Implementation of automated assembly

Research has shown that about 60 - 80% wealth producing activities is related to manufacturing in major industrial countries. Increased competition in industry has resulted in a greater emphasis on using automation to improve productivity and quality and also to reduce cost. Most of the manufacturing works such as machining, painting, storage, retrieval, inspection and transportation have changed to automation successfully, except assembly. Manual assembly is predominant over automatic assembly techniques due to inherent assembly problem and the fact that the assembly machines lack the innate intelligence of human operator and lack sufficient flexibility to changeover when product designs and market demands change. With the advent of flexible manufacturing systems, which involve very large capital costs and complex interactions. For the reduction the risk of the investment and analyze the system, simulation is a valuable tool in planning the systems and in analyzing their behavior, and get the best use of them. This thesis applies animation techniques to simulate an automatic assembly system. In chapter 1 to 9, we cover some of the fundamental concepts and principles of automatic assembly and simulation. Some manufacturers put the subject of part orientation first on their list of priorities; but design for assembly (DFA) techniques have proven extremely valuable in developing better assembly techniques and ultimately, better products. We discuss DFA in chapter 1, part feeding and orientation in chapter 2. Chapter 3, 4 and 5 are concerned with assembly process, machines and control system, respectively. Annual sales for industrial robots have been growing at the rate of about 25 percent per year in major industrial countries, we review the robot application in chapter 6. The cost of material handling is a significant portion of the total cost of production, material storage uses valuable space and consumes investment, we cover these two topics in chapter 7 and 8. Chapter 9 is concerned with simulation. In chapter 10, 11,12 and 13, we implement a software package IGRIP to build a model of an automatic assembly system and analyze the result

Simulation modelling software approaches to manufacturing problems

Increased competition in many industries has resulted in a greater emphasis on developing and using advanced manufacturing systems to improve productivity and reduce costs. The complexity and dynamic behaviour of such systems, make simulation modelling one of the most popular methods to facilitate the design and assess operating strategies of these systems. The growing need for the use of simulation is reflected by a growth in the number of simulation languages and data-driven simulators in the software market. This thesis investigates which characteristics typical manufacturing simulators possess, and how the user requirements can be better fulfilled. For the purpose of software evaluation, a case study has been carried out on a real manufacturing system. Several simulation models of an automated system for electrostatic powder coating have been developed using different simulators. In addition to the evaluation of these simulators, a comprehensive evaluation framework has been developed to facilitate selection of simulation software for modelling manufacturing systems. Different hierarchies of evaluation criteria have been established for different software purposes. In particular, the criteria that have to be satisfied for users in education differ from those for users in industry. A survey has also been conducted involving a number of users of software for manufacturing simulation. The purpose of the survey was to investigate users' opinions about simulation software, and the features that they desire to be incorporated in simulation software. A methodology for simulation software selection is also derived. It consists of guidelines related to the actions to be taken and factors to be considered during the evaluation and selection of simulation software. On the basis of all the findings, proposals on how manufacturing simulators can be improved are made, both for use in education and in industry. These software improvements should result in a reduction in the amount of time and effort needed for simulation model development, and therefore make simulation more beneficial

Development of VR-simulator software for manufacturing systems as a decision making and simulation tool

Modern manufacturing is characterised by high levels of automation and integration, complex interactions among system elements, and high capital costs. Simulation and Virtual Reality technologies hold tremendous promise for reducing costs, improving quality, process data management, enhancing control over operations and shortening the time-to-market for manufactured goods. Unfortunately, these technologies still remains largely underutilised by industry today due to the requirement for a high standard of skills in programming and modelling methodologies. Visualisation has become a critical component of simulation technology in manufacturing applications. It provides the simulation practitioners with an environment to discuss and get a better understanding of the simulation model’s behaviour. Graphical presentation and animation can be a significant tool to communicate the outcome of simulation models for the non-technical audience. Decision makers often do not have the technical knowledge to understand the statistical results of a simulation model. But when the outcome can be expressed using animation, a better level of understanding becomes possible. This thesis presents a VR-Simulator software developed entirely by the author to overcome some of the limitations of simulation packages to allow users (who are not specialists in simulation and virtual reality techniques, or have no programming skills) to develop simulation and virtual models of manufacturing systems automatically without any need for excessive training on modelling techniques or programming. The users can interact with the generated models using voice commands and virtual reality devices (e.g. HMD). The VR-Simulator can be used as an operational décision-support tool to enable decision makers to model and analyse manufacturing systems