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3D Printing and Additive Manufacturing     Full-text available via subscription   (Followers: 12)
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Journal Cover Assembly Automation
  [SJR: 0.439]   [H-I: 20]   [1 followers]  Follow
    
   Hybrid Journal Hybrid journal (It can contain Open Access articles)
   ISSN (Print) 0144-5154
   Published by Emerald Homepage  [312 journals]
  • An interactive Virtual Lighting Maintenance Environment for Human Factors
           Evaluation
    • Authors: Qichang He, Shiguang Qiu, Xiumin Fan, Keyan Liu
      Abstract: Assembly Automation, Volume 36, Issue 1, February 2016.
      Purpose The paper aims to establish a VLME (Virtual Lighting Maintenance Environment), and to analyze the visibility related HFs (Human Factors) during maintenance operations through interactive simulations. Design/methodology/approach Firstly, an accurate task lighting modeling method was developed, which includes lighting information modeling and illuminant parameters calibration. Then, the real-time interaction between the task lighting and 3D virtual human was modeled. After that, the attenuation coefficient of visibility was determined. Also, the HFs analysis process in VLME was described in detail. Findings A case study of PSM (Power Supply Module) replacement of radar equipment was performed in VLME. The HFs analysis demonstrated that the task lighting significantly affects the visibility, which causes indirect impact on posture comfort and operation safety. Practical implications Through evaluating maintenance operation processing in lighting environment, engineers can better analyze and validate the maintainability design for complex equipment, and some potential ergonomics and safety issues can be found and dealt earlier. Originality/value A VLME was built for interactive “human-in-loop” maintenance operation simulation, which can support HFs evaluation in lighting environment accurately and effectively.
      Citation: Assembly Automation
      PubDate: 2015-12-18T12:43:06Z
      DOI: 10.1108/AA-04-2015-029
       
  • Geometric tolerance analysis through Jacobian model for rigid assemblies
           with translational deviations
    • Authors: Wilma Polini, Andrea Corrado
      Abstract: Assembly Automation, Volume 36, Issue 1, February 2016.
      Purpose Tolerance analysis is an important task to design and to manufacture high precision mechanical assemblies; it has received considerable attention by the literature. The Jacobian model is one of the methods proposed by the literature for tolerance analysis. The Jacobian model cannot deal with geometric tolerances for mechanical assemblies. The geometric tolerances may not be neglected for assemblies, since they significantly influence their functional requirements. Design/methodology/approach This work presents how it is possible to deal with geometric tolerances when a tolerance analysis is carried out by means of a Jacobian model for a 2D and 3D assemblies for which the geometric tolerances applied to the components involves only translational deviations. The three proposed approaches modify the expression of the stack-up function in order to overcome the shortage of Jacobian model that the geometric error cannot be processed. Findings The proposed approach has been applied to a case study. The results of the case study show how, when a statistical approach is implemented, the Jacobian model with the three developed methods give results very similar to those due to other models of the literature, such as vector loop and variational. Research limitations/implications In particular, the proposed approach may be applied only when the applied geometrical tolerances involve translational variations in 3D assemblies. Practical implications Tolerance analysis is a valid tool to foresee geometric interferences among the components of an assembly before getting the physical assembly. It involves a decrease of the manufacturing costs. Originality/value The original contribution of the paper is due to three methods to make a Jacobian model able to consider form and geometric deviations.
      Citation: Assembly Automation
      PubDate: 2015-12-18T12:43:04Z
      DOI: 10.1108/AA-11-2015-088
       
  • A novel assembly simulation method based on semantics and geometric
           constraint
    • Authors: Pan Wang, Yuan Li, Lin Yu, Jie Zhang, Zhijia Xu
      Abstract: Assembly Automation, Volume 36, Issue 1, February 2016.
      Purpose Currently, assembly simulation is always carried out by human-computer interaction, which is a time-consuming and tedious work. The most responsible reason for this problem is that the assembly simulation is a mapping between human intent and movements of models, at the same time, assembly information is transferred from semantic level to geometric level. However, some essential assembly information lost during the transfer, and it must be accomplished through manual definition. To address the issue, a novel assembly simulation method is proposed in this paper based on semantics and geometric constraint. Design/methodology/approach Firstly, an assembly operation semantic model is put forward to integrate and manage the semantic information of assembly, and some rules for modeling are generalized. Secondly, method for transferring assembly information from semantic level to geometric level is presented by dividing assembly operation into a set of simulation actions and providing some rules of the dividing. Then, a geometric constraint based calculation method is proposed to obtain the essential parameters of each simulation action. Finally, cases are studied to demonstrate the effectiveness of the method. Findings The results show that the laborious work would be reduced and the redundant human participation would be avoided in assembly simulation. Practical implications It has the potential and possibility to change the current pattern of assembly simulation. Originality/value A novel assembly simulation method based on semantics and geometric constraint is presented to make assembly simulation more convenient and faster.
      Citation: Assembly Automation
      PubDate: 2015-12-18T12:42:52Z
      DOI: 10.1108/AA-05-2015-036
       
  • A multi-manned assembly line balancing problem with classified teams: A
           new approach
    • Authors: Hamid Yilmaz, Mustafa Yilmaz
      Abstract: Assembly Automation, Volume 36, Issue 1, February 2016.
      Purpose This paper draws attention to assembly line balancing problem in which workers have been assigned to teams in advance due to the need for specialized skills or equipment on the line for the first time. Within team-oriented approaches, tasks are assigned to teams before being assigned to workstations as a reality of industry. So it becomes clear that, which workers assemble which tasks. Design/methodology/approach Team numbers of the assembly line can increase with the number of tasks, but at same time, due to physical situations of the stations, there will be limitations of maximum working team numbers in a station. For this purpose heuristic assembly line balancing procedure is used and mathematical model is developed for the problem. Findings Well-known assembly line test problems widely used in the literature are solved to indicate the effectiveness and applicability of the proposed approach in practice. Originality/value This paper draws attention to assembly line balancing problem in which workers have been assigned to teams in advance due to the need for specialized skills or equipment on the line for the first time.
      Citation: Assembly Automation
      PubDate: 2015-12-18T12:42:50Z
      DOI: 10.1108/AA-04-2015-035
       
  • Determination of the base position and working area for mobile
           manipulators
    • Authors: Shunan Ren, Xiangdong Yang, Jing Xu, Guolei Wang, Ying Xie, Ken Chen
      Abstract: Assembly Automation, Volume 36, Issue 1, February 2016.
      Purpose The purpose of this article is to determine the base position and the largest working area for mobile manipulators. The base position determines the workspace of the mobile manipulator, particularly when the operation mode is intermittent (i.e., the mobile platform stops when the manipulator conducts the task). When the base of the manipulator is in the intersection area of the Base’s Workable Location Spaces (BWLSes), the end effector (EE) can reach all path points. In this study, the intersection line of BWLSes is calculated numerically, and the largest working area is determined using the BWLS concept. The performance of this method is validated with simulations on specific surface segments, such as plane, cylinder, and conical surface segments. Design/methodology/approach The BWLS is used to determine the largest working area and the base position in which the mobile manipulator can reach all path points with the objective of reducing off-line planning time. Findings Without considering the orientation of the EE, the base position and the working area for the mobile manipulator are determined using the BWLS. Compared to other methods, the proposed algorithm is beneficial when the planning problem has six dimensions, ensuring the reachability and stability of the EE. Originality/value The algorithm needs no manual configuration, and its performance is investigated for typical surfaces in practical applications.
      Citation: Assembly Automation
      PubDate: 2015-12-18T12:42:48Z
      DOI: 10.1108/AA-11-2015-101
       
  • Human-inspired motion model of upper-limb with fast response and learning
           ability - A promising direction for robot system and control
    • Authors: Hong Qiao, Chuan Li, Peijie Yin, Wei Wu, Zhi-Yong Liu
      Abstract: Assembly Automation, Volume 36, Issue 1, February 2016.
      Purpose Human movement system is a Multi-DOF, redundant, complex and nonlinear system formed by coordinating combination of neural system, bones, muscles and joints, which is robust and has fast response and learning ability. Imitating human movement system can improve robustness, fast response and learning ability of the robots. Design/methodology/approach In this paper, we propose a new motion model based on the human motion pathway, especially the information propagation mechanism between the cerebellum and spinal cord. Findings The proposed motion model proves to have fast response and learning ability through experiments, which matches the features of human motion. Originality/value The proposed model in this paper introduces the habitual theory in kinesiology and neuroscience into robot control, and improves robustness, fast response and learning ability of the robots. This paper proves that introduction of neuroscience has an important guiding significance for precise and adaptive robot control, such as assembly automation.
      Citation: Assembly Automation
      PubDate: 2015-12-18T12:42:47Z
      DOI: 10.1108/AA-11-2015-099
       
  • Error sensitivity analysis of a microassembly system with coaxial
           alignment function
    • Authors: Xin Ye, Pan Liu, Zhijing Zhang, Chao Shao, Yan Li
      Abstract: Assembly Automation, Volume 36, Issue 1, February 2016.
      Purpose This paper is to analyze the sensitivity of the motion error parameters in microassembly process, thereby improving the assembly accuracy. For the motion errors of the precision motion stages directly affect the final assembly quality after the machine visual alignment. Design/methodology/approach This paper presents the error parameters of the in-house microassembly system with coaxial alignment function; builds the error transfer model by the multi-body system theory; analyzes the error sensitivity on the sensitive direction using the Sobol method which was based on variance; and then gets the ones which made a great degree of influence. Before the sensitivity analyzing, parts of the error sources have been measured to obtain their distribution ranges. Findings The results of the sensitivity analysis by the Sobol method which was based on variance are coincident with the theoretical analysis. Besides, the results provide a reference for the error compensation in control process; for the selection of the precision motion stages; and for the installation index of the motion stages of the assembly system with coaxial alignment. Originality/value This kind of error sensitivity analysis method is of great significance for improving the assembly accuracy after visual system positioning, and increasing efficiency from the initial motion stage selection to final error compensation for designers. It is suitable for general precision motion systems be of multi degree of freedom, for the method of modeling, measuring and analyzing used in this paper are all universal and applicative.
      Citation: Assembly Automation
      PubDate: 2015-12-18T12:42:37Z
      DOI: 10.1108/AA-02-2015-010
       
  • Design for assembly and disassembly for remanufacturing
    • Authors: SL Soh, S K Ong, A Y C Nee
      Abstract: Assembly Automation, Volume 36, Issue 1, February 2016.
      Purpose This research proposes a methodology for a systematic, concurrent consideration of design for assembly and disassembly guidelines and constraints for product remanufacturing. The methodology provides a holistic approach to product design from the remanufacturing perspective. Design/methodology/approach The proposed methodology incorporates parts integration assessment, and evaluation of part complexity and accessibility taking into consideration both DFA and DFD design guidelines and constraints. Metrics for accessibility and complexity in retrieving the remanufacturable cores from a product are evaluated to determine the best possible disassembly route considering the practical constraints which an operator might face during disassembly. As there could be more than one feasible disassembly route to retrieve a core during remanufacturing, a disassembly evaluation is conducted to determine the optimal path after parts combination of the assembly. Findings In remanufacturing, products need to be disassembled and re-assembled again. Conflicts exist between design for assembly and disassembly. The proposed methodology serves to address these conflicting issues. The proposed methodology eases a designer’s effort systematically to incorporate both aspects, by incorporating practical consideration to determine an optimal disassembly sequence through integrating the handling aspect of assembly complexity assessment with the U-Rating disassembly effort indexing scheme to provide a quantitative evaluation of disassembly complexity since disassembly still largely requires human effort. Research limitations/implications Further research can be looked into how the methodology proposed can be realized through implementation of a Design for Assembly and Disassembly software interface, to allow designers to input require data as well as extract relevant product information automatically from the CAD environment. Originality/value This paper proposed a methodology for a systematic, concurrent consideration of design for assembly and disassembly to provide a holistic approach to product design from the remanufacturing perspective to ease the designer’s task. Practical considerations will be made to determine the optimal disassembly route of the product. Design for disassembly will only be required to be applied to the selected disassembly route to minimize conflicts with design for assembly.
      Citation: Assembly Automation
      PubDate: 2015-12-18T12:42:34Z
      DOI: 10.1108/AA-05-2015-040
       
  • An efficient evolutionary method of assembly sequence planning for
           shipbuilding industry
    • Abstract: Assembly Automation, Volume 36, Issue 1, February 2016.
      Purpose The main aim of this article is to develop the method of generating assembly sequences, which can be used in the shipbuilding industry. The method must take into account the assumptions specific for assembly processes of large-size steel ship hulls, among others, a large number of connections, multi-stage and parallel assembly, set priority relations between connections. Design/methodology/approach The assembly sequence is presented as a directed acyclic graph, which vertices are mutually uniquely assigned to connections on a hull structure. The minimization of the number of unmet priority precedence of performing connections has been proposed as a criterion of optimization. The genetic algorithm has been proposed as a method to solve problems. Findings The proposed method allows to model the acyclic assembly process of welded structures and find solutions minimizing the objective function even for very complex problems. Because of this, the method has a chance to be used in shipbuilding. Research limitations/implications Mathematical formulation of priority assumptions is quite laborious. The possibility of partial automation of this process should be considered. Due to the complexity of the problem a relatively simplified objective function has been proposed. In assembling a hull additional criteria should be taken into account. It is the direction of further research. Practical implications The method can be successfully used in shipbuilding and in planning the production of other steel welded structures, among others, tanks, components of bridges, offshore structures. Examples of calculations were performed on an actual structure of a hull fragment. Originality/value A new way of coding the acyclic serial-parallel sequence was designed. The proposed method allows to analyse the sequence using the graph theory. Original, two-part crossover and mutation operators for assembling sequence were proposed.
      Citation: Assembly Automation
      PubDate: 2015-12-18T12:42:29Z
      DOI: 10.1108/AA-02-2015-013
       
  • Synchronization of discrete-time multi-agent systems under input sets with
           limited precision
    • Authors: Yang Meng, Zi Wang
      Abstract: Assembly Automation, Volume 36, Issue 1, February 2016.
      Purpose The paper mainly aims to study that for multi-agent systems, how to find proper control protocols to ensure synchronization when the input set of each agent is not the whole real axis but a discrete set, and how the coarseness of imprecise input sets affect the synchronization control of the multi-agent systems. Design/methodology/approach The paper uses a relative state feedback method and nonlinear mapping functions to design a proper control protocol which matches the coarseness of the input set and ensures synchronization. For theoretical analysis, the paper uses an error analysis method and mathematic induction to prove the effectiveness of the designed control protocol. Findings The paper provides a method for protocol design when the input set of each agent is imprecise. The paper establish a bi-direction relationship which suffices for synchronization between the coarseness of the input set and the synchronization precision, and find that this relationship describes how the coarseness of the input set affects the synchronization control of the multi-agent system. Research limitations/implications The authors are encouraged to study the synchronization control of multi-agent systems under input sets with more general distributions. Practical implications The paper includes implications for coordination control of multi-agent networks when the actuator of each agent is with limit capacity, which leads to the case of discrete input sets with limit precision. Originality/value This paper fulfils an identified need to study how the coarseness of the input set of each agent affects the synchronization control of the whole multi-agent system.
      Citation: Assembly Automation
      PubDate: 2015-12-18T12:42:28Z
      DOI: 10.1108/AA-12-2015-117
       
  • A zigzag path based joining method for fuselage panels in digital assembly
    • Authors: Qing Wang, Yadong Dou, Jiangxiong Li, Yinglin Ke
      First page: 289
      Abstract: Assembly Automation, Volume 35, Issue 4, September 2015.
      Purpose A fuselage panel is primarily composed of skins, stringers, frames and clips. Both inserted and nested structures are adopted in the panels to improve the strength and hermeticity of the fuselage. Due to the complex structures and relationships, it is a challenge to coordinate the arc-shaped panels in the assembly process. The purpose of this paper is to design a reasonable joining path and achieve assembly automation for multiple arc-shaped panels. Design/methodology/approach A motion sequence model which achieves arc approximation based on the relative motion of multiple panels is established. The initial position of the panels is obtained by decomposing the CAD model of the panels. Two translation rules, i.e. progressively decreasing translation and limited deformation translation, are applied to determine the moving path of the panels. If a panel is not at its path node, a search algorithm is used to find the nearest path node. Finally, the key algorithms are implemented in an integration system to promote joining automation of multiple panels. Findings The zigzag path is effective for the joining of multiple panels with complex mating relationships. The automation of the join-separate-rejoin operations is time-saving and safety-assuring. The proposed method is demonstrated in practical engineering and a good efficiency is obtained. Practical implications This method has been used in a middle fuselage assembly project. The practical results show that the zigzag path is convenient to be stored and reused, and the synchronous movements of multiple curved panels are precisely realized. Additionally, the posture accuracy of panels is significantly improved, and the operating time is reduced considerably. Originality/value This paper gives a solution including path planning and process integration to solve the joining problem of multiple panels. The research will promote the automation of fuselage assembly.
      Citation: Assembly Automation
      PubDate: 2015-09-17T01:06:06Z
      DOI: 10.1108/AA-05-2015-042
       
  • Auto-body assembly process fault diagnosis based on a dynamic variation
           modeling approach
    • Authors: Yinhua Liu, Xialiang Ye, Feixiang Ji, Sun Jin
      First page: 302
      Abstract: Assembly Automation, Volume 35, Issue 4, September 2015.
      Purpose This paper aims to provide a new dynamic modeling approach for root cause detection of the auto-body assembly variation Design/methodology/approach The dynamic characteristics, such as fixture element wear and quality of incoming parts, are considered in assembly variation modeling with the dynamic Bayesian network. Based on the network structure mapping, the parameter learning of different kinds of nodes is conducted by integrating process knowledge and Monte Carlo Simulation. The inference could take both the measurement data and maintenance actions as evidence to improve diagnosis accuracy. Findings The proposed assembly variation model which has incorporated dynamic manufacturing features could be used to detect multiple process faults effectively. Originality/value A dynamic variation modeling method is proposed. This method could be used to provide more accurate diagnosis results and preventive maintenance guidelines for the assembly process.
      Citation: Assembly Automation
      PubDate: 2015-09-17T01:05:56Z
      DOI: 10.1108/AA-03-2015-014
       
  • Influence of assembly predicate consideration on optimal assembly sequence
           generation
    • Authors: M V A Raju Bahubalendruni, Bibhuti Bhusan Biswal, Manish Kumar, Radharani Nayak
      First page: 309
      Abstract: Assembly Automation, Volume 35, Issue 4, September 2015.
      Purpose An appropriate assembly sequence results in minimal lead time and low cost of assembly. Assembly sequence generation (ASG) is a complex combinatorial optimization problem which deals with several assembly predicates to result an optimal assembly sequence. The consideration of each assembly predicate highly influences the search space and thereby computational time to achieve valid assembly sequence. Often the ignoring an assembly predicate leads to inappropriate assembly sequence, which may not be physically possible, sometimes predicate assumption drastic ally raises the search space with high computational time. The purpose of the article is to find out the significant influence of assembly predicate consideration on optimal assembly sequence generation in terms of search space, computational time, and possibility of resulting practically not feasible assembly sequences. Design/methodology/approach The influence of assuming and considering different assembly predicates on optimal assembly sequence generation have been clearly illustrated with examples using part concatenation method. Findings The presence of physical attachments and type of assembly liaisons decides the consideration of assembly predicate to reduce the complexity of the problem formulation and overall computational time Originality/value Most of the times assembly predicates are ignored to reduce the computational time without considering their impact on the assembly sequence problem irrespective of assembly attributes. The current research proposes direction towards predicate considerations based on the assembly configurations for effective and efficient assembly sequence generation.
      Citation: Assembly Automation
      PubDate: 2015-09-17T01:06:52Z
      DOI: 10.1108/AA-03-2015-022
       
  • An adaptive BPSO algorithm for multi-skilled workers assignment problem in
           aircraft assembly lines
    • Authors: Bo Xin, Yuan Li, Jian-feng YU, Jie Zhang
      First page: 317
      Abstract: Assembly Automation, Volume 35, Issue 4, September 2015.
      Purpose The purpose of this paper is to investigate the multi-skilled workers assignment problem in complex assembly systems such as aircraft assembly lines. An adaptive binary particle swarm optimization (A-BPSO) algorithm is proposed, which is used to balance the workload of both assembly stations and processes and to minimize the human cost. Design/methodology/approach Firstly, a cycle time model considering the cooperation of multi-skilled workers is constructed. This model provides a quantitative description of the relationship between the cycle time and multi-skilled workers by means of revising the standard learning curve with the ‘Partition-And-Accumulate’ method. Then, in order to improve the accuracy and stability of the current heuristic algorithms, an A-BPSO algorithm that suits for the discrete optimization problems is proposed to assign multi-skilled workers to assembly stations and processes based on modified sigmoid limiting function. Findings The proposed method has been successfully applied to a practical case and the result justifies its advantage as well as adaptability to both theory and engineering application. Originality/value (1) A novel cycle time model considering cooperation of multi-skilled workers is constructed so that the calculation results of cycle time are more accurate and closer to reality. (2) An adaptive BPSO algorithm is proposed to improve the stability and convergence in dealing with the problems with higher dimensional search space. This research can be used by the project managers and dispatchers on assembly field.
      Citation: Assembly Automation
      PubDate: 2015-09-17T01:07:17Z
      DOI: 10.1108/AA-06-2015-051
       
  • Coordination error control for accurate positioning in movable robotic
           drilling
    • Authors: Biao Mei, Weidong Zhu, Huiyue Dong, Yinglin Ke
      First page: 329
      Abstract: Assembly Automation, Volume 35, Issue 4, September 2015.
      Purpose Fastener hole drilling for multi-station aircraft assembly demands a robotic drilling system with expanded working volume and high positioning accuracy. However, coordination errors often exist between the robot and the subassembly to be drilled because of disturbances. This paper proposes a roadmap to control the robot-subassembly (R-S) coordination errors in movable robotic drilling. Design/methodology/approach Mechanical pre-locating and vision-based robot base frame (RBF) calibration are consecutively implemented to achieve in-process robot relocation after station transfer. Thus coordination errors induced by robotic platform movements, inconsistent thermal effects, etc., are eliminated. The 2D vision system is applied to measure the remainder of the R-S coordination errors, which is used to enhance the positioning accuracy of the robot. Accurate estimation of measured positioning errors is of great significance for evaluating the positioning accuracy. For well estimation of the positioning errors with small samples, a bootstrap approach is put forward. Findings A roadmap for R-S coordination error control using a 2D vision system, composed of in-process relocation, coordination error measurement and drilled position correction, is developed for the movable robotic drilling. Practical implications The proposed roadmap has been integrated into a drilling system for the assembly of flight control surfaces of a transport aircraft in Aviation Industry Corporation of China. The position accuracy of the drilled fastener holes is well ensured. Originality/value A complete roadmap for controlling coordination errors and improving positioning accuracy is proposed, which makes the high accuracy and efficiency available in movable robotic drilling for aircraft manufacturing.
      Citation: Assembly Automation
      PubDate: 2015-09-17T01:06:49Z
      DOI: 10.1108/AA-04-2015-024
       
  • Workspace, dexterity and dimensional optimization of microhexapod
    • Authors: E. Rouhani, M. J. Nategh
      First page: 341
      Abstract: Assembly Automation, Volume 35, Issue 4, September 2015.
      Purpose Most of the micromanipulators suffer from their restricted workspace because of using flexure joints compared to the conventional ones. In addition, the controllability of micromanipulators inside the whole workspace is very important. The purpose of this paper is to study the workspace and dexterity of a microhexapod which is a 6-DOF parallel compliant manipulator, and also to investigate its dimensional synthesis in order to maximize the workspace and the global dexterity index at the same time. Design/methodology/approach Most of the micromanipulators suffer from their restricted workspace because of using flexure joints compared to the conventional ones. In addition, the controllability of micromanipulators inside the whole workspace is very important. The purpose of this paper is to study the workspace and dexterity of a microhexapod which is a 6-DOF parallel compliant manipulator, and also to investigate its dimensional synthesis in order to maximize the workspace and the global dexterity index at the same time. Findings It has been shown that the proposed procedure for the workspace calculation can considerably speed the required calculations.The optimization results show that a converged- diverged configuration of pods and an increase in the difference between the moving and the stationary platforms’ radii cause the global dexterity index to increase and the workspace to decrease. Originality/value It has been shown that the proposed procedure for the workspace calculation can considerably speed the required calculations.The optimization results show that a converged- diverged configuration of pods and an increase in the difference between the moving and the stationary platforms’ radii cause the global dexterity index to increase and the workspace to decrease.
      Citation: Assembly Automation
      PubDate: 2015-09-17T01:06:51Z
      DOI: 10.1108/AA-03-2015-020
       
  • A new design tool for DFA/DFD based on rating factors
    • Authors: Devdas Shetty, Ahad Ali
      First page: 348
      Abstract: Assembly Automation, Volume 35, Issue 4, September 2015.
      Purpose Design engineers need an automated tool to effectively analyze the ease of assembly and disassembly of the products or subassemblies. A good assembly design helps in easier disassembly and thus makes it easier to service, repair and maintain. Reuse and recycling aspects are given importance in the present days due to environmental regulations. Designers now use the life cycle design of the products. This creates an environment for the successful application of design for manufacturing, assembly, and disassembly tools. This paper address some of those issues. Design/methodology/approach The analysis of a product design for ease of assembly/disassembly depends largely on whether the product is to be assembled / disassembled manually, with automation, or a combination of these. For example, the criteria for ease of automatic feeding and orienting are much more stringent than those for manual handling of parts. The New Design for Assembly / Disassembly (DFA/DFD) evaluation tool explained here enables the designer to review the existing design. This paper examines the existing techniques in the area of DFA/DFD and suggests a new methodology based on Rating Factors. Excel is used to create the interface for the user. Other popular methods were examined such as Boothroyd-Dewhurst, Lucas. Access, Reuse, Removal, Tool, Task and Time (AR3T3) method and Assembly Score method (Poli) were used as a base for this study. Findings The end result of this research is a new approach linked to assembly/disassembly rating score. Originality/value The new DFA/DFD evaluation tool enables the designer to review the existing design for assembly and disassembly difficulties.
      Citation: Assembly Automation
      PubDate: 2015-09-17T01:07:50Z
      DOI: 10.1108/AA-11-2014-088
       
  • Improvement of location and orientation tolerances propagation control in
           cylindrical components assembly using stack-build assembly technique
    • Authors: lei wang, chuanzhi sun, Jiubin Tan, bo zhao, Gu Wan
      First page: 358
      Abstract: Assembly Automation, Volume 35, Issue 4, September 2015.
      Purpose This paper aims to provide an assembly method to improve cylindrical components assembly quality. The proposed method not only could be applied to tolerance allocation, but also could guide the assembly of cylindrical components. Design/methodology/approach The paper claims to provide a stack-build assembly method using a connective assembly model to take the location and orientation tolerances of a rotor stage into account. Through the separate analysis of the location and orientation tolerances propagation process in the assembly, the quality of the final assembly of the rotationally symmetric cylindrical components assembly could be improved by properly selecting component orientations to minimize the eccentric deviation in the assembly. Findings The effectiveness of the proposed stack-build assembly technique in improving the tolerance propagation in the assembly of cylindrical components was verified through experiments run with a measuring machine. A real aero-engine rotor was assembly using the proposed method, compared to the direct-build assembly technique, which the component orientations without consideration, the stack-build assembly technique could be used to reduce the eccentric deviation in cylindrical components assembly by nearly 50%. Originality/value Different with the old methods, the new method defined the tolerances in detail, such as perpendicularity and angle of the lowest point, and could guide the assembly by the features of surfaces on different components. Through measure the special tolerances of surfaces on the components, the best assembly angle for each component could be obtained.
      Citation: Assembly Automation
      PubDate: 2015-09-17T01:07:12Z
      DOI: 10.1108/AA-03-2015-023
       
  • Proximity query based on second order cone programming using convex
           superquadrics: a static collision detection algorithm for narrow-phase
    • Authors: Lin Chen, Chongqi Ni, Junjie Feng, Jun Dai, Bingqiong Huang, Liu Huaping, Haihong Pan
      First page: 367
      Abstract: Assembly Automation, Volume 35, Issue 4, September 2015.
      Purpose Proximity queries have been used widely in robot trajectory planning, automatic assembly planning, virtual surgery and many other applications. The core of proximity query is the precise computation of (minimum) separation distance in narrow phase,and specific object representation scheme corresponds to different methods of separation distance computation.So the issue in final analysis is to find an objects representation scheme with high precision and to compute the objects’ separation distance effectively. Design/methodology/approach In this paper, a second order cone programming based (minimum) separation distance computation algorithm was proposed. It treats convex superquadrics, descriptive primitives of complex object as the study objects.The separation distance between two convex superquadrics was written as a general nonlinear programming (NLP) problem with superquadric constraints, then transformed into an SOCP problem with the method of conic formulation of superquadric constraints. Finally, a primal-dual interior point method embedded in MOSEK was used for solving the SOCP problem. Findings The proposed algorithm achieved exact separation distance computation between convex superquadrics, with a relative error of 10-6. It is particularly suitable for proximity queries in narrow phase of static collision detection algorithms. Further, the proposed algorithm achieved continuous collision detection between rectilinear translation superquadrics. Originality/value The proposed algorithm in narrow phase of static collision detection algorithms makes objects’ separation distance effectively computed. Proximity queries are easy and more accurate to perform in this way.
      Citation: Assembly Automation
      PubDate: 2015-09-17T01:07:49Z
      DOI: 10.1108/AA-03-2015-018
       
  • Real-virtual interaction in AR assembly simulation based on component
           contact handling strategy
    • Authors: X Wang, S K Ong, A Y C Nee
      First page: 376
      Abstract: Assembly Automation, Volume 35, Issue 4, September 2015.
      Purpose In this paper, an Integrated Augmented-Reality-aided Assembly Environment (IARAE) is proposed and implemented to incorporate the interaction between real and virtual components, so that users can obtain a more immersive experience of the assembly simulation in real-time and achieve better assembly design. Design/methodology/approach A component contact handling strategy is proposed to model all the possible movements of virtual components when they interact with real components. A novel assembly information management approach is proposed to access and modify the information instances dynamically corresponding to user manipulation. To support the interaction between real and virtual components, a hybrid marker-less tracking method is implemented. Findings A prototype system has been developed, and a case study of an automobile alternator assembly is presented. A set of tests is implemented to validate the feasibility, efficiency, accuracy and intuitiveness of the system. Research limitations/implications The prototype system allows the users to manipulate and assemble the designed virtual components to the real components, so that the users can check for possible design errors and modify the original design in the context of their final use and in the real world scale. Originality/value This paper proposes an integrated AR simulation and planning platform based on hybrid-tracking and ontology-based assembly information management. Component contact handling strategy based on collision detection and assembly feature surfaces mating reasoning is proposed to solve component DOF.
      Citation: Assembly Automation
      PubDate: 2015-09-17T01:05:58Z
      DOI: 10.1108/AA-02-2015-012
       
 
 
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