Assembly Process Design Research Articles

An Integrated Framework for Aircraft Digital Assembly Coordination Design and Simulation

The framework and application process of aircraft digital assembly coordination design and simulation are proposed by analyzing the information development situation of aircraft manufacturing enterprise, aircraft assembly coordination design status and development trending. Key technologies of visual and integrated coordinate design, feasibility simulation for assembly coordination scheme and feasibility evaluation based on the knowledge are researched in detail. It provides a new integrated framework for assembly process design of aircraft digital manufacturing, and also provides a reference for smart assembly accuracy analysis of complex products.

Research on Application of Engine Assembly Process Design Based on Assembly Simulation Technology

This paper summarized the problems existing in the traditional assembly process design, and analyzed the advantages and applications of assembly simulation technology. In order to address the real issues of aero-engine production, a novel assembly process applied to assembly simulation platform was established by the combination of the professional knowledge of Aero-Engine Assembly and assembly simulation technology. The convenience for aero-engine assembly process design was brought by the key technologies in flow of three-dimensional process planning, interference checking, ergonomics simulation, working state analysis, simulation Video and interactive Graphical with examples of assembly simulation technology application introducing. The conclusion that the success rate of assembly process design will be greatly improved and the assembly operators can be provided efficient assembly guidance when the assembly simulation technology used to engine assembly process design in the simulation platform, was proved with examples of engine assembly engineering.

Research on Assemblability Evaluation Method of Aero-engine Based on Assembly Data Model

In order to improve the assemblability of aero-engine products, this paper combined with the assembly process design features of the engine, and divided the assemblability into five directions, assembly performance, assembly structure, assembly connection, equipment capability and other requirements. The engine assembly data model was used as the carrier of product assembly process information integration; the fuzzy set and expert system were introduced to organically combine the product assembly process and the assembly parameters. Evaluation levels in all aspects of the engine structure assemblability are determined by the analysis and evaluation of a single factor and comprehensive impact. High-level assemblability analysis was achieved by means of that. The algorithm proposed in the paper had been applied to engine assembly process design practice and had achieved good practical results.

Research on high-resolution improved projection 3D localization algorithm and precision assembly of parts based on virtual reality

Traditional assembly process design tasks are generally performed manually by experienced craftsmen using 2D drawings, which often require the use of physical prototypes. This kind of assembly process design mode inevitably has the defects of low optimization degree, low design efficiency, and high cost. The current computer-aided assembly process design also has problems such as “combination explosion.” Assembly process design technology and algorithm based on virtual reality and artificial intelligence is an effective way to solve the above problems. The application of the system in a virtual reality system provides an accurate positioning method in a virtual reality system. The ultrasonic three-dimensional space positioning system uses a differential method to improve the ranging accuracy. The system has the advantages of strong anti-electromagnetic interference, insensitivity to light and no electromagnetic radiation; thus, it is suitable for application in virtual reality systems. In the paper, two different methods of assembly process planning are proposed for interactive constraint definition assembly and automatic constraint recognition assembly, which make up for the lack of a single method, make the assembly process more realistic, and realize the assembly path by acquiring sampling points. The recording and playback of the assembly process planning process is achieved using screenshots and video compression techniques.

Research on Application of Digital Assembly Technology based on MBD in Spacecraft Field

With the development of technology based on MBD, three-dimensional model has already been the sole basis during spacecraft assembly process, three-dimensional process design technology on MBD has all-around been applied in spacecraft assembly field. On the base of the five key technology which include digital assembly process design, visualization of three-dimensional process, simulation verification of three-dimensional assembly process, three-dimensional work instruction browsing and digital inspection, spacecraft assembly has realized the transformation from two-dimensional process design system to three-dimensional process design system. The digital assembly technology on MBD has thoroughly changed the spacecraft assembly flow. Through the implement of three-dimensional process design technology, the process design results are transferred to the workshop assembly site in the form of three-dimensional assembly instruction, improving the working environment of the production site, the level of spacecraft assembly is improved.

Safety Design and Development of a Human-Robot Collaboration Assembly Process in the Automotive Industry

Human-robot collaboration (HRC) is a complex procedure in manufacturing due to the problems posed by compatibility and operational safety among humans and robots, and by task definitions among them in a collaborative order. In this paper, the research results of the human-robot collaboration study for the case of an automotive brake disc assembly is presented. The analytic hierarchy process (AHP) is proposed as a decision-making method for the human-robot collaboration system, and detailed hierarchical task analysis (HTA) is applied to allocate operational tasks to humans and robots, thus reducing the chance of duty interference. Additionally, a virtual environment software (Tecnomatix Process Simulate, version 11.1,80, Siemens, Munich, BY, Germany, 2012) is used to model the assembly workstation, providing an opportunity to evaluate the feasibility of the process through different scenarios. Finally, an experimental test is conducted to evaluate the performance of the assembly procedure. This research proves that, although human-robot collaboration increases the total process time slightly, this collaboration improves human ergonomics considerably and reduces the operator injury risk.

Aircraft digital assembly process design technology based on 3D Model

In order to improve the quality, efficiency and cooperativity of aircraft assembly, based on the analysis of the characteristics of aircraft assembly process, a method for assembly process design, simulation and application based on three dimensional (3D) product model was proposed. The basic working process and system structure of the method were introduced, and the 3D digital assembly process planning, design and simulation optimization application mode was explored. This method has been applied in the design of aircraft assembly process, the efficiency and synergy of process design have been greatly improved.

Case study: Application of Design for Automated Assembly methods in the development of an electronic product from early design to design freeze

The paper discusses experiences from a concurrent product- and automated assembly process-development in a manufacturing company from early design to design freeze. The product is a compact product consisting of a plastic casing housing electronic components which is currently entering production. The company is a high-tech manufacturer operating in a high-cost country delivering safety products in a business to business market. The case study is based on project documentation, analyses of product and assembly concept, lab tests as well as dialogue with the manufacturer and the product designer. The main author was involved in the automated assembly process development and Design for Automatic Assembly (DFAA). The product and the automated assembly line were designed in parallel, throughout the entire product development process; from idea and concept development until the pre-production stages. In the early stages of the project the product was redesigned on a frequent basis, and each new design was evaluated for its automated manufacturability. In this process several DFAA methods were applied. The product designers also produced several prototypes by a plastic additive technology (3D printers) that were assembled in a prototype automated cell to assess product design and assembly solutions, and to reveal weaknesses that were not detected in the analysis. This paper compares the different DFAA methods used such as DFA2, as well as a custom DFAA review spreadsheet. Additionally, the paper discusses the interaction between product design and production process design, and effects on the outcome. Finally, the paper suggests design process improvements and guidelines.

Research on Operation Analysis and Evaluation Method of Ergonomics for Virtual Assembly

With the rapid development of digital technology and virtual reality technology, virtual reality technology has been paid more and more attention by more and more people. To investigate the application of virtual assembly simulation and improve ergonomics, the study on the interactive assembly operation has been performed. A Comprehensive Evaluation Method for ergonomics based on simulation of virtual assembly operations is proposed, aiming at avoid inadequate working postures, effectively improve assembly quality and shorten the production cycle. In this paper, the virtual assembly technology is introduced to the assembly process of an industrial manipulator. Details of the virtual assembly simulation process of an industrial manipulator design and its implementation are presented. This proposed method provides great support to the design of assembly process and brings about good change in the ergonomics of machine and system visualization. The analysis of this instance plays a guiding role in the optimization of human factors engineering.

Finite element design for the HPHT synthesis of diamond

The finite element method is used to simulate the steady-state temperature field in diamond synthesis cell. The 2D and 3D models of the China-type cubic press with large deformation of the synthesis cell was established successfully, which has been verified by situ measurements of synthesis cell. The assembly design, component design and process design for the HPHT synthesis of diamond based on the finite element simulation were presented one by one. The temperature field in a high-pressure synthetic cavity for diamond production is optimized by adjusting the cavity assembly. A series of analysis about the influence of the pressure media parameters on the temperature field are examined through adjusting the model parameters. Furthermore, the formation mechanism of wasteland was studied in detail. It indicates that the wasteland is inevitably exists in the synthesis sample, the distribution of growth region of the diamond with hex-octahedral is move to the center of the synthesis sample from near the heater as the power increasing, and the growth conditions of high quality diamond is locating at the center of the synthesis sample. These works can offer suggestion and advice to the development and optimization of a diamond production process.

English

A review On Utilizing Ontological Approaches in Integrating Assembly Design and Assembly Process Planning

Research on visual 3D assembly process design and simulation for marine diesel engine

In view of the backward traditional assembly process design model in shipbuilding industry, the research on the visual assembly process design and simulation of the marine diesel engine is an innovation for the marine diesel engine manufacturing model. This paper studied the key technologies such as structural assembly process design and assembly process simulation. In addition, following the principle of unified data source, through independent development and application on the platforms of Teamcenter and Vis MockUp, this research removed the obstacles in the integration of visual 3D assembly process design and simulation, took the lead in transforming the whole marine diesel engine assembly model from 2 dimensions to 3 dimensions, and made the methods of process verification and assessment more advanced. Finally, taking key parts of certain marine diesel engine as an example, this research verified the feasibility of the assembly process design system, and improved the stability and reliability of the marine diesel engine assembly process design.

Integrating ergonomics and lean manufacturing principles in a hybrid assembly line

Lean manufacturing is a production method that was established in the wake of the Japanese Toyota Production System and rapidly established in the worldwide manufacturing industry. Lean characteristics combine just-in-time practices, work-in-progress and waste reduction, improvement strategies, defect-free production, and standardization. The primary goal of lean thinking is to improve profits and create value by minimizing waste. This study introduces a novel mathematical model to design lean processes in hybrid assembly lines. The aim was to provide an effective, efficient assembly line design tool that meets the lean principles and ergonomic requirements of safe assembly work. Given the production requirements, product characteristics and assembly tasks, the model defines the assembly process for hybrid assembly lines with both manual workers and automated assembly machines. Each assembly line solution ensures an acceptable risk level of repetitive movements, as required by current law.This model helps managers and practitioners to design hybrid assembly lines with both manual workers and automated assembly machines. The model was tested in a case study of an assembly line for hard shell tool cases. Results show that worker ergonomics is a key parameter of the assembly process design, as other lean manufacturing parameters, e.g. takt time, cycle time and work in progress.

Modeling for assembly simulations: Data description and a data-driven construction framework

Assembly simulations such as assembly process simulation and assembly tolerance simulation have become an effective means to evaluate and analyze product assembly design and assembly process planning. Being core aspect of simulation implementation, building an assembly simulation model is rather time-consuming because of its high complexity. Furthermore, modeling has a significant influence on the popularization and application of simulation technology. In this paper, data needed by assembly process and tolerance simulation are addressed to propose a data-driven approach for assembly simulation modeling. The application process and the architecture of modeling framework for assembly simulation are presented as well. An assembly sequence simulation example is given to illustrate the application of the framework. The framework provides a new idea for the realization of automatic modeling for assembly simulation.

Structure failure of the sealing in the assembly process for proton exchange membrane fuel cells

Sealing stability in proton exchange membrane fuel cell (PEMFC) is critical to the performance and safety of stacks. However, sealing structure failure (SSF), which leads to the leakage of reactant gases, often occurs in the assembly process or start-up operation for PEMFCs. This study aims to investigate the effects of geometrical structure and material parameters of sealing components on the sealing structure failure. Slippage angle and slippage distance are adopted to evaluate the risk of SSF. Finite element (FE) simulations are conducted with consideration of the assembly process and start-up operation. Experiments are carried out to validate the accuracy of the FE model. Influences of parameters of gasket, membrane electrode assembly (MEA) frame, sealing groove shape of bipolar plate (BPP), and gas pressure are discussed in detail. Meanwhile, the risks of SSF for the stack by using metallic and graphite BPPs are compared. It is demonstrated that material properties and geometrical parameters of sealing components in PEMFC have great effects on SSF. The methodology developed is beneficial to the understanding of the SSF, and it can also be applied to guide the design of PEMFC stack assembly process to keep a good sealing reliability.

An Investigation into the Interrelationship between Aircraft Systems and Final Assembly Process Design

Modern aircraft are more integrated with advanced systems functionalities, which result in ever-increasing aircraft complexity, further development difficulties and development delays. These system complexities are mostly in the form of system interactions that make it difficult to understand the overall system characteristics. At the early stages of final assembly line (FAL) design, one of the most important objectives is to arrange the installation and test tasks from components to sub-systems and systems in the proper sequence to meet the designed functions and prevent hazards from the integration process. Improper sequencing of the final assembly process will cause rework, time delays, cost and potential safety risk in development. In the field of final assembly line design, previous research has mostly focused on assembly line balancing or supply chain design based on structural parts assembly. However, these approaches do not consider the early final assembly line definition or test allocation for system functions. In this paper, the research proposes a method based on a systems engineering view and integrated computer aided design (CAD) to help better understand system interactions and generate viable final assembly process sequencing. This research aims to develop a concept of unified master data for final assembly design, which contains 3D geometrical CAD, system functions and interaction characteristics. The paper will present the methodology framework, key concepts and associated industrial software packages for implementation. The paper concludes with further discussion of an initial case study.

An augmented reality tool to validate the assembly sequence of a discrete product

The need for more flexible tools and reduction of time and cost has led to the implementation of augmented reality (AR) and virtual reality (VR) techniques in the product design and development process. Those techniques have already been used in the conceptual, manufacturing and assembly stages of product design instead of or in extension of the physical prototypes. Such virtual applications have demonstrated superior performance in assembly process design and evaluation of activities that present information about different assembly states in real time, thanks to their flexibility in manipulating and creating new working scenarios. Here, the development of an AR application, called PoliART, aimed at the visual evaluation of assembly sequences at early stages of design is presented. At an industrial level this allows collaborative work between designers and manufacturing engineers from the very beginning in order to consider assembly devices, times and resources, with a short implementation time and reduced costs.

Research of the Technology and Application of Spacecraft Assembly Data-package Construction Based on MBD

In order to implement spacecraft assembly based on MBD, this article proposes a method to construct data-package automatically based on 3D model. First, an Assembly Digital Mock-up (ADMU) is constructed. Second, we propose the way of assembly process design based on 3D structural process design. Third, we construct the product data-package automatically based on the relationship among ADMU, the process files and production parameters Finally, the paper describes the application of the technology, and analyses the effect of the scheme during a satellite development. The technology and systems should be applied on other sophisticated products development, with some essential modifications.

Research of the Technology and Application of 3D Model Based Assembly Structural Process Design for Spacecraft

In order to implement spacecraft assembly based on MBD, this article proposes a method of structural process design based on 3D model. First, an Assembly Digital Mock-up (ADMU) is constructed. Second, we propose the way of assembly process design based on 3D structural process design scheme. Finally, the paper describes the application of the technology, and analyses the effect of the scheme during a satellite development. The technology and systems should be applied on other sophisticated products development, with some essential modifications.

Model of automated design of assembly process

The article provides an analysis of the basic laws of the assembly process simulation. Mathematical formulas describing the basic properties of the structure, as well as the interdependence of design elements are given. The basic requirements for the order of the assembly process, based on the conditions of locating and access are revealed. The process of order formation of the product assembly process is considered. It is given the generalized model of the assembly process. It is formulated objective function of assembly that takes into account the incidence matrix, the matrix dimensions, as well as an array of logic regularities characterizing the combination of assembly units in detail. This model allows to create a basis for the development of specific models that have already correspond to the objective function and will simplify and speed up the design process of the assembly. It is proposed the frame model representation of assembly process representation, which allows to formalize the assembly of individual units, select the best sequence of assembly of plurality of possible sequences. These models can be the basis for assembly design automation using intelligent technologies such as voice control.