Knowledge-based automatic tolerance analysis system

Tolerance measure is an important part of engineering, however, to date the system of applying this important technology has been left to the assessment of the engineer using appropriate guidelines. This work offers a major departure from the trial and error or random number generation techniques that have been used previously by using a knowledge-based system to ensure the intelligent optimisation within the manufacturing system. A system to optimise manufacturing tolerance allocation to a part known as Knowledge-based Automatic Tolerance Analysis (KATA) has been developed. KATA is a knowledge-based system shell built within AutoCAD. It has the ability for geometry creation in CAD and the capability to optimise the tolerance heuristically as an expert system. Besides the worst-case tolerancing equation to optimise the tolerance allocation, KATA's algorithm is supported by actual production information such as machine capability, types of cutting tools, materials, process capabilities etc. KATA's prototype is currently able to analyse a cylindrical shape workpiece and a simple prismatic part. Analyses of tolerance include dimensional tolerance and geometrical tolerance. KATA is also able to do angular cuts such as tapers and chamfers. The investigation has also led to the significant development of the single tolerance reference technique. This method departs from the common practice of multiple tolerance referencing technique to optimise tolerance allocation. Utilisation of this new technique has eradicated the error of tolerance stackup. The retests have been undertaken, two of which are cylindrical parts meant to test dimensional tolerance and an angular cut. The third is a simple prismatic part to experiment with the geometrical tolerance analysis. The ability to optimise tolerance allocation is based on real production data and not imaginary or random number generation and has improved the accuracy of the expected result after manufacturing. Any failure caused by machining parameters is cautioned at an early stage before an actual production run has commenced. Thus, the manufacturer is assured that the product manufactured will be within the required tolerance limits. Being the central database for all production capability information enables KATA to opt for several approaches and techniques of processing. Hence, giving the user flexibility of selecting the process plan best suited for any required situation

Automating Robot Planning Using Product and Manufacturing Information

AbstractAdvances in sensing, modeling, and control have made it possible to increase the accuracy of robots, and enable them to perform in dynamic environments. Often, performance deficiencies are not evident until late in the development of the manufacturing process, which delays the beginning of production and may cause damage to parts that have already undergone costly manufacturing steps. The goal of this research is to determine if a robot can meet manufacturing requirements, how to optimally plan robot activities, and to monitor robot processes to track performance. To achieve this, representations of product and manufacturing information and robot capabilities should be carried through the design, process planning, production, and analysis phases. Standards for the exchange of this information have been developed, such as ISO 10303 Part 242 for semantic product and manufacturing information and device kinematics, and the Robot Operating System Industrial specification for robot modeling, path planning, and execution. This paper surveys the relevant technologies and standards needed to enable automated deployment of robots in new application areas

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

Feature-based hybrid inspection planning for complex mechanical parts

Globalization and emerging new powers in the manufacturing world are among many challenges, major manufacturing enterprises are facing. This resulted in increased alternatives to satisfy customers\u27 growing needs regarding products\u27 aesthetic and functional requirements. Complexity of part design and engineering specifications to satisfy such needs often require a better use of advanced and more accurate tools to achieve good quality. Inspection is a crucial manufacturing function that should be further improved to cope with such challenges. Intelligent planning for inspection of parts with complex geometric shapes and free form surfaces using contact or non-contact devices is still a major challenge. Research in segmentation and localization techniques should also enable inspection systems to utilize modern measurement technologies capable of collecting huge number of measured points. Advanced digitization tools can be classified as contact or non-contact sensors. The purpose of this thesis is to develop a hybrid inspection planning system that benefits from the advantages of both techniques. Moreover, the minimization of deviation of measured part from the original CAD model is not the only characteristic that should be considered when implementing the localization process in order to accept or reject the part; geometric tolerances must also be considered. A segmentation technique that deals directly with the individual points is a necessary step in the developed inspection system, where the output is the actual measured points, not a tessellated model as commonly implemented by current segmentation tools. The contribution of this work is three folds. First, a knowledge-based system was developed for selecting the most suitable sensor using an inspection-specific features taxonomy in form of a 3D Matrix where each cell includes the corresponding knowledge rules and generate inspection tasks. A Travel Salesperson Problem (TSP) has been applied for sequencing these hybrid inspection tasks. A novel region-based segmentation algorithm was developed which deals directly with the measured point cloud and generates sub-point clouds, each of which represents a feature to be inspected and includes the original measured points. Finally, a new tolerance-based localization algorithm was developed to verify the functional requirements and was applied and tested using form tolerance specifications. This research enhances the existing inspection planning systems for complex mechanical parts with a hybrid inspection planning model. The main benefits of the developed segmentation and tolerance-based localization algorithms are the improvement of inspection decisions in order not to reject good parts that would have otherwise been rejected due to misleading results from currently available localization techniques. The better and more accurate inspection decisions achieved will lead to less scrap, which, in turn, will reduce the product cost and improve the company potential in the market

Review of dimensioning and tolerancing: representation and processing

The paper surveys the current state of knowledge of techniques for representing, manipulating and analysing dimensioning and tolerancing data in computer-aided design and manufacturing. The use of solid models and variational geometry, and its implications for the successful integration of CAD and CAM, are discussed. The topics explored so far can be grouped into four categories: (a) the representation of dimensioning and tolerancing (D & T), (b) the synthesis and analysis of D & T, (c) tolerance control, and (d) the implications of D & T in CAM. The paper describes in detail the recent work in each group, and concludes with speculation on a general framework for future research.Peer Reviewedhttp://deepblue.lib.umich.edu/bitstream/2027.42/29159/1/0000204.pd

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

Aggregate process planning and manufacturing assessment for concurrent engineering

The introduction of concurrent engineering has led to a need to perform product development tasks with reduced information detail. Decisions taken during the early design stages will have the greatest influence on the cost of manufacture. The manufacturing requirements for alternative design options should therefore be considered at this time. Existing tools for product manufacture assessment are either too detailed, requiring the results of detailed design information, or too abstract, unable to consider small changes in design configuration. There is a need for an intermediate level of assessment which will make use of additional design detail where available, whilst allowing assessment of early designs. This thesis develops the concept of aggregate process planning as a methodology for supporting concurrent engineering. A methodology for performing aggregate process planning of early product designs is presented. Process and resources alternatives are identified for each feature of the component and production plans are generated from these options. Alternative production plans are assessed in terms of cost, quality and production time. A computer based system (CESS, Concurrent Engineering Support System) has been developed to implement the proposed methodology. The system employs object oriented modelling techniques to represent designs, manufacturing resources and process planning knowledge. A product model suitable for the representation of component designs at varying levels of detail is presented. An aggregate process planning functionality has been developed to allow the generation of sets of alternative plans for a component in a given factory. Manufacturing cost is calculated from the cost of processing, set-ups, transport, material and quality. Processing times are calculated using process specific methods which are based on standard cutting data. Process quality cost is estimated from a statistical analysis of historical SPC data stored for similar operations performed in the factory, where available. The aggregate process planning functionality has been tested with example component designs drawn from industry