draw the contour lines on the panel displaying the out-of-tolerance regions. Presently the contour lines can only be displayed on the computer screens. Research is also being performed on improving and automating the method of scribing the panels. Presently the panels are manually scribed with a sharp knife. The use of a low power laser or water jet is being studied as a method of scribing the panels. The contour drawing pen will be replaced with scribing tool and the robot will then move along the contour lines. With these developments the Automatic Gore Mapping Systems will provide a reduction in time and labor costs associated with manufacturing the External Task. The system also has the potential of inspecting other manufactured parts.