Manufacturing requirements in design: The RTM process in aeronautics

A sub-unit of an aeronautical structure (fuselage, fin, wing, etc.) consists of a set of components fixed rigidly together. One of today’s major industrial challenges is to produce these sub-units out of composite materials in order to increase the level of integration and reduce and cost. This article describes a procedure to assist in the industrialisation of aeronautical components produced from composite materials in a design for manufacturing context. In a multi-expertise approach, the problem of optimising integration is combined with the feasibility of injection for the Resin Transfer Molding process. This approach then takes into account admissible manufacturing deviations, defined from a classification of the structure parts. The limits set for admissible deviations guarantee the mechanical behaviour of the assembled component and the requirements of the assembly as a whole. Finally, an industrialisation solutions space is defined. A constraint satisfaction problem solver is used to carry out this research with a spar from a horizontal plane in an aircraft used to illustrate the procedure

Conceptual Graphs in CAD

This paper elaborates on the use of conceptual graphs in a prototype of a computer based support system for re-design. Re-design support involves the modelling of assemblies and components. The requirements of the components to be modelled are a compromise between the functioning of the assembly and the manufacturability of the individual components. Conceptual graphs provide for an elegant way of representing both functioning and manufacturing aspects. In the prototype system, conceptual graphs are used for representing and defining assemblies, components and features as well as the relations between these entities. Constraints, such as kinematic, tolerance and manufacturing constraints are also represented using conceptual graphs

A constraint manager to support virtual maintainability

Virtual prototyping tools have already captivated the industry's interest as viable design tool. One of the key challenges for the research community is to extend the capabilities of Virtual Reality technology beyond its current scope of ergonomics and design reviews. The research presented in this paper is part of a larger research programme that aims to perform maintainability assessment on virtual prototypes. This paper discusses the design and implementation of a geometric constraint manager that has been designed to support physical realism and interactive assembly and disassembly tasks within virtual environments. The key techniques employed by the constraint manager are direct interaction, automatic constraint recognition, constraint satisfaction and constrained motion. Various optimization techniques have been implemented to achieve real-time interaction with large industrial models

Set-based design of mechanical systems with design robustness integrated

This paper presents a method for parameter design of mechanical products based on a set-based approach. Set-based concurrent engineering emphasises on designing in a multi-stakeholder environment with concurrent involvement of the stakeholders in the design process. It also encourages flexibility in design through communication in terms of ranges instead of fixed point values and subsequent alternative solutions resulting from intersection of these ranges. These alternative solutions can then be refined and selected according to the designers’ preferences and clients’ needs. This paper presents a model and tools for integrated flexible design that take into account the manufacturing variations as well as the design objectives for finding inherently robust solutions using QCSP transformation through interval analysis. In order to demonstrate the approach, an example of design of rigid flange coupling with a variable number of bolts and a choice of bolts from ISO M standard has been resolved and demonstrated

Prototype system for supporting the incremental modelling of vague geometric configurations

In this paper the need for Intelligent Computer Aided Design (Int.CAD) to jointly support design and learning assistance is introduced. The paper focuses on presenting and exploring the possibility of realizing learning assistance in Int.CAD by introducing a new concept called Shared Learning. Shared Learning is proposed to empower CAD tools with more useful learning capabilities than that currently available and thereby provide a stronger interaction of learning between a designer and a computer. Controlled computational learning is proposed as a means whereby the Shared Learning concept can be realized. The viability of this new concept is explored by using a system called PERSPECT. PERSPECT is a preliminary numerical design tool aimed at supporting the effective utilization of numerical experiential knowledge in design. After a detailed discussion of PERSPECT's numerical design support, the paper presents the results of an evaluation that focuses on PERSPECT's implementation of controlled computational learning and ability to support a designer's need to learn. The paper then discusses PERSPECT's potential as a tool for supporting the Shared Learning concept by explaining how a designer and PERSPECT can jointly learn. There is still much work to be done before the full potential of Shared Learning can be realized. However, the authors do believe that the concept of Shared Learning may hold the key to truly empowering learning in Int.CAD

Automated sequence and motion planning for robotic spatial extrusion of 3D trusses

While robotic spatial extrusion has demonstrated a new and efficient means to fabricate 3D truss structures in architectural scale, a major challenge remains in automatically planning extrusion sequence and robotic motion for trusses with unconstrained topologies. This paper presents the first attempt in the field to rigorously formulate the extrusion sequence and motion planning (SAMP) problem, using a CSP encoding. Furthermore, this research proposes a new hierarchical planning framework to solve the extrusion SAMP problems that usually have a long planning horizon and 3D configuration complexity. By decoupling sequence and motion planning, the planning framework is able to efficiently solve the extrusion sequence, end-effector poses, joint configurations, and transition trajectories for spatial trusses with nonstandard topologies. This paper also presents the first detailed computation data to reveal the runtime bottleneck on solving SAMP problems, which provides insight and comparing baseline for future algorithmic development. Together with the algorithmic results, this paper also presents an open-source and modularized software implementation called Choreo that is machine-agnostic. To demonstrate the power of this algorithmic framework, three case studies, including real fabrication and simulation results, are presented.Comment: 24 pages, 16 figure

Review of research in feature-based design

Research in feature-based design is reviewed. Feature-based design is regarded as a key factor towards CAD/CAPP integration from a process planning point of view. From a design point of view, feature-based design offers possibilities for supporting the design process better than current CAD systems do. The evolution of feature definitions is briefly discussed. Features and their role in the design process and as representatives of design-objects and design-object knowledge are discussed. The main research issues related to feature-based design are outlined. These are: feature representation, features and tolerances, feature validation, multiple viewpoints towards features, features and standardization, and features and languages. An overview of some academic feature-based design systems is provided. Future research issues in feature-based design are outlined. The conclusion is that feature-based design is still in its infancy, and that more research is needed for a better support of the design process and better integration with manufacturing, although major advances have already been made

A constraint-based methodology for product design with virtual reality

This paper presents a constraint-based methodology for product design with advanced virtual reality technologies. A hierarchically structured and constraint-based data model is developed to support product design from features to parts and further to assemblies in a VR environment. Product design in the VR environment is performed in an intuitive manner through precise constraint-based manipulations. Constraint-based manipulations are accompanied with automatic constraint recognition and precise constraint satisfaction to establish constraints between objects, and are further realized by allowable motions for precise 3D interactions in the VR environment. The allowable motions are represented as a mathematical matrix and derived from constraints between objects by constraint solving. A procedure-based degrees-of-freedom combination approach is presented for 3D constraint solving. A rule-based constraint recognition engine is developed for both constraint-based manipulations and implicitly incorporating constraints into the VR environment. An intuitive method is presented for recognizing pairs of mating features between assembly components. Examples are presented to demonstrate the efficacy of the proposed methodology