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....

An intelligent knowledge based cost modelling system for innovative product development

This research work aims to develop an intelligent knowledge-based system for product cost modelling and design for automation at an early design stage of the product development cycle, that would enable designers/manufacturing planners to make more accurate estimates of the product cost. Consequently, a quicker response to customers’ expectations. The main objectives of the research are to: (1) develop a prototype system that assists an inexperienced designer to estimate the manufacturing cost of the product, (2) advise designers on how to eliminate design and manufacturing related conflicts that may arise during the product development process, (3) recommend the most economic assembly technique for the product in order to consider this technique during the design process and provide design improvement suggestions to simplify the assembly operations (i.e. to provide an opportunity for designers to design for assembly (DFA)), (4) apply a fuzzy logic approach to certain cases, and (5) evaluate the developed prototype system through five case studies. The developed system for cost modelling comprises of a CAD solid modelling system, a material selection module, knowledge-based system (KBS), process optimisation module, design for assembly module, cost estimation technique module, and a user interface. In addition, the system encompasses two types of databases, permanent (static) and temporary (dynamic). These databases are categorised into five separate groups of database, Feature database, Material database, Machinability database, Machine database, and Mould database. The system development process has passed through four major steps: firstly, constructing the knowledge-based and process optimisation system, secondly developing a design for assembly module. Thirdly, integrating the KBS with both material selection database and a CAD system. Finally, developing and implementing a ii fuzzy logic approach to generate reliable estimation of cost and to handle the uncertainty in cost estimation model that cannot be addressed by traditional analytical methods. The developed system has, besides estimating the total cost of a product, the capability to: (1) select a material as well as the machining processes, their sequence and machining parameters based on a set of design and production parameters that the user provides to the system, and (2) recommend the most economic assembly technique for a product and provide design improvement suggestion, in the early stages of the design process, based on a design feasibility technique. It provides recommendations when a design cannot be manufactured with the available manufacturing resources and capabilities. In addition, a feature-by-feature cost estimation report was generated using the system to highlight the features of high manufacturing cost. The system can be applied without the need for detailed design information, so that it can be implemented at an early design stage and consequently cost redesign, and longer lead-time can be avoided. One of the tangible advantages of this system is that it warns users of features that are costly and difficult to manufacture. In addition, the system is developed in such a way that, users can modify the product design at any stage of the design processes. This research dealt with cost modelling of both machined components and injection moulded components. The developed cost effective design environment was evaluated on real products, including a scientific calculator, a telephone handset, and two machined components. Conclusions drawn from the system indicated that the developed prototype system could help companies reducing product cost and lead time by estimating the total product cost throughout the entire product development cycle including assembly cost. Case studies demonstrated that designing a product using the developed system is more cost effective than using traditional systems. The cost estimated for a number of products used in the case studies was almost 10 to 15% less than cost estimated by the traditional system since the latter does not take into consideration process optimisation, design alternatives, nor design for assembly issue

An integrated system to design machine layouts for modular special purpose machines

This thesis introduces the development of an integrated system for the design of layouts for special purpose machines (SPMs). SPMs are capable of performing several machining operations (such as drilling, milling, and tapping) at the same time. They consist of elements that can be arranged in different layouts. Whilst this is a unique feature that makes SPMs modular, a high level of knowledge and experience is required to rearrange the SPM elements in different configurations, and also to select appropriate SPM elements when product demand changes and new layouts are required. In this research, an integrated system for SPM layout design was developed by considering the following components: an expert system tool, an assembly modelling approach for SPM layouts, an artificial intelligence tool, and a CAD design environment. SolidWorks was used as the 3D CAD environment. VisiRule was used as the expert system tool to make decisions about the selection of SPM elements. An assembly modelling approach was developed with an SPM database using a linked list structure and assembly relationships graph. A case-based reasoning (CBR) approach was developed and applied to automate the selection of SPM layouts. These components were integrated using application programing interface (API) features and Visual Basic programming language. The outcome of the application of the novel approach that was developed in this thesis is reducing the steps for the assembly process of the SPM elements and reducing the time for designing SPM layouts. As a result, only one step is required to assemble any two SPM elements and the time for the selection process of SPM layouts is reduced by approximately 75% compared to the traditional processes. The integrated system developed in this thesis will help engineers in design and manufacturing fields to design SPM layouts in a more time-effective manner

Assessing the Remanufacturability of Office Furiniture: A Multi-Criteria Decision Making Approach

While the average life cycle of consumer goods is continuously decreasing, the amount of used product at their end-of-life (EOL) is accumulating fast at and at the same pace. Most EOL products end up in landfills, and many of which are not biodegradable. These two challenges have necessitated renewed global interest in product EOL management strategies by manufacturers, third party companies, consumers and governments. Remanufacturing is one of the EOL strategies which is highly environmental-friendly. Additionally, remanufacturing is seen as one of the highly profitable re-use business strategies. The selling price of remanufactured products is usually about 50—80% of a new one, making remanufacturing a win—win solution, saving both money and preserving the environment as well as raising the bottom-line of enterprises. Through the literature review of remanufacturing, we realize many researchers in this area have focused on a few product categories such as automotive, electrical and electronic equipment as well as ink cartridge, thus accelerating innovations for the remanufacture of these product categories. There is therefore, a need to explore the remanufaturability of other products, especially the ones with high market potential growth as well as profit margin. Furniture industry is the one that fits the description and is the focus of this thesis. The goal of this exploratory research is to present the first framework of its kind that aims at assessing the remanufacturability of office furniture. The proposed evaluation model considers three aspects of the assessment problem: economic, social and environmental to obtain a holistic view of remanufacturability of office furniture. We apply the fuzzy TOPSIS methodology to deal with incomplete and often subjective information during the evaluation. Furthermore, we validate our evaluation model using published research data for a multi-criteria allocation decision making (MCDM) problem. Through the model validation, we show that the proposed evaluation model has the capability to solve MCDM problems. Lastly, a case study which involves three pieces of office furniture is used to illustrate the function of the proposed model

Engines of Order

Over the last decades, and in particular since the widespread adoption of the Internet, encounters with algorithmic procedures for ‘information retrieval’ – the activity of getting some piece of information out of a col-lection or repository of some kind – have become everyday experiences for most people in large parts of the world

CAFixD: A Case-based Reasoning Method for Fixture Design

Fixtures accurately locate and secure a part during machining operations such that the part can be manufactured to design specifications. To reduce the design costs associated with fixturing, various computer-aided fixture design (CAFD) methods have been developed through the years to assist the fixture designer. Much research has been directed towards developing systems that determine an optimal fixture plan layout, but there is still a need to develop a CAFD method that can continue to assist designers at the unit level where the key task is identifying the appropriate structure that the individual units comprising a fixture should take. This research work details the development of a CAFD methodology (called CAFixD) that seeks to fill this hole in the CAFD field. The approach taken is to consider all operational requirements of a fixture problem, and use them to guide the design of a fixture at the unit level. Based upon a case-based reasoning (CBR) methodology where relevant design experience is retrieved and adapted to provide a new fixture design solution, the CAFixD methodology adopts a rigorous approach to indexing design cases in which axiomatic design functional requirement decomposition is adopted. Thus, the design requirement is decomposed in terms of functional requirements, physical solutions are retrieved and adapted for each individual requirement, and the design re-constituted to form a complete fixture design. Case adaptation knowledge is used to guide the retrieval process. Possible adaptation strategies for modifying candidate cases are identified and then evaluated. Case and adaptation strategy combinations that result in adapted designs that best satisfy the preferences of the designer are used as the final design solutions. Possible means of refining the effectiveness of the method include combining adaptation strategies and considering the order in which design decisions are taken

Intelligent design and optimization of machining fixtures

U radu je predstavljen integralni sustav za projektiranje i optimizaciju konstrukcije naprava za strojnu obradu. Dio sustava za optimizaciju omogućuje, s jedne strane, određivanje optimalnih pozicija elemenata za baziranje i stezanje kako bi se postigla potrebna točnost i kvaliteta obrađene površine izratka, a s druge strane, generiranje konstrukcije naprava bez kolizija. Dio sustava za projektiranje osigurava izbor pojedinih elemenata naprava na osnovi prethodno definiranih produkcijskih pravila. Prilagođeni kriteriji izbora definirani su za elemente za baziranje, elemente za stezanje, elemente za vođenje alata, elemente za podešavanje položaja alata, elemente tijela naprava, elemente za povezivanje i nadogradne elemente. Sustav je baziran na geometrijskim karakteristikama i karakterističnim obilježjima djela, kao i dodatnim informacijama o obradi i informacijama iz tehnološkog procesa. Sustav je razvijan za operacije tokarenja, bušenja, glodanja i brušenja koje se izvode na rotacijskim i prizmatičnim radnim predmetima. U radu su djelomično prikazani izlazni rezultati razvijenog sustava. Na kraju rada dani su odgovarajući zaključci i istaknuti mogući pravci daljih istraživanja.This work presents an integral system for machining fixture layout design and optimization. The optimization module of this system allows determination of optimal positions of locating and clamping elements, which provides required accuracy and surface quality, while at the same time guarantees design of collision-free fixtures. The design module performs selection of required fixture elements based on a set of predefined production rules. Adequate criteria for the selection of fixture elements are defined for locating, clamping, tool guiding, and tool adjustment elements, as well as for fixture body elements, connecting elements and add-on elements. The system uses geometry and feature workpiece characteristics, as well as the additional machining, and process planning information. It has been developed to accommodate machining processes of turning, drilling, milling, and grinding of rotational and prismatic workpieces. A segment of output results is also shown. Finally, conclusions are presented with directions for future investigation

Méthode interactive et par l'apprentissage pour la generation de trajectoire en conception du produit

The accessibility is an important factor considered in the validation and verification phase of the product design and usually dominates the time and costs in this phase. Defining the accessibility verification as the motion planning problem, the sampling based motion planners gained success in the past fifteen years. However, the performances of them are usually shackled by the narrow passage problem arising when complex assemblies are composed of large number of parts, which often leads to scenes with high obstacle densities. Unfortunately, humans’ manual manipulations in the narrow passage always show much more difficulties due to the limitations of the interactive devices or the cognitive ability. Meanwhile, the challenges of analyzing the end users’ response in the design process promote the integration with the direct participation of designers.In order to accelerate the path planning in the narrow passage and find the path complying with user’s preferences, a novel interactive motion planning method is proposed. In this method, the integration with a random retraction process helps reduce the difficulty of manual manipulations in the complex assembly/disassembly tasks and provide local guidance to the sampling based planners. Then a hypothesis is proposed about the correlation between the topological structure of the scenario and the motion path in the narrow passage. The topological structure refers to the medial axis (2D) and curve skeleton (3D) with branches pruned. The correlation runs in an opposite manner to the sampling based method and provide a new perspective to solve the narrow passage problem. The curve matching method is used to explore this correlation and an interactive motion planning framework that can learn from experience is constructed in this thesis. We highlight the performance of our framework on a challenging problem in 2D, in which a non-convex object passes through a cluttered environment filled with randomly shaped and located non-convex obstacles.L'accessibilitéest un facteur important pris en compte dans la validation et la vérification en phase de conception du produit et augmente généralement le temps et les coûts de cette phase. Ce domaine de recherche a eu un regain d’intérêt ces quinze dernières années avec notamment de nouveaux planificateurs de mouvement. Cependant, les performances de ces méthodes sont généralement très faibles lorsque le problème se caractérise par des passages étroits des assemblages complexes composées d'un grand nombre de pièces. Cela conduit souvent àdes scènes àforte densitéd'obstacles. Malheureusement, les manipulations manuelles des humains dans le passage étroit montrent toujours beaucoup de difficultés en raison des limitations des dispositifs interactifs ou la capacitécognitive. Pendant ce temps, les défis de l'analyse de la réponse finale des utilisateurs dans le processus de conception promeut l'intégration avec la participation directe des concepteurs.Afin d'accélérer la planification dans le passage étroit et trouver le chemin le plus conforme aux préférences de l'utilisateur, une nouvelle méthode de planification de mouvement interactif est proposée. Nous avons soulignéla performance de notre algorithme dans certains scénarios difficiles en 2D et 3D environnement.Ensuite, une hypothèse est proposésur la corrélation entre la structure topologique du scénario et la trajectoire dans le passage étroit. La méthode basée sur les courbures est utilisée pour explorer cette corrélation et un cadre de planification de mouvement interactif qui peut apprendre de l'expérience est construit dans cette thèse. Nous soulignons la performance de notre cadre sur un problème difficile en 2D, dans lequel un objet non-convexe passe à travers un environnement encombrérempli d'obstacles non-convexes de forme aléatoire et situés

An Ontology for Product-Service Systems

Industries are transforming their business strategy from a product-centric to a more service-centric nature by bundling products and services into integrated solutions to enhance the relationship between their customers. Since Product- Service Systems design research is currently at a rudimentary stage, the development of a robust ontology for this area would be helpful. The advantages of a standardized ontology are that it could help researchers and practitioners to communicate their views without ambiguity and thus encourage the conception and implementation of useful methods and tools. In this paper, an initial structure of a PSS ontology from the design perspective is proposed and evaluated