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

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

Automatic generation of robot and manual assembly plans using octrees

This paper aims to investigate automatic assembly planning for robot and manual assembly. The octree decomposition technique is applied to approximate CAD models with an octree representation which are then used to generate robot and manual assembly plans. An assembly planning system able to generate assembly plans was developed to build these prototype models. Octree decomposition is an effective assembly planning tool. Assembly plans can automatically be generated for robot and manual assembly using octree models. Research limitations/implications - One disadvantage of the octree decomposition technique is that it approximates a part model with cubes instead of using the actual model. This limits its use and applications when complex assemblies must be planned, but in the context of prototyping can allow a rough component to be formed which can later be finished by hand. Assembly plans can be generated using octree decomposition, however, new algorithms must be developed to overcome its limitations

Automated design analysis, assembly planning and motion study analysis using immersive virtual reality

Previous research work at Heriot-Watt University using immersive virtual reality (VR) for cable harness design showed that VR provided substantial productivity gains over traditional computer-aided design (CAD) systems. This follow-on work was aimed at understanding the degree to which aspects of this technology were contributed to these benefits and to determine if engineering design and planning processes could be analysed in detail by nonintrusively monitoring and logging engineering tasks. This involved using a CAD-equivalent VR system for cable harness routing design, harness assembly and installation planning that can be functionally evaluated using a set of creative design-tasks to measure the system and users' performance. A novel design task categorisation scheme was created and formalised which broke down the cable harness design process and associated activities. The system was also used to demonstrate the automatic generation of usable bulkhead connector, cable harness assembly and cable harness installation plans from non-intrusive user logging. Finally, the data generated from the user-logging allowed the automated activity categorisation of the user actions, automated generation of process flow diagrams and chronocyclegraphs

Using automatic robot programming for space telerobotics

The interpreter of a task level robot programming system called Handey is described. Handey is a system that can recognize, manipulate and assemble polyhedral parts when given only a specification of the goal. To perform an assembly, Handey makes use of a recognition module, a gross motion planner, a grasp planner, a local approach planner and is capable of planning part re-orientation. The possibility of including these modules in a telerobotics work-station is discussed

Multiple viewpoint modelling framework enabling integrated product-process design

Nowadays, companies have to cope with numerous constraints at organisational and technical levels in order to improve their competitiveness edges such as productivity, efficiency, and flexibility. Integrated product-process design becomes more and more complex to manage because of increasingly customized products related to various stakeholders and concerns geographically distributed. It is still represents a huge challenge, especially in the early phases of product development process. In such a context, the management of information within integrated product-process design highlights needs in a consistent engineering model that enables product lifecycle management (PLM) integration. The paper presents a novel multiple viewpoint framework called multiple viewpoint assembly oriented, considering product design and assembly process domains in the broader context of concurrent engineering and PLM. The proposed framework describes the consistency, the propagation of information change, and mechanisms of views generation among the product lifecycle stages in order to support assembly oriented design philosophy. A new modelling language called System Modeling Language is used to describe the proposed model from a systems engineering point of view. The implementation of the model in a Web-service called PEGASUS as an application for PLM systems is describe