GPS Navigating Concept Aids Manufacturing Process

By Ellen McCarthy
Thursday, June 9, 2005

More than 10 years ago, two professors and a graduate student at Virginia Tech began tinkering with Global Positioning System technology, trying to find out if the navigation tool could guide a drill inside a factory as well as it guides a submarine under the sea.

Eventually, they took the GPS concept and collapsed it from a global system to a local one, which is employed inside the manufacturing facilities of the biggest airplane, auto and ship builders in the world. As the technology that developed around the GPS has leapt from military to civilian use, it is changing the way companies build their products.

"We help automate things that they didn't think were able to be automated in the past," said Edward R. Barrientos , chief executive of Arc Second , the company that grew from the research done in Blacksburg, Va. Barrientos joined in 1997, and the original researchers remained shareholders.

Like a lot of young tech companies, Arc Second is trying to make money by finding new ways to apply an emerging technology. While much of the GPS market had been claimed by big players in recreational and driving navigation, Arc Second's similar technology was in a niche that had yet to be taken.

The system does not bounce signals off satellites in far-away orbit. Instead, it puts transmitters on the perimeters of a manufacturing plant and attaches sensors to machinery and parts used in the assembly of a product. Lasers are then emitted by the transmitters, and with such close range, the movement of the equipment can be precisely tracked to within a tenth of a millimeter, or about the width of a human hair. When Arc Second's positioning system is hooked into the computer-aided design software used by the manufacturer, machines can follow automated instructions.

So if a bolt needs to be drilled to a specific depth in a specific spot on the nose of an airliner, a machine guided by Arc Second's system can complete the task, rather than a technician.

Arc Second first applied the technology to the construction industry, Barrientos said, but with the encouragement of Boeing Co . revised the system to work in a manufacturing setting in 2003.

Since then, a cadre of big-name manufacturers such as Toyota , Honda , Lockheed Martin , Airbus and Volkswagen have used the technology, according to Barrientos.

Bombardier Aerospace , a Montreal aircraft manufacturer, has been working with Arc Second to customize the system for constructing its next line of planes. Kornelis Kroon , special adviser of Bombardier's tooling and experimental unit, said Arc Second's technology allows for faster, cheaper manufacturing. "It's amazing, and the whole system is very compact," Kroon said.

The 30-person company, which has raised $20 million in venture funding from Reston-based SpaceVest and CDP Capital of Montreal, won't disclose its financials, but Barrientos said the technology sells for between $50,000 and more than $1 million, depending on the scope of the project.

Barrientos's eyes light up when he talks about what's to come. Engineers at companies such as Honda and Toyota have already begun to use the system to help robotic devices move about their surroundings, he said, a step that could someday lead to the home use of robots.

But for now, it's all about factories. "We simply want to be standard infrastructure in every facility in the world," Barrientos said.

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