Virtual bloXing - assembly rapid prototyping for near net shapes

Virtual reality (VR) provides another dimension to many engineering applications. Its immersive and interactive nature allows an intuitive approach to study both cognitive activities and performance evaluation. Market competitiveness means having products meet form, fit and function quickly. Rapid Prototyping and Manufacturing (RP&M) technologies are increasingly being applied to produce functional prototypes and the direct manufacturing of small components. Despite its flexibility, these systems have common drawbacks such as slow build rates, a limited number of build axes (typically one) and the need for post processing. This paper presents a Virtual Assembly Rapid Prototyping (VARP) project which involves evaluating cognitive activities in assembly tasks based on the adoption of immersive virtual reality along with a novel nonlayered rapid prototyping for near net shape (NNS) manufacturing of components. It is envisaged that this integrated project will facilitate a better understanding of design for manufacture and assembly by utilising equivalent scale digital and physical prototyping in one rapid prototyping system. The state of the art of the VARP project is also presented in this paper

Virtual assembly rapid prototyping of near net shapes

Virtual reality (VR) provides another dimension to many engineering applications. Its immersive and interactive nature allows an intuitive approach to study both cognitive activities and performance evaluation. Market competitiveness means having products meet form, fit and function quickly. Rapid Prototyping and Manufacturing (RP&M) technologies are increasingly being applied to produce functional prototypes and the direct manufacturing of small components. Despite its flexibility, these systems have common drawbacks such as slow build rates, a limited number of build axes (typically one) and the need for post processing. This paper presents a Virtual Assembly Rapid Prototyping (VARP) project which involves evaluating cognitive activities in assembly tasks based on the adoption of immersive virtual reality along with a novel non-layered rapid prototyping for near net shape (NNS) manufacturing of components. It is envisaged that this integrated project will facilitate a better understanding of design for manufacture and assembly by utilising equivalent scale digital and physical prototyping in one rapid prototyping system. The state of the art of the VARP project is also presented in this paper

A computer-based product classification and component detection for demanufacturing processes

This is an Author's Accepted Manuscript of an article published in International Journal of Computer Integrated Manufacturing, 24(10), 900-914, 2011 [copyright Taylor & Francis], available online at: http://www.tandfonline.com/10.1080/0951192X.2011.579169.The aim of this paper is to propose a novel computer-based product classification, component detection and tracking for demanufacturing and disassembly process. This is achieved by introducing a series of automated and sequential product scanning, component identification, image analysis and sorting – leading to the development of a bill of material (BOM). The produced BOM can then be associated with the relevant disassembly/demanufacture proviso. The proposed integrated image sorting and product classification (ISPC) approach can be considered as a step forward in automation of demanufacturing activities. The ISPC model proposed in this paper utilises and builds on the state-of-the-art technology and current body of research in computer-integrated demanufacturing and remanufacturing (CIDR). An appraisal of the latest research material and the factors that inhibit CIDR methods inpractice are presented. A novel solution for the integration of imaging and material identification techniques toovercome some of the existing shortcomings of automated recycling processes is proposed in this paper. The proposed product scanning and component detection ISPC software consists of four distinct models: the repertory database, the search engine, the product-attributes updater and the image sorting and classification algorithm. The software framework that integrates the four components is presented in this paper. Finally, an overall assessment of applying ISPC at various stages of CIDR processes concludes the article.University of Ibadan MacArthur Foundation Gran

Computer-Aided Assembly Sequence Planning for High-Mix Low-Volume Products in the Electronic Appliances Industry

Electronic appliance manufacturers are facing the challenge of frequent product orders. Based on each product order, the assembly process and workstations need to be planned. An essential part of the assembly planning is defining the assembly sequence, considering the mechanical product’s design, and handling of the product’s components. The assembly sequence determines the order of processes for each workstation, the overall layout, and thereby time and cost. Currently, the assembly sequence is decided by industrial engineers through a manual approach that is time-consuming, complex, and requires technical expertise. To reduce the industrial engineers’ manual effort, a Computer-Aided Assembly Sequence Planning (CAASP) system is proposed in this paper. It compromises the components for a comprehensive system that aims to be applied practically. The system uses Computer-Aided Design (CAD) files to derive Liaison and Interference Matrices that represent a mathematical relationship between parts. Subsequently, an adapted Ant Colony Optimization Algorithm generates an optimized assembly sequence based on these relationships. Through a web browser-based application, the user can upload files and interact with the system. The system is conceptualized and validated using the CAD file of an electric motor example product. The results are discussed, and future work is outlined

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

Automated knowledge capture in 2D and 3D design environments

In Life Cycle Engineering, it is vital that the engineering knowledge for the product is captured throughout its life cycle in a formal and structured manner. This will allow the information to be referred to in the future by engineers who did not work on the original design but are wanting to understand the reasons that certain design decisions were made. In the past, attempts were made to try to capture this knowledge by having the engineer record the knowledge manually during a design session. However, this is not only time-consuming but is also disruptive to the creative process. Therefore, the research presented in this paper is concerned with capturing design knowledge automatically using a traditional 2D design environment and also an immersive 3D design environment. The design knowledge is captured by continuously and non-intrusively logging the user during a design session and then storing this output in a structured eXtensible Markup Language (XML) format. Next, the XML data is analysed and the design processes that are involved can be visualised by the automatic generation of IDEF0 diagrams. Using this captured knowledge, it forms the basis of an interactive online assistance system to aid future users who are carrying out a similar design task

Design and implementation of a compliant robot with force feedback and strategy planning software

Force-feedback robotics techniques are being developed for automated precision assembly and servicing of NASA space flight equipment. Design and implementation of a prototype robot which provides compliance and monitors forces is in progress. Computer software to specify assembly steps and makes force feedback adjustments during assembly are coded and tested for three generically different precision mating problems. A model program demonstrates that a suitably autonomous robot can plan its own strategy

Multi-community command and control systems in law enforcement: An introductory planning guide

A set of planning guidelines for multi-community command and control systems in law enforcement is presented. Essential characteristics and applications of these systems are outlined. Requirements analysis, system concept design, implementation planning, and performance and cost modeling are described and demonstrated with numerous examples. Program management techniques and joint powers agreements for multicommunity programs are discussed in detail. A description of a typical multi-community computer-aided dispatch system is appended

CAD/CAM integration based on machining features for prismatic parts

The development of CAD and CAM technology has significantly increased efficiency in each individual area. The independent development, however, greatly restrained the improvement of overall efficiency from design to manufacturing. The simple integration between CAD and CAM systems has been achieved. Current integrated CAD/CAM systems can share the same geometry model of a product in a neutral or proprietary format. However, the process plan information of the product from CAPP systems cannot serve as a starting point for CAM systems to generate tool paths and NC programs. The user still needs to manually create the machining operations and define geometry, cutting tool, and various parameters for each operation. Features play an important role in the recent research on CAD/CAM integration. This thesis investigated the integration of CAD/CAM systems based on machining features. The focus of the research is to connect CAPP systems and CAM systems by machining features, to reduce the unnecessary user interface and to automate the process of tool path preparation. Machining features are utilized to define machining geometries and eliminate the necessity of user interventions in UG. A prototype is developed to demonstrate the CAD/CAM integration based on machining features for prismatic parts. The prototype integration layer is implemented in conjunction with an existing CAPP system, FBMach, and a commercial CAD/CAM system, Unigraphics. Not only geometry information of the product but also the process plan information and machining feature information are directly available to the CAM system and tool paths can be automatically generated from solid models and process plans