Stream-of-Variation Modeling I: A Generic 3D Variation Model for Rigid Body Assembly in Single Station Assembly Processes

2006 ◽  
Author(s):  
Wenzhen Huang ◽  
Jijun Lin ◽  
Michelle Bezdecny ◽  
Zhenyu Kong ◽  
Dariusz Ceglarek
Keyword(s):  
Rigid Body ◽  
Manufacturing Systems ◽  
Assembly Model ◽  
Single Station ◽  
Generic Modeling ◽  
Rigid Model ◽  
Stream Of Variation ◽  
Product And Process ◽  
Industrial Software ◽  
Relationship Of

A stream-of variation analysis (SOVA) model for 3D rigid body assemblies in single station is developed. Both product and process information such as part and fixture locating errors are integrated in the model. The model represents a linear relationship of the variations between Key Product Characteristics (KPCs) and Key Control Characteristics (KCCs). The generic modeling procedure and framework are provided, which involves: (1) an assembly graph (AG) to represent the kinematical constraints among parts and fixtures; (2) a unified method to transform all constraints (mating interface and fixture locators etc.) into a 3-2-1 locating scheme; and (3) a 3D rigid model for variation flow in a single station. The generality of the model is achieved by formulating all these constraints with a unified generalized fixture model. Thus, the new model accommodates various types of assemblies. This model provides a building block for complex multi station assembly model, in which the inter-station interactions are taken into account. The model has been verified by using Monte Carlo (MC) simulation and a standardized industrial software. It provides the basis for variation control through tolerance design analysis, synthesis and diagnosis in manufacturing systems.

Stream-of-Variation Modeling—Part I: A Generic Three-Dimensional Variation Model for Rigid-Body Assembly in Single Station Assembly Processes

2007 ◽  
Vol 129 (4) ◽  
pp. 821-831 ◽  
Author(s):  
Wenzhen Huang ◽  
Jijun Lin ◽  
Michelle Bezdecny ◽  
Zhenyu Kong ◽  
Dariusz Ceglarek
Keyword(s):  
Rigid Body ◽  
Manufacturing Systems ◽  
Three Dimensional ◽  
Single Station ◽  
Generic Modeling ◽  
Stream Of Variation ◽  
Product And Process ◽  
Industrial Software ◽  
Multistation Assembly ◽  
Relationship Of

A stream-of-variation analysis (SOVA) model for three-dimensional (3D) rigid-body assemblies in a single station is developed. Both product and process information, such as part and fixture locating errors, are integrated in the model. The model represents a linear relationship of the variations between key product characteristics and key control characteristics. The generic modeling procedure and framework are provided, which involve: (1) an assembly graph (AG) to represent the kinematical constraints among parts and fixtures, (2) an unified method to transform all constraints (mating interface and fixture locators etc.) into a 3-2-1 locating scheme, and (3) a 3D rigid model for variation flow in a single-station process. The generality of the model is achieved by formulating all these constraints with an unified generalized fixture model. Thus, the model is able to accommodate various types of assemblies and provides a building block for complex multistation assembly model, in which the interstation interactions are taken into account. The model has been verified by using Monte Carlo simulation and a standardized industrial software. It provides the basis for variation control through tolerance design analysis, synthesis, and diagnosis in manufacturing systems.

Stream-of-Variation (SOVA) Modeling II: A Generic 3D Variation Model for Rigid Body Assembly in Multistation Assembly Processes

2007 ◽  
Vol 129 (4) ◽  
pp. 832-842 ◽  
Author(s):  
Wenzhen Huang ◽  
Jijun Lin ◽  
Zhenyu Kong ◽  
Dariusz Ceglarek
Keyword(s):  
Tolerance Analysis ◽  
Computation Efficiency ◽  
Simulation Based ◽  
Automatic Model Generation ◽  
Stream Of Variation ◽  
Product And Process ◽  
Process Factors ◽  
Industrial Software ◽  
Backward Analysis ◽  
Multistation Assembly

A 3D rigid assembly modeling technique is developed for stream of variation analysis (SOVA) in multi-station processes. An assembly process is modeled as a spatial indexed state transition dynamic system. The model takes into account product and process factors such as: part-to-fixture, part-to-part, and inter-station interactions, which represent the influences coming from both tooling errors and part errors. The incorporation of the virtual fixture concept (Huang et al., Proc. of 2006 ASME MSEC) and inter-station interaction leads to the generic, unified SOVA model formulation. An automatic model generation technique is also developed for surmounting difficulties in modeling based on first principles. It enhances the applicability in modeling complex assemblies. The developed SOVA methodology outperforms the current simulation based techniques in computation efficiency, not only in forward analysis of complex assembly systems (tolerance analysis, sensitivity analysis), but it is also more powerful in backward analysis (tolerance synthesis and dimensional fault diagnosis). The model is validated using industrial case studies and series of simulations conducted using standardized industrial software (3DCS Analyst).

Stream-of-Variation (SOVA) Modeling II: A Generic 3D Variation Model for Rigid Body Assembly in Multi Station Assembly Processes

2006 ◽  
Author(s):  
Wenzhen Huang ◽  
Jijun Lin ◽  
Zhenyu Kong ◽  
Dariusz Ceglarek
Keyword(s):  
Tolerance Analysis ◽  
Model Formulation ◽  
Computation Efficiency ◽  
Simulation Based ◽  
Automatic Model Generation ◽  
Stream Of Variation ◽  
Product And Process ◽  
Process Factors ◽  
Industrial Software ◽  
Backward Analysis

A 3D rigid assembly modeling technique is developed for stream of variation analysis (SOVA) in multi-station processes. An assembly process is modeled as a spatial indexed state transition dynamic system. The model takes into account product and process factors such as: part-to-fixture, part-to-part and inter-station interactions, which represent the influences coming from both tooling errors and part errors. The incorporation of the virtual fixture concept [14] and inter-station interaction leads to the generic, unified SOVA model formulation. An automatic model generation technique is also developed for surmounting difficulties in modeling based on first principles. It enhances the applicability in modeling complex assemblies. The developed SOVA methodology outperforms the current simulation based techniques in computation efficiency, not only in forward analysis of complex assembly systems (tolerance analysis, sensitivity analysis), but it is also more powerful in backward analysis (tolerance synthesis and dimensional fault diagnosis). The model is validated using industrial case studies and series of simulations conducted using standardized industrial software (3DCS).

Stream of Variation Based Error Compensation Strategy in Multi-Stage Manufacturing Processes

2005 ◽  
Author(s):  
Dragan Djurdjanovic ◽  
Jie Zhu
Keyword(s):  
Control Theory ◽  
State Space ◽  
Error Compensation ◽  
Manufacturing Systems ◽  
Tolerance Allocation ◽  
Measurement Technology ◽  
Natural Connection ◽  
Manufacturing Errors ◽  
Stream Of Variation ◽  
Linear State

Linear state space Stream of Variation (SoV) models of error flow in multistation assembly and machining systems have been well studied in the past decade. SoV models were utilized for identification of process-level root causes of manufacturing errors, quantitative characterization of measurements in multistation manufacturing systems, systematic selection of measurement points and features, as well as tolerance allocation and process design. Nevertheless, natural connection of the linear state space form of SoV models with traditional control theory has not been utilized to automatically compensate observed manufacturing errors and thus close the quality control loop. Recent advances in measurement technology and flexible fixtures make such operations possible and in this paper, we propose a method for strategic elimination of root causes of quality problems based on the SoV models of the flow of manufacturing errors. Furthermore, the concept of compensability that quantitatively depicts the capacity of error compensation in a specific system is proposed. Based on this concept analogous to the controllability in the traditional control theory, compensable and non-compensable subspaces of dimensional errors are identified and quantitatively described. Theoretical results have been demonstrated using the SoV model of a real industrial process used for machining of automotive cylinder heads.

scholarly journals Multidomain Simulation Model for Analysis of Geometric Variation and Productivity in Multi-Stage Assembly Systems

2020 ◽  
Vol 10 (18) ◽  
pp. 6606
Author(s):  
Sergio Benavent Nácher ◽  
Pedro Rosado Castellano ◽  
Fernando Romero Subirón ◽  
José V. Abellán-Nebot
Keyword(s):  
Manufacturing Systems ◽  
Production Quality ◽  
Assembly Systems ◽  
New Era ◽  
Multistage Manufacturing ◽  
Multi Stage ◽  
Potential Applicability ◽  
Stream Of Variation ◽  
Manufacturing Environments ◽  
Geometric Variation

Nowadays, the new era of industry 4.0 is forcing manufacturers to develop models and methods for managing the geometric variation of a final product in complex manufacturing environments, such as multistage manufacturing systems. The stream of variation model has been successfully applied to manage product geometric variation in these systems, but there is a lack of research studying its application together with the material and order flow in the system. In this work, which is focused on the production quality paradigm in a model-based system engineering context, a digital prototype is proposed to integrate productivity and part quality based on the stream of variation analysis in multistage assembly systems. The prototype was modelled and simulated with OpenModelica tool exploiting the Modelica language capabilities for multidomain simulations and its synergy with SysML. A case study is presented to validate the potential applicability of the approach. The proposed model and the results show a promising potential for future developments aligned with the production quality paradigm.

Roll-to-Roll Manufacturing System Modeling and Analysis by Stream of Variation Theory

2016 ◽  
Author(s):  
Huanyi Shui ◽  
Xiaoning Jin ◽  
Jun Ni
Keyword(s):  
Product Quality ◽  
Physical Model ◽  
Manufacturing Systems ◽  
Manufacturing System ◽  
Equilibrium Analysis ◽  
Multistage Model ◽  
Roll To Roll ◽  
Virtual Metrology ◽  
Stream Of Variation ◽  
Multiple Stages

A multistage system that consists of multiple stages for sequential operations to finish products is widely employed in modern manufacturing systems. Due to the characteristics of multistage systems, the product quality not only depends on operations in current stage but is also affected by operations in upstream stages. Most existing studies use Stream of Variation models to analyze error propagation and interactions among multiple stages in discrete manufacturing systems such as machining shops and assembly systems. In this paper, a multistage model based on the “Stream of Variation” concept is developed to investigate the tension propagation in a flexible material roll-to-roll manufacturing system. This modeling method uses a physical model coupled with a data-driven model to correlate the roller operation performance and product quality characteristics. Torque equilibrium analysis and Hooke’s law are employed for physical model and the censored regression model is used to explore unknown structures/parameters. A web unwinding process demonstrates the feasibility and prediction performance of the proposed model. The result shows that the proposed multistage model can serve as a virtual metrology method to increase system visibility, enhance health management capability and eventually improve product quality.

Trends in Precision Manufacturing Based on Intelligent Design and Advanced Metrology

2013 ◽  
Vol 581 ◽  
pp. 417-422 ◽  
Author(s):  
M. Numan Durakbasa ◽  
Gokcen Bas ◽  
Jorge Martin Bauer ◽  
Günther Poszvek
Keyword(s):  
Environmental Sustainability ◽  
Manufacturing Systems ◽  
Process Development ◽  
Raw Materials ◽  
Cost Effective ◽  
Intelligent Manufacturing ◽  
Production Engineering ◽  
Comprehensive Knowledge ◽  
Product And Process ◽  
The One

ts of extreme importance in present time of worldwide international competition in industry and production engineering to safe time on the one hand and on the other keep an eye on increasingly higher costs of energy and raw materials. Comprehensive knowledge in the areas of market requirements, product and process development and design, intelligent metrology and end of life management are important presuppositions to achieve rapid, agile, waste free and cost-effective production of innovative, customized complex products using next-generation materials as well as to protect the environment by making zero emissions and improve environmental sustainability and reduce the use of energy by using intelligent manufacturing systems.

The Study on Automatic Extraction and Conversion of Assembly Relation

2014 ◽  
Vol 488-489 ◽  
pp. 1138-1141
Author(s):  
Yan Dong ◽  
Mei Li
Keyword(s):  
Three Dimensional ◽  
Automatic Extraction ◽  
Effective Management ◽  
Assembly Model ◽  
Retrieval Model ◽  
Relationship Of

Aim at the assembly model of three-dimensional CAD focusing on determining the geometric location relationship of parts, the constraints define of assembly being inconsistent, this paper put forward the concept of assembly relationship to describe the geometry connecting relationship between the parts. The cooperation, insert and tangent constraints of inventor assembly are converted to pasting, centering and tangency of retrieval model, and marked with the attribute. This assembly model can support retrieving assembly, realize the effective management of the model.

Analysis of Rotational Precision for an Isosceles-Trapezoidal Flexural Pivot

2008 ◽  
Vol 130 (5) ◽  
Author(s):  
Pei Xu ◽  
Yu Jingjun ◽  
Zong Guanghua ◽  
Bi Shusheng ◽  
Yu Zhiwei
Keyword(s):  
Rigid Body ◽  
Mechanical Design ◽  
Leaf Type ◽  
Body Model ◽  
Pure Rotation ◽  
Rigid Body Model ◽  
Simulation And Experiment ◽  
Dimensional Parameters ◽  
Rigid Model ◽  
Analytical Result

An isosceles-trapezoidal flexural pivot can be of great use for practical designs, especially in the cases that a pure rotation about a virtual pivot is required. The analysis of rotational precision for such a structure is important for the mechanical design in precise-required applications. For this purpose, a rigid isosceles-trapezoidal linkage model is first proposed to provide an accurate analytical result for its notch-type flexural counterpart. The influence of dimensional parameters on the center shift is discussed. In order to disclose the equivalence between leaf-type flexure structure and its pseudo-rigid-body model, a transitional model is introduced, from which an equivalent pseudo-rigid-body model for leaf-type isosceles-trapezoidal flexure structure is then derived. The results of both simulation and experiment verify that the equivalent rigid model is also accurate enough in the case of a larger deflection.

Design for Lean Manufacturing: Incorporating Lean Considerations During Product Development

2006 ◽  
Author(s):  
S. J. Pavnaskar ◽  
D. Weaver ◽  
J. K. Gershenson
Keyword(s):  
System Design ◽  
Continuous Improvement ◽  
Lean Manufacturing ◽  
Manufacturing Systems ◽  
Manufacturing System ◽  
Manufacturing Operations ◽  
Manufacturing System Design ◽  
Lean Engineering ◽  
Product And Process ◽  
Lean Operations

Lean has become a “must-use” philosophy for businesses today. Lean manufacturing focuses on the elimination of waste in manufacturing operations. Similarly, companies have started using lean engineering to eliminate wastes from their engineering processes. Both lean manufacturing and lean engineering yield dramatic improvements in quality, cost, and delivery. However, the philosophy of lean (manufacturing and engineering) revolves around the continuous improvement of existing processes. Costs associated with continuous improvement can be significantly reduced by incorporating “lean” considerations when designing a product, process, or manufacturing system. This is known as design for lean manufacturing (DfLM). DfLM guides the design of a product, process, or a manufacturing system to enable lean operations when in production, just as design for assembly (DFA) guides the design of a product to allow easier assembly during production. Currently, there are no guidelines that would help a product or process designer in considering to lean operations during design. Note that usage of the word “product” in this paper must be interpreted in a literary sense and not as a “widget.” The “product” of a manufacturing engineering process is a complete manufacturing system. In this paper, we consider manufacturing system design and propose a novel set of structured DfLM guidelines for designing a manufacturing system. These guidelines will be a valuable resource for manufacturing engineers to guide manufacturing system design for new products to enable lean operations once the system is in production. DfLM guidelines for system design also will help plant engineers and rapid continuous improvement managers to assess existing manufacturing systems and identify and prioritize improvement efforts. The proposed DfLM guidelines are then validated for accuracy, completeness, and redundancy by using them to evaluate an existing benchmark manufacturing system. The initial DfLM guidelines show promise for use in designing manufacturing systems that are easy to manage, flexible, safe, build quality into the products, optimize material flow, fully utilize all resources, maximize throughput, and continuously produce what the customer wants just in time. Similar guidelines can be proposed for product and process design to further enhance the efficiency of operations and reduce the overhead of continuous improvement efforts.

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