AUTOMATIC SUBASSEMBLY SEQUENCING FOR OFFSHORE RIGS

Ph.DDOCTOR OF PHILOSOPH

Computer Aided Optimal Robotic Assembly Sequence Generation

Robots are widely used for assembly operations across manufacturing industries to attain high productivity through automation. An appropriate robotic assembly sequence further minimizes the total production lead time and overall cost by minimizing the number of assembly direction changes, assembly gripper changes and assembly energy thus selection of a valid optimal robotic assembly sequence is significantly essential to achieve economized manufacturing process. An optimal assembly sequence must comply with various assembly requirements in order to make sure that the sequence of assembly operations is functionally feasible in physical environment. In order to test an assembly sequence for its practical possibility, necessary assembly information must be collected accurately from the product. Obtaining such assembly information from product drawings or Computer Aided Design (CAD) models in manual mode were involved in lots of complexity and needs high level skills to ensure correctness. Though retrieving such information from products with less number of parts is simple and less time consuming, for products composed of huge number parts it is very complicated and time consuming. Besides retrieving the assembly information, using it for validating an assembly sequence further raises the complexity of the Assembly Sequence Generation (ASG) problem. To perform optimal feasible assembly sequence generation efficiently, an effective computer aided automated method is developed and executed at two phases. The first phase of research is mainly focused on representing the assembly information in a streamlined manner by considering all possible states of assembly configurations for ease of computerization and developing efficient methods to extract the assembly information automatically from CAD environment though Computer Aided Automation (CAA). These methods basically use assembly contact analysis, part transformations and laws of equilibrium & balancing of rigid bodies. From the existing ASG methods, it is observed most of the researchers ignored/not-considered few of the assembly information such as assembly stability data and mechanical feasibility data due to higher complexity in retrieving it from CAD environment....

A priori checking inconsistencies among strategic constraints for assembly plan generation.

International audienceThis paper is related to the field of assembly plan generation. It describes a new approach to a priori check the consistency of an assembly strategy that is given by the assembly system designers before running an assembly plan generation algorithm. The aim of this work is to improve the assembly plan designer's efficiency by reducing the research space while proving the existence of acceptable solutions. The assembly strategy combined with the product's model implies a set of constraints on the assembly processes. The proposed method determines whether the given assembly strategy produces possible assembly processes. In case of inconsistencies among the strategic constraints, the method will help the designer to identify the contradictory constraints. The set of constraints can be expressed by a Boolean equation. First we present the key concepts and models related to the product, processes and added values in the field of assembly plan generation. Second we define existing strategic constraints, and propose three new ones and a classification of strategic assembly constraints. The originality of the proposed method consists in defining an elementary strategic constraint that is used to describe every other constraint. The proposed method leads to model an assembly strategy by a single Boolean equation that is used to check the inconsistencies. An industrial case study is provided to highlight and to demonstrate the interests of this approach

Fiber link design for the NASA-NSF extreme precision Doppler spectrograph concept "WISDOM"

We describe the design of the fiber-optic coupling and light transfer system of the WISDOM (WIYN Spectrograph for DOppler Monitoring) instrument. As a next-generation Precision Radial Velocity (PRV) spectrometer, WISDOM incorporates lessons learned from HARPS about thermal, pressure, and gravity control, but also takes new measures to stabilize the spectrograph illumination, a subject that has been overlooked until recently. While fiber optic links provide more even illumination than a conventional slit, careful engineering of the interface is required to realize their full potential. Conventional round fiber core geometries have been used successfully in conjunction with optical double scramblers, but such systems still retain a memory of the input illumination that is visible in systems seeking sub-m/s PRV precision. Noncircular fibers, along with advanced optical scramblers, and careful optimization of the spectrograph optical system itself are therefore necessary to study Earth-sized planets. For WISDOM, we have developed such a state-of-the-art fiber link concept. Its design is driven primarily by PRV requirements, but it also manages to preserve high overall throughput. Light from the telescope is coupled into a set of six, 32 μm diameter octagonal core fibers, as high resolution is achieved via pupil slicing. The low-OH, step index, fused silica, FBPI-type fibers are custom designed for their numerical aperture that matches the convergence of the feeding beam and thus minimizes focal ratio degradation at the output. Given the demanding environment at the telescope the fiber end tips are mounted in a custom fused silica holder, providing a perfect thermal match. We used a novel process, chemically assisted photo etching, to manufacture this glass fiber holder. A single ball-lens scrambler is inserted into the 25m long fibers. Employing an anti-reflection (AR) coated, high index, cubic-zirconia ball lens the alignment of the scrambler components are straightforward, as the fiber end tips (also AR coated) by design touch the ball lens and thus eliminate spacing tolerances. A clever and simple opto-mechanical design and assembly process assures micron-level self-alignment, yielding a ~87% throughput and a scrambling gain of >20,000. To mitigate modal noise the individual fibers then subsequently combined into a pair of rectangular fibers, providing a much larger modal area thanks to the 34x106 micron diameter. To minimize slit height, and thus better utilize detector area, the octagonal cores are brought very close together in this transition. The two outer fibers are side polished at one side, into a D-shaped cladding, while the central fiber has a dual side polish. These tapered, side-flattening operations are executed with precise alignment to the octagonal core. Thus the cores of the 3 fibers are brought together and aligned within few microns of each other before spliced onto the rectangular fiber. Overall throughput kept high and FRD at bay by careful management of fiber mounting, vacuum feed-through, application of efficient AR coatings, and implementation of thermal breaks that allow for independent expansion of the fibers and the protective tubing

End-of-Life Efficient Disassembly of Complex Structures Using Product and Process Focused Approach

RÉSUMÉ Le démantèlement durable des avions, contenant un nombre élevé de composants métalliques et non métalliques, devient, de nos jours, un problème de plus en plus urgent dans l’industrie aéronautique. Le désassemblage de la structure, en tant que principale tâche de cette procédure, a toujours été un défi considérable que ce soit en matière d’efforts requis qu’en termes de valeur économique apportée. Ce processus est, depuis toujours, apparu comme un service couteux et pas forcément écologique. La revue de la littérature indique que le désassemblage semi-destructif a des bénéfices significatifs contrairement à la destruction totale voir la non-destruction des appareils. Malgré un grand champ d’applications, à l’heure actuelle, il n’existe aucun moyen d’évaluer, indépendamment d’estimations subjectives, quantitativement l’effort nécessaire pour appliquer une telle méthode sur des structures métalliques complexes telles que celles d’un avion. Le but de cette thèse est donc, de développer une échelle d’évaluation à multiples variables afin de déterminer la performance de chaque opération avant de commencer le travail matériel. Ce modèle serait capable d’évaluer la facilité de désassembler la structure, et ce de manière quantitative, incorporant les aspects relatifs au produit ainsi qu’au procédé. Dans chacune de ces deux catégories (c’est à dire produit et procédé), différents facteurs déterminants, peuvent amener à un résultat économique, environnemental et /ou social décevant, s’ils ne sont pas pris en considération. C’est pourquoi cette méthode explore divers facteurs tels que le temps, la difficulté, la compatibilité des matériaux utilisés dans les pièces/modules de la structure afin que la stratégie choisie corresponde aux objectifs techniques, économiques, et environnementaux. Dans cette étude de cas, un stabilisateur horizontal provenant d’un appareil Bombardier CRJ series a été sélectionné afin d’évaluer la pertinence et l’efficacité de l’approche proposée. La partie expérimentale s’est appuyée sur des travaux pratiques de désassemblage établis sur une période de plus de deux ans, des analyses des documents de maintenance appartenant à cet avion, ainsi que des entretiens avec des spécialistes de ce domaine. Les résultats ont démontré que l’approche proposée est à la fois facilement réalisable, plus rapide et permet une meilleure récupération des matériaux en comparaison avec d’autres méthodes. Enfin, avec de tels avantages, ce procédé apporte une importante contribution dans le domaine du désassemblage de la structure puisqu'il est aisément exploitable par les sites de désassemblage, pour les fabricants et propriétaires d'avions.----------ABSTRACT Sustainable decommissioning of aircraft with a high content of metallic and non-metallic components is becoming an urgent issue in today’s aviation industry. Airframe disassembly, as a principal step in this procedure, has always been a challenge in terms of the required effort and regained values. This process has historically appeared to be economically costly, socially unviable, and not necessarily environmentally benign. Literature indicates that, unlike entirely destructive and totally non-destructive techniques, semi-destructive disassembly may bring significant benefits. However, despite their use in a wide variety of applications, there are currently no feasible solutions on how to measure the associated physical difficulties and required efforts without any dependencies on expert views or filling out spreadsheet-like forms. The purpose of this dissertation is then to develop a multiple-variable model in order to determine the performance of each disassembly operation prior to the physical work. The model could accurately evaluate the disassembly easiness of an airframe quantitatively incorporating both product and process features. There are various driving factors in each of these categories (i.e., process and product features) that failing to appropriately address them could result in either significant economic loss, environmental and/or social inconvenience. The methodology used in this study is one of the first investigations in this field, known as a Multivariable Disassembly Evaluator (MDE). It explores 1- time; 2- difficulty; and 3- material compatibility of the airframe parts/modules to ensure that the defined disassembly strategies meet technical, economic and environmental objectives. A horizontal stabilizer of Bombardier CRJ series was selected as a case study to provide a detailed vision of disassembly evaluating the suitability and effectiveness of the proposed approach. The experimental investigations are based upon the real disassembly works for over two years, aircraft maintenance documentation analysis and discussions with technical domain specialists. The findings demonstrated that the proposed method is easier to fulfil, faster and allows the user to gain more recovery than other current approaches. These advantages should make an important contribution to the field of airframe disassembly since they can be readily used by disassembly sites, aircraft owners and manufacturers

Optimization of Operation Sequencing in CAPP Using Hybrid Genetic Algorithm and Simulated Annealing Approach

In any CAPP system, one of the most important process planning functions is selection of the operations and corresponding machines in order to generate the optimal operation sequence. In this paper, the hybrid GA-SA algorithm is used to solve this combinatorial optimization NP (Non-deterministic Polynomial) problem. The network representation is adopted to describe operation and sequencing flexibility in process planning and the mathematical model for process planning is described with the objective of minimizing the production time. Experimental results show effectiveness of the hybrid algorithm that, in comparison with the GA and SA standalone algorithms, gives optimal operation sequence with lesser computational time and lesser number of iterations

Optimization of Operation Sequencing in CAPP Using Hybrid Genetic Algorithm and Simulated Annealing Approach

In any CAPP system, one of the most important process planning functions is selection of the operations and corresponding machines in order to generate the optimal operation sequence. In this paper, the hybrid GA-SA algorithm is used to solve this combinatorial optimization NP (Non-deterministic Polynomial) problem. The network representation is adopted to describe operation and sequencing flexibility in process planning and the mathematical model for process planning is described with the objective of minimizing the production time. Experimental results show effectiveness of the hybrid algorithm that, in comparison with the GA and SA standalone algorithms, gives optimal operation sequence with lesser computational time and lesser number of iterations

Autonomous Navigation of Automated Guided Vehicle Using Monocular Camera

This paper presents a hybrid control algorithm for Automated Guided Vehicle (AGV) consisting of two independent control loops: Position Based Control (PBC) for global navigation within manufacturing environment and Image Based Visual Servoing (IBVS) for fine motions needed for accurate steering towards loading/unloading point. The proposed hybrid control separates the initial transportation task into global navigation towards the goal point, and fine motion from the goal point to the loading/unloading point. In this manner, the need for artificial landmarks or accurate map of the environment is bypassed. Initial experimental results show the usefulness of the proposed approach.COBISS.SR-ID 27383808

Autonomous Navigation of Automated Guided Vehicle Using Monocular Camera

This paper presents a hybrid control algorithm for Automated Guided Vehicle (AGV) consisting of two independent control loops: Position Based Control (PBC) for global navigation within manufacturing environment and Image Based Visual Servoing (IBVS) for fine motions needed for accurate steering towards loading/unloading point. The proposed hybrid control separates the initial transportation task into global navigation towards the goal point, and fine motion from the goal point to the loading/unloading point. In this manner, the need for artificial landmarks or accurate map of the environment is bypassed. Initial experimental results show the usefulness of the proposed approach.COBISS.SR-ID 27383808