Automated Assembly Using Feature Localization

Automated assembly of mechanical devices is studies by researching methods of operating assembly equipment in a variable manner; that is, systems which may be configured to perform many different assembly operations are studied. The general parts assembly operation involves the removal of alignment errors within some tolerance and without damaging the parts. Two methods for eliminating alignment errors are discussed: a priori suppression and measurement and removal. Both methods are studied with the more novel measurement and removal technique being studied in greater detail. During the study of this technique, a fast and accurate six degree-of-freedom position sensor based on a light-stripe vision technique was developed. Specifications for the sensor were derived from an assembly-system error analysis. Studies on extracting accurate information from the sensor by optimally reducing redundant information, filtering quantization noise, and careful calibration procedures were performed. Prototype assembly systems for both error elimination techniques were implemented and used to assemble several products. The assembly system based on the a priori suppression technique uses a number of mechanical assembly tools and software systems which extend the capabilities of industrial robots. The need for the tools was determined through an assembly task analysis of several consumer and automotive products. The assembly system based on the measurement and removal technique used the six degree-of-freedom position sensor to measure part misalignments. Robot commands for aligning the parts were automatically calculated based on the sensor data and executed.

A Concurrent Smalltalk Compiler for the Message-Driven Processor

This thesis describes Optimist, an optimizing compiler for the Concurrent Smalltalk language developed by the Concurrent VLSI Architecture Group. Optimist compiles Concurrent Smalltalk to the assembly language of the Message-Driven Processor (MDP). The compiler includes numerous optimization techniques such as dead code elimination, dataflow analysis, constant folding, move elimination, concurrency analysis, duplicate code merging, tail forwarding, use of register variables, as well as various MDP-specific optimizations in the code generator. The MDP presents some unique challenges and opportunities for compilation. Due to the MDP's small memory size, it is critical that the size of the generated code be as small as possible. The MDP is an inherently concurrent processor with efficient mechanisms for sending and receiving messages; the compiler takes advantage of these mechanisms. The MDP's tagged architecture allows very efficient support of object-oriented languages such as Concurrent Smalltalk. The initial goals for the MDP were to have the MDP execute about twenty instructions per method and contain 4096 words of memory. This compiler shows that these goals are too optimistic -- most methods are longer, both in terms of code size and running time. Thus, the memory size of the MDP should be increased.

Strategies for Lean Product Development

The essence of lean is very simple, but from a research and implementation point of view overwhelming. Lean is the search for perfection through the elimination of waste and the insertion of practices that contribute to reduction in cost and schedule while improving performance of products. This concept of lean has wide applicability to a large range of processes, people and organizations, from concept design to the factory floor, from the laborer to the upper management, from the customer to the developer. Progress has been made in implementing and raising the awareness of lean practices at the factory floor. However, the level of implementation and education in other areas, like product development, is very low.