A History of the I Automated ' Automdtinci I the Manufacturing Future Research QC 100 .U57 N0.967 I Institute of Standards and Te Administration, U.S. Department of Commerce 2001 jy c. 3. AUTOMATING THE FUTURE A HISTORY OF THE AUTOMATED MANUFACTURING RESEARCH FACILITY 1980-1995 NIST Special Publication 967 Joan M. Zenzen Manufacturing Engineering Laboratory National Institute of Standards and Technology Gaithersburg, Maryland 20899-8200 March 2001 U.S. DEPARTMENT OF COMMERCE Donald L. Evans, Secretary Technology Administration Karen H. Brown, Acting Under Secretary for Technology National Institute of Standards and Technology Karen H. Brown, Acting Director Disclaimer Statement Commercial equipment and materials are identified in order to specify adequately certain procedures and/or research. In no case does such identification imply recommendation or endorsement by the NIST, nor does it imply that the materials or equipment identified are necessarily the best available for the purpose. National Institute of Standards and Technology Special Publication 967 Natl. Inst. Stand. Technol. Spec. Publ. 967, 104 pages (March 2001) CODEN: NSPUE2 U.S. GOVERNMENT PRINTING OFFICE - WASHINGTON: 2001 For sale by the Superintendent of Documents, U.S. Government Printing Office Internet: bookstore.gpo.gov — Phone: (202) 512-1800 — Fax: (202) 512-2250 Mail: Stop SSOP, Washington, DC 20402-0001 CONTENTS List of Figures iv Foreword v Acknowledgments vi Chapters 1 Measuring for Manufacturing 1 2 Envisioning a Future with Automation 9 3 Magical Manufacturing 25 4 Graduation 49 5 Legacy 73 Appendixes 1 Acronyms 83 2 Awards 84 3 Standards 85 4 Donations 86 5 Industrial Research Associates 88 6 Patents 89 7 Products 90 8 Thesis Research 91 9 Academic Connections 92 10 Personal Interviews 93 Bibliography 94 About the Author 98 Automated Manufacturing Research Facility iii FIGURES 1 The robot arm of the Turning Workstation 1 2 Robert J. Hocken 12 3 Drill-Up 18 4 Visitors viewed the AMRF through a wall of windows 26 5 Horizontal Workstation 29 6 Vertical Workstation 30 7 Turning Workstation 30 8 Inspection Workstation 31 9 Cleaning and Deburring Workstation 31 10 Materials Handling System 32 11 Smokestacks Design 33 12 James Albus 40 1 3 Horizontal Workstation's robot vision system 41 14 Horizontal Workstation robot gripper 42 15 Turning Workstation 42 16 1983 AMRF floor map 47 17 Demonstration of Vertical Workstation's automated process planning system 53 18 Cleaning and Deburring Workstation 54 19 The Advanced Deburring and Chamfering System (ADACS) 54 20 Inspection Workstation 55 21 Turning Workstation 56 22 1986 AMRF floor map 61 23 Mare Island Flexible Manufacturing Workstation 63 24 Portsmouth Naval Shipyard Level I Fastener Workstation 65 25 National Advanced Manufacturing Testbed (NAMT) 81 National Institute of Standards and Technology FOREWORD HE TECHNICAL STORY of the National Institute of Standards and Technology's (NIST's) Automated Manufacturing Research Facility (AMRF) is, in fact, the story of the integration of robots, computers, and machine tools into "the free world's largest and most advanced public research facility for the study of automated manufacturing," according to the December 1986 issue of American Machinistmagazine. While the technical aspects that led up to and were the AMRF have been covered in depth in documents and conference presentations, little has been written about the researchers who actually conceived the idea for the AMRF and made it a reality, and how they did that. As NIST prepared to celebrate its centennial in 2001 , each laboratory was asked to make a contribution to the celebration. Richard H. F. Jackson, Director of the Manufacturing Engineering Laboratory (MEL) at the time, had already identified the void in the historical documentation of the AMRF and realized such a history would be the perfect item for MEL to contribute to the centennial. He had the foresight to contract with an established historian and writer to produce that history. This document, the result of that effort, is an outstanding contribution to the NIST Centennial Celebration and more than fills the void that Jackson identified. My thanks to Ric for his idea and to the author for making it a reality. Raymond G. Kammer Former Director, NIST Automated Manufacturing Research Facility v ACKNOWLEDGMENTS ANY FOLKS HAVE CONTRIBUTED to this history about the people who coordinated robots, ; computers, and machine tools into the Automated Manufacturing Research Facility (AMRF). At the 4 National Institute of Standards and Technology (NIST), Joan Wellington in the Manufacturing Engineering Laboratory (MEL) provided invaluable support throughout the process. She tracked down | documentation, identified people for interviews, and facilitated the writing and revising stages. Harry Brooks and the other NIST librarians cheerfully and professionally fielded my many guestions about technical and congressional documents. NIST historian Lisa Greenhouse pointed me to biographical files in the NIST Archives and found some photographs. Jim Schooley graciously allowed me a sneak peak of his Centennial history of NIST, Responding to National Needs. Barbara Horner sent out pages of the draft manuscript to the many interviewees and reviewers and valiantly kept track of all responses so that I could incorporate them into the revised text. Howard Bloom, first as MEL deputy director and then as MEL acting director, enthusiastically embraced this project and ensured that I had the support and resources needed to get the history done. His staff in the laboratory office, especially Rosalie Avant, Cathy Graham, Norma Purcell, and John Slotwinski, made me feel welcome and comfortable as I conducted research and completed the book. Avant also typed in some of the appendixes. Mike Schmitt helped with some administrative questions. NIST attorneys Michael Rubin and Mark Madsen made sure the oral history interviewees had proper waivers. Paul Vasallo and Sandy Kelley aided the process of initiating the contract for this book. Former MEL Director Ric Jackson recognized the value of a history of the AMRF and secured the funding for its writing. He shared his own thoughts about the significance of the facility and allowed me to sift through the documentation and make my own interpretations. He, along with Howard Bloom, James Albus, Phil Nanzetta, John Slotwinski, Charles McLean, Don Eitzen, Joan Wellington, John Simpson, and Ernest Ambler, read the entire draft manuscript and provided invaluable comments. Beamie Young created a striking book cover and shepherded the manuscript through the printing process. Bill Welsh turned the manuscript into an attractive and readable book. Special thanks goes to each of the people I interviewed, whose stories made the AMRF come alive. Dian and Brian Belanger connected me with the people at NIST and reminded me that "stay-at-home" moms (even me with a Ph.D.) could balance home and work. My children, Sarah and Aaron, kept me focused on the important stuff, withstood my occasional absences, and always gave me hugs and kisses when I returned. My husband Stuart Weinstein encouraged me and supported me throughout this project. He read every page of the manuscript and kept our home computer from running away with my bits. I dedicate this book to my father, Nick E. Zenzen, and my brother, Nick J. Zenzen, both of whom taught me the beauty of machines. > and Technology Chapter One MEASURING FOR MANUFACTURING WATCHING A ROBOT AND MACHINE TOOL manufacture a widget is like watching a graceful dance. First, you hear the steady rhythm of a person typing a command into the computer terminal. Bits of information stream through silicon chips and are routed through a maze of networks, directing the performance as a part order is entered into the system. Then, you hear the motorized humming of a robot cart, rear red lights flashing alternately to the same staccato beat of the typing. Once the cart reaches the workstation, the robot, stout and squat at its base but long and extended of arm, grips the desired metal blank and sweeps it into the air in controlled, precisely directed movements. The gripper head twirls almost 360 degrees while the blank sits squarely in its hold, edges shining as they flash in and away from the light. Stop, the robot arm adjusts its position, stop, the robot arm turns again in a smaller space, and stop, the robot arm brings the blank into position for acceptance by the machine tool. The hydraulic cylinders compress and extend with each movement, sounding like each colorful balloon being blown up and tied for a festive occasion. With the blank ready for cutting, coolant rushes in and the cutter whirls and slices metal down to the desired shape. The shrill high-pitched sound of metal cutting metal is softened by the soothing liquid, washing away cuttings and cooling the pieces. With finished widget in hand, the robot arm again sweeps into its carefully orchestrated dance to transfer its product back to the robot cart (Fig. 1). Off to another partner, the cleaning and deburring station, where the widget is buffed and shined by so many whirring brushes. Finally, at its last stop, the inspection station, a calibrated glass sensor rod briefly touches and steps away, touches and steps away from the shiny metal Figure 1 . The robot arm of the Turning Workstation (TWS) widget. The dance is done, the widget waits for its next swings into action to pick up the finished product from the turning center machine tool. (Photo collection, AMRF partner, and the robot and machine tool commence their Files, NIST) next routine. What was ultimately magical about the Automated Manufacturing Research Facility at the National Institute of Standards and Technology, the former National Bureau of Standards, was the elegant coordination of computers, robots, and machine tools to produce small batches of designed parts. This dance was a visible performance of the many achievements contributed by a host of scientists, engineers, technicians, managers, and theorists.