An assembly oriented design framework for product structure engineering and assembly sequence planning

The paper describes a novel framework for an assembly-oriented design (AOD) approach as a new functional product lifecycle management (PLM) strategy, by considering product design and assembly sequence planning phases concurrently. Integration issues of product life cycle into the product development process have received much attention over the last two decades, especially at the detailed design stage. The main objective of the research is to define assembly sequence into preliminary design stages by introducing and applying assembly process knowledge in order to provide an assembly context knowledge to support life-oriented product development process, particularly for product structuring. The proposed framework highlights a novel algorithm based on a mathematical model integrating boundary conditions related to DFA rules, engineering decisions for assembly sequence and the product structure definition. This framework has been implemented in a new system called PEGASUS considered as an AOD module for a PLM system. A case study of applying the framework to a catalytic-converter and diesel particulate filter sub-system, belonging to an exhaust system from an industrial automotive supplier, is introduced to illustrate the efficiency of the proposed AOD methodology

Integrated product relationships management : a model to enable concurrent product design and assembly sequence planning

The paper describes a novel approach to product relationships management in the context of concurrent engineering and product lifecycle management (PLM). Current industrial practices in product data management and manufacturing process management systems require better efficiency, flexibility, and sensitivity in managing product information at various levels of abstraction throughout its lifecycle. The aim of the proposed work is to manage vital yet complex and inherent product relationship information to enable concurrent product design and assembly sequence planning. Indeed, the definition of the product with its assembly sequence requires the management and the understanding of the numerous product relationships, ensuring consistency between the product and its components. This main objective stresses the relational design paradigm by focusing on product relationships along its lifecycle. This paper gives the detailed description of the background and models which highlight the need for a more efficient PLM approach. The proposed theoretical approach is then described in detail. A separate paper will focus on the implementation of the proposed approach in a PLM-based application, and an in-depth case study to evaluate the implementation of the novel approach will also be given

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

Design Concepts for Automating Maintenance Instructions

This research task was performed under the Technology for Readiness and Sustainment (TRS) contract (F33615-99-D-6001) for the Air Force Research Laboratory (AFRL), Sustainment Logistics Branch (HESS) at Wright-Patterson AFB, OH. The period of performance spanned one year starting 29 January 1999. The objective of this task was to develop and demonstrate a framework that can support the automated validation and verification of aircraft maintenance Technical Orders (TOs). The research team examined all stages ofTO generation to determine which tasks most warranted further research. From that investigation, validation and verification of appropriate, safe, and correct procedure steps emerged as the primary research target. This process would be based on available computer-aided design (CAD) data, procedure step ordering from existing sources, and human models. This determination was based on which tasks could yield the greatest impact on the authoring process and offer the greatest potential economic benefits. The team then developed a research roadmap and outlined specific technologies to be addressed in possible subsequent Air Force research tasks. To focus on the potential technology integration of the validation and verification component into existing or future TO generation procedures, we defined a demonstration scenario. Using the Front Uplock Hook assembly from an F/A-18 as the subject, we examined task procedure steps and failures that could be exposed by automated validation tools. These included hazards to personnel, damage to equipment, and incorrect disassembly order. Using the Parameterized Action Representation (PAR) developed on previous projects for actions and equipment behaviors, we characterized procedure steps and their positive and negative consequences. Finally, we illustrated a hypothetical user interface extension to a typical Interactive Electronic Technical Manual (IETM) authoring system to demonstrate how this process might appear to the TO author

NASA space station automation: AI-based technology review

Research and Development projects in automation for the Space Station are discussed. Artificial Intelligence (AI) based automation technologies are planned to enhance crew safety through reduced need for EVA, increase crew productivity through the reduction of routine operations, increase space station autonomy, and augment space station capability through the use of teleoperation and robotics. AI technology will also be developed for the servicing of satellites at the Space Station, system monitoring and diagnosis, space manufacturing, and the assembly of large space structures

Process capability modelling: a review report of feature representation methodologies

Approximately 150 technical papers on the features methodology have been carefully studied and some selected papers have been commented upon. The abstracts of the comments are documented and attached to this report. The methodologies reviewed are mainly divided into two approaches, ie. feature recognition and design by features. Papers which deal with some specific topics such as feature taxonomies, dimensions and tolerances, feature concepts, etc. are also included in the document

Off-Line Error Prediction, Diagnosis and Recovery Using Virtual Assembly Systems

Automated assembly systems often stop their operation due to the unexpected failures occurred during their assembly process. Since these large-scale systems are composed of many parameters, it is difficult to anticipate all possible types of errors with their likelihood of occurrence. Several systems were developed in the literature, focusing on online diagnosing and recovering the assembly process in an intelligent manner based on the predicted error scenarios. However, these systems do not cover all of the possible errors and they are deficient in dealing with the unexpected error situations. The proposed approach uses Monte Carlo simulation of the assembly process with the 3D model of the assembly line to predict the possible errors in an offline manner. After that, these predicted errors can be diagnosed and recovered using Bayesian reasoning and genetic programming. A case study composed of a peg-in-hole assembly was performed and the results are discussed. It is expected that with this new approach, errors can be diagnosed and recovered accurately and costly downtime of robotic assembly systems will be reduced.Peer Reviewedhttp://deepblue.lib.umich.edu/bitstream/2027.42/87271/4/Saitou102.pd

Design descriptions to support reasoning about tolerances

This thesis is concerned with the use of Artificial Intelligence techniques to support human designers. The thesis argues that support for human designers can be improved by adopting an Al-based rather than a geometry-based approach to engineering design. Design Support Systems (DSSs) are proposed as an effective means of delivering this improved support. Representing and reasoning about tolerance statements in design is introduced as a valid area to test these claims. Tolerance statements describe the allowable variations in the geometry of a designed artefact. Two distinct, but related problems involving the use of toler¬ ance statements in design are tackled, namely: tolerance combination (including the way tolerance distributions combine), and tolerance allocation. The problem of tolerance combination (and distribution) involves determining the necessary consequences of the application of known tolerance statements to one or more designed artefact features. Tolerance allocation concerns the assignment of tol¬ erance statements during the design process. Solutions to this second problem are essential before manufactured instances of designed artefacts can be tested for compliance with design descriptions. The use of an experimental DSS, the Edinburgh Designer System (EDS), to solve design problems is illustrated. The implementation of techniques to im¬ prove the support of tolerance combination and tolerance allocation is described and where possible has been tested using EDS. The way that design is situated within the product creation process is investigated and the derivation of parts list information from an EDS design description is demonstrated. The thesis con¬ cludes that the Al-based approach can improve support for human designers, but that further research will be required to demonstrate the effective delivery of this support through DSSs

Integrating CAD files and automatic assembly sequence planning

In this research study, a fully automated assembly sequence planner was developed, which automatically extracts geometrical information directly from STEP CAD files and then generates feasible assembly sequences with minimum assembly direction reorientations. The effectiveness of using the planner to reduce assembly time was also verified. The research study included three parts;In the first part of the research study, algorithms and software were developed for extracting geometrical information contained in STEP CAD files and for detecting potential collisions between parts during assembly along principal-axis assembly directions, based upon the extracted geometrical information. The developed software directly takes a STEP CAD file of a designed product assembly as input, and outputs six interference-free matrices representing collision information between parts in six principal assembly directions;In the second part of the research study, the algorithm developed in the first part was integrated into a genetic algorithm-based assembly sequence planner. The enhanced planner then was used to find assembly sequences with minimum reorientations automatically. The integrated assembly sequence planner directly takes a STEP CAD file of a designed product assembly as input, and outputs geometrically feasible assembly sequences requiring minimum reorientations;In the third part of the research study, a case study was conducted to verify the impact of assembly direction reorientations on assembly time, for both robot assembly and human operator assembly. Results of the case study show that, for both robot and human operator assembly processes, the number of reorientations in an assembly sequence has a significant impact on assembly time. The results support the primary research hypothesis that more assembly direction reorientations in a sequence require a longer assembly time. The case study helped verify and quantify the importance and effectiveness of using a fully automated assembly sequence planner to reduce the number of assembly direction reorientations in assembly sequence planning