Shop Tools and Enablers Open Topic

OUSD (R&E) CRITICAL TECHNOLOGY AREA(S): Human-Machine Interfaces; Renewable Energy Generation and Storage and Hypersonics, Trusted AI and Autonomy, Integrated Network Systems of Systems

OBJECTIVE: To equip artisans with technology that enhances operational capabilities, their breadth of logistical support, and property accountability. Proposals should allow for the flexibility of artisans to respond to mixed model production and innovations that enable artisans to execute ergonomically challenging tasks. There is a need for technologies that equip artisans with standard yet flexible enduring technologies to sustain air missile defense and power generation systems, ensuring that assets are returned to combat swiftly. Production lines must be mixed-model and adaptable to expand and contract. Functional tool sets and manufacturing equipment must also be adaptable, fluid, and multi-use. Property accountability is a priority, so technologies enabling accountability are desired. Such technological advancements will fortify military readiness and potentially influence civilian sectors with limited infrastructure, maintaining operational logistics and sustainability superiority.

DESCRIPTION: This topic accepts Phase I proposals submissions for a cost up to $250,000 for a 6–12-month period of performance.

This solicitation seeks innovative research and development proposals for tool sets and lifting/moving equipment specifically designed for a flexible manufacturing system within dynamic mechanical and electrical repair facilities. The focus should be on:

• Integrating Smart Tool Technologies: Proposals should explore the development of smart tools that utilize IoT (Internet of Things) capabilities for real-time tracking and adaptive responses to changing production needs. Research could involve developing algorithms that optimize tool performance based on the task and material at hand.
• Enhanced Mechanical Assist Systems: Research into developing next-generation exoskeletons tailored for specific repair tasks in military environments. These systems should incorporate AI to dynamically adapt to various load requirements and user movements, offering adjustable support that optimizes both efficiency and safety. The focus could be on innovative features like automated load-balancing, energy conservation techniques, and real-time biomechanical feedback to prevent injuries and enhance task execution.
• Collaborative Robotics (Cobots): Proposals may focus on customizing cobots for tasks that require precision and flexibility, such as wiring in electronic assemblies or positioning components in tight spaces. Research might include developing advanced sensory and vision systems to enable cobots to work more intuitively with human operators.
• Modular Production Systems: Development of a modular, scalable production line system that can be quickly reconfigured for different products such as vehicles or power generators. This involves R&D into rapid setup and breakdown mechanisms, as well as adaptable logistic support systems that maintain operational efficiency and property accountability.

These research initiatives should demonstrate how the proposed technologies will not only fulfill the current needs but also provide scalable solutions that can adapt to future demands and potentially be applied in civilian contexts with limited infrastructure. The ultimate goal is to enhance operational efficiency, reduce physical strain on artisans, and ensure thorough accountability of valuable assets.

Benefits of partnering with LEAD: LEAD operates under 10 USC 2474 as a designated Center of Industrial and Technical Excellence for Air Defense & Tactical Missile Ground Support Equipment and Mobile Electric Power. This designation allows for establishing public-private partnerships that align with LEAD's core competencies, as long as they do not interfere with National Defense Priority Programs. LEAD has ample production space to support various mechanical, electronic, and fabrication projects. The facility can handle everything from large trailer beds to intricate circuit card repairs and is equipped with sophisticated machinery such as multi-axis mills, water jets, and laser cutters. LEAD's capabilities are broad, spanning automotive repairs, heavy metal fabrication, and more.

PHASE I:

Companies will complete a feasibility study demonstrating the firm’s competitive technical advantage relative to other commercial products (if other products exist) and develop concept plans for how the company’s technology addresses Army modernization priority areas.

Studies should clearly detail and identify a firm’s technology at both the individual component and system levels, provide supporting literature for technical feasibility, highlight existing performance data, showcase the technology’s application opportunities to a broad base of customers outside the defense space, a market strategy for the commercial space, how the technology directly addresses the Army’s modernization area as well as include a technology development roadmap to demonstrate scientific and engineering viability.

At the end of Phase I, the Army will require the company to provide a concept demonstration of their technology to demonstrate a high probability that continued design and development will result in a Phase II mature product.

PHASE II:

Produce prototype solutions that Soldiers can easily operate. Firms will provide these products to select Army units for further evaluation by the Soldiers. In addition, companies will offer technology transition and commercialization plans for the Department of Defense and commercial markets.

PHASE III DUAL USE APPLICATIONS:

Complete the maturation of the company’s technology developed in Phase II to TRL 6/7 and produce prototypes to support further development and commercialization. The Army will evaluate each product in a realistic field environment and provide small solutions to stakeholders for evaluation. Based on Soldier field assessments, companies will update the previously delivered prototypes to meet the final design configuration.

Maintenance Operations, disaster relief operations, field construction in rural or undeveloped areas, forestry, and agricultural heavy lifting, emergency medical setups in disaster zones, off-grid construction projects, wildlife research and conservation efforts, archaeological digs in remote locations, search and rescue missions, oil and gas exploration in isolated areas, humanitarian aid delivery in conflict or disaster-stricken regions.

Other Use Cases:

• Automated Tool Sets: Standardized durable tool sets that are compact when not in use, and allow for ease of inventory and accountability. Could include gravity lines for hydraulic tools that can be stored above the work space when not in use.
• Expandable clean room or component repair areas: expanded based on mission requirements
• Electro-static Discharge protection for workers
• Reconfigurable Work Stations: easily re-configurable work bays that can be shifted to expand or condense production lines, create hospital bays or support short term missions. Must include the ability to hook into shop air
• Creative line side storage solutions: configurable racks and bins that allow easy access and for parts storage and resupply
• Addon-type Visual Tools: Easy to use and interpret visual signals that enable support systems such as resupply, engineering or supervisor alerts
• Dual-use Robotics:  Easy to program robotics that are multi-functional, shop floor durable technologies. For example, a robot may autonomously deliver parts to a designated station while cleaning the shop floor or collect and filter out particulates from the air.

REFERENCES:

1. Optimizing Cellular Manufacturing Systems Through Multi-Objective Cobot Coordination and Tool Allocation
2. Intelligent machining: real-time tool condition monitoring and intelligent adaptive control systems
3. Cooperative Robotics and Machine Learning for Smart Manufacturing: Platform Design and Trends Within the Context of Industrial Internet of Things
4. Holistic planning and optimization of human-centred workplaces with integrated Exoskeleton technology
5. Assembly 4.0: Wheel Hub Nut Assembly Using a Cobot
6. Development of a new robotic programming support system for operators
7. Inside Toyota's Takaoka #2 Line: The Most Flexible Line In The World (thedrive.com)
8. Ultimate Guide: What Is Flexible Manufacturing System (FMS)? | Global Sources

KEYWORDS: automotive tool sets, lifting and moving devices, energy efficiency, limited power access, minimal internet connectivity, durability, adaptability, extreme conditions, military operations, operational capabilities, logistical support, strategic advantage, resource-scarce locations, manual operation, solar power integration, hand-powered devices, autonomous lifting solutions, portable equipment, environmental resilience.