2 research outputs found
A graph-based data structure for assembly dimensional variation control at a preliminary phase of product design
Dimensional quality control remains a challenge in assembly of complex products. Currently dimensional variation control research efforts include tolerance analysis and allocation, fixture layout design, assembly sequence planning, and others, without systematically viewing assembly as a proxy for a wide range of design decisions to produce final products with least cost, most productivity and best quality. A literature review in current assembly modelling methods shows that a unified data structure has yet to be developed at a preliminary design phase in order to design product and plan assembly process automatically. This paper serves to develop such a data structure, which captures heterogeneous product and assembly process information available at a preliminary design phase and unifies them in a data structure represented as a hierarchical graph. The graph-based data structure, on one side, facilitates automatic product design and assembly process planning at the preliminary design phase by utilising research results developed in graph theory, and on the other side, allows easier embedding the assembly model into computer aided design (CAD) software since they share the similar data structure. The presented graph-based data structure is illustrated by a sport utility vehicle (SUV) side frame assembly
Robust dimensional variation control of compliant assemblies through the application of sheet metal joining process sequencing
Imperfections are inherent in every manufactured part - when the
hundreds of sheet metal components that form the automotive Body
In White (BIW) are assembled together, significant deformation
and variability are possible. Although early work by Takazawa
(1980) showed that compliant components can absorb individual
component variability when assembled, interactions between the
components and successive operations complicates analysis of the
assembly process and prediction of the assembled output.
Therefore, improving vehicle dimensional quality requires more
detailed knowledge of the assembly process and control of
features critical to functionality and aesthetic appeal. In the
automotive industry, these features include: uneven gaps and
flushness between panels, high closure forces, and incorrect seal
gaps leading to leaks and excessive noise. Despite significant
research in the field of compliant assembly, there have not been
sufficiently detailed studies regarding the joining sequence
process. Further, existing works are based on a number of
assumptions that limits the applicability of their results.
This thesis addresses this gap by utilising the joining process
sequence to control deformations and minimise dimensional
variation during the assembly of complex non-ideal compliant
components. In this work, a geometry class to represent complex
compliant assemblies is presented; the interactions of process
sequences and variations examined; the criteria for robust
sequence selection established; and a method for the rapid
identification of robust sequences is developed.
In addressing the aim of this research a number of key findings
were developed. A broad method of classifying the input variation
of the components is presented.
Using this basis, identifying when the joining process has a
significant influence on final assembly dimensionality can be
established. The pre-existing guidelines of fixed-to-free end
were then further generalised for complex geometries, resulting
in the approach of most-to-least rigid configuration, noting the
importance of prior joining operations and the fixture boundary
conditions. In determining the potential impact of the joining
sequence, the need to consider the build-up of internal stresses
while modelling the assembly process is highlighted. A novel
method, which analyses the natural frequency shift of the
structure between successive joins, is presented as a technique
of calculating a robust joining sequence. This technique requires
no knowledge of the part deformations, only the component
geometry, fixture configuration and weld locations, and hence is
more practical to industry. Experimental studies to validate the
simulation-based work were then performed. Although
sequence-based trends are identifiable in some of the extracted
data patterns, the twist induced in the experimental structure
was less significant when compared to the simulated results. This
difference is a result of a number of factors which are then
postulated and analysed. Further investigation of this effect
would be beneficial to further validate the approach.
To build on the work in this thesis, two notable directions in
addition to further industrial validation have been identified.
By assessing the functional impact of variation patterns in
measurement data, functional variation sequence synthesis could
be investigated; where the goal is to select a sequence that best
controls these critical functional variations. Evolvable assembly
systems that utilise the input work and holding forces to
optimise the sequence operations and minimise potential
spring-back of the component can also be considered. This
strategy would negate the need for the additional measurement
step for process feedback which currently hampers existing
adaptive techniques.
With between four and six thousand joins performed per vehicle,
an estimated 300 billion joining operations are performed
annually worldwide. With minimal knowledge available to industry
regarding the impact of the joining process sequence, the results
from this work have the potential to significantly improve
quality in the automotive market