Part-by-part dimensional error compensation in compliant sheet metal assembly processes

2012 ◽  
Vol 31 (2) ◽  
pp. 152-161 ◽  
Author(s):  
Kang Xie ◽  
Jaime A. Camelio ◽  
L. Eduardo Izquierdo
Keyword(s):  
Sheet Metal ◽  
Error Compensation ◽  
Dimensional Error ◽  
Sheet Metal Assembly

Variation Analysis for Compliant Assembly

2000 ◽  
Author(s):  
S. Jack Hu ◽  
Yufeng Long ◽  
Jaime Camelio
Keyword(s):  
Sheet Metal ◽  
Assembly Line ◽  
Assembly Process ◽  
Variation Analysis ◽  
Assembly Lines ◽  
Compliant Assembly ◽  
Single Station ◽  
Dimensional Variation ◽  
Sheet Metal Assembly

Abstract Assembly processes for compliant non-rigid parts are widely used in manufacturing automobiles, furniture, and electronic appliances. One of the major issues in the sheet metal assembly process is to control the dimensional variation of assemblies throughout the assembly line. This paper provides an overview of the recent development in variation analysis for compliant assembly. First, the unique characteristics of compliant assemblies are discussed. Then, various approaches to variation modeling for compliant assemblies are presented for single station and multi-station assembly lines. Finally, examples are given to demonstrate the applications of compliant assembly variation models.

Improving the Accuracy of Multi-Axis Machines Through On-Line Error Compensation Using Neural Networks

1998 ◽  
Author(s):  
Abderrazak El Ouafi ◽  
Michel Guillot ◽  
Abdellah Bedrouni
Keyword(s):  
Error Compensation ◽  
Error Modeling ◽  
Precision Engineering ◽  
Dimensional Error ◽  
New Approach ◽  
Turning Center ◽  
On Line ◽  
Dynamic Errors ◽  
Compensation Approach ◽  
Compensation Function

Abstract This research is devoted to one of the most fundamental problems in precision engineering: multi-axis machines accuracy. The paper presents a new approach designed to support the implementation of software error compensation of geometric, thermal and dynamic errors for enhancing the accuracy of multi-axis machines. The accuracy of multi-axis machines can be significantly improved using an intelligent integration of sensor information to perform the compensation function. The compensation process consists of the following major steps carried out on-line: continuous monitoring of the machine conditions using position, force, speed and temperature sensors mounted on the machine structure. Error forecasting through sensor fusion. Volumetric error synthesis and software compensation. To improve the effectiveness of error modeling, an artificial neural network is extensively applied. Implemented on a turning center, the compensation approach has enabled improvement of the machine accuracy by reducing the maximum dimensional error from 70 μm initially to less than 4 μm.

A Chronological Framework for Virtual Sheet Metal Assembly Design

2013 ◽  
pp. 173-190
Author(s):  
Johan Segeborn ◽  
Anders Carlsson ◽  
Johan S. Carlson ◽  
Rikard Söderberg
Keyword(s):  
Sheet Metal ◽  
Assembly Design ◽  
Sheet Metal Assembly

scholarly journals Evaluation of anti-vibration interventions for the hand during sheet metal assembly work

Work ◽  
2011 ◽  
Vol 39 (2) ◽  
pp. 169-176 ◽  
Author(s):  
Ann Marie Dale ◽  
A.E. Rohn ◽  
A. Burwell ◽  
W. Shannon ◽  
J. Standeven ◽  
...  
Keyword(s):  
Sheet Metal ◽  
Assembly Work ◽  
Sheet Metal Assembly

Variation Simulation for Deformable Sheet Metal Assemblies Using Finite Element Methods

1997 ◽  
Vol 119 (3) ◽  
pp. 368-374 ◽  
Author(s):  
S. Charles Liu ◽  
S. Jack Hu
Keyword(s):  
Monte Carlo Simulation ◽  
Finite Element ◽  
Monte Carlo ◽  
Sheet Metal ◽  
Finite Element Methods ◽  
Free Form ◽  
Direct Monte Carlo Simulation ◽  
Free Form Surfaces ◽  
Variation Simulation ◽  
Sheet Metal Assembly

Traditional variation analysis methods, such as Root Sum Square method and Monte Carlo simulation, are not applicable to sheet metal assemblies because of possible part deformation during the assembly process. This paper proposes the use of finite element methods (FEM) in developing mechanistic variation simulation models for deformable sheet metal parts with complex two or three dimensional free form surfaces. Mechanistic variation simulation provides improved analysis by combining engineering structure models and statistical analysis in predicting the assembly variation. Direct Monte Carlo simulation in FEM is very time consuming, because hundreds or thousands of FEM runs are required to obtain a realistic assembly distribution. An alternative method, based on the Method of Influence Coefficients, is developed to improve the computational efficiency, producing improvements by several orders of magnitude. Simulations from both methods yield almost identical results. An example illustrates the developed methods used for evaluating sheet metal assembly variation. The new approaches provide an improved understanding of sheet metal assembly processes.

An Industrially Validated Method for Weld Load Balancing in Multi Station Sheet Metal Assembly Lines

2013 ◽  
Vol 136 (1) ◽  
Author(s):  
Johan Segeborn ◽  
Daniel Segerdahl ◽  
Fredrik Ekstedt ◽  
Johan S. Carlson ◽  
Mikael Andersson ◽  
...  
Keyword(s):  
Sheet Metal ◽  
Cycle Time ◽  
Industrial Robot ◽  
Complex Problem ◽  
Line Balancing ◽  
Processing Unit ◽  
Mathematical Methods ◽  
Central Processing ◽  
Robot Positioning ◽  
Sheet Metal Assembly

Sheet metal assembly is investment intense. Therefore, the equipment needs to be efficiently utilized. The balancing of welds has a significant influence on achievable production rate and equipment utilization. Robot line balancing is a complex problem, where each weld is to be assigned to a specific station and robot, such that line cycle time is minimized. Industrial robot line balancing has been manually conducted in computer aided engineering (CAE)-tools based on experience and trial and error rather than mathematical methods. However, recently an automatic method for robot line balancing was proposed by the authors. To reduce robot coordination cycle time losses, this method requires identical reach ability of all line stations. This limits applicability considerably since in most industrial lines, reach ability differs over the stations to further line reach ability and flexibility. Therefore, in this work we propose a novel generalized simulation-based method for automatic robot line balancing that allows any robot positioning. It reduces the need for robot coordination significantly by spatially separating the robot weld work loads. The proposed method is furthermore successfully demonstrated on automotive stud welding lines, with line cycle times lower than that of the corresponding running production programs. Moreover, algorithm central processing unit (CPU)-times are mere fractions of the lead times of existing CAE-tools.

High-Accuracy and Low-Cost Chamfering System by a Material-Handling Robot –Individual Error Compensation Using Image Processing–

2009 ◽  
Vol 3 (4) ◽  
pp. 465-470 ◽  
Author(s):  
Naoki Asakawa ◽  
◽  
Hidetake Tanaka ◽  
Tomoya Kiyoshige ◽  
Masatoshi Hirao ◽  
...  
Keyword(s):  
Image Processing ◽  
Error Compensation ◽  
Material Handling ◽  
Low Cost ◽  
High Accuracy ◽  
Processing Technology ◽  
Experimental Result ◽  
Robot Hand ◽  
Dimensional Error ◽  
System A

The study deals with an automation of chamfering by a material-handling robot with considering of accuracy and costs. The study focused on automation of chamfering without influence of individual dimensional error of workpiece. A casted impeller usually chamfered with handwork is treated in the study as an example of a workpiece having individual dimensional error. In the system, a file driven by air reciprocating actuator is used as a chamfering tool and image processing technology is used to compensate the dimensional error of the workpiece. The robot hand carries a workpiece instead of a chamfering tool both for chamfering and for material handling. From the experimental result, the system is found effective to chamfer a workpiece having dimensional error automatically.

Quality design of fixture planning for sheet metal assembly

2006 ◽  
Vol 32 (7-8) ◽  
pp. 690-697 ◽  
Author(s):  
Bing Li ◽  
Hui Tang ◽  
Xiaoping Yang ◽  
Hao Wang
Keyword(s):  
Sheet Metal ◽  
Fixture Planning ◽  
Quality Design ◽  
Sheet Metal Assembly
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