Shape error modelling and analysis by conditional simulations of Gaussian random fields for compliant non-ideal sheet metal parts

Accurate modelling of geometric and dimensional errors of sheet metal parts is crucial in designing correct GD&T and preventing unnecessary design changes during the development and launch of a new assembly process. A novel conditional simulation based methodology to probabilistically model and generate non-ideal sheet metal part geometric variations is developed. The methodology generates part geometric variations, which accurately emulate part fabrication process in terms of covariance of generated deviations. The methodology uses as inputs one or more of the following: measurement data of current parts, historical measurements of similar parts or FEM-based simulations. The proposed methodology emulates real processes and products accurately by generating non-ideal part representatives based on the aforementioned input data. Results provide an easy engineering interpretation to the designer. The methodology is demonstrated using automotive door hinge reinforcement

A tolerance analysis and optimization methodology: the combined use of 3D CAT, a dimensional hierarchization matrix and an optimization algorithm

We propose a methodology in this study for the analysis and the optimization of assembly tolerances. A combination of three components, it involves the use of 3D CAT software, a table referred to as a “dimensional hierarchization matrix” and a tolerance optimization algorithm. The Antolin Group, a Spanish multinational in the automobile components sector, employs this system to optimize tolerance values and to reduce manufacturing costs. The matrix was designed to enable easy identification, in a single table, of all requirements that fail to meet the specifications in the different approximations, prior to the definition of the dimensional and the geometric tolerances that comply with the functional requirements, and to identify which tolerances contribute most to variations in all of the functional conditions of the mechanism. Through its different iterations, this matrix allows us to see which of the tolerances should first be modified to optimize the design requirement specifications. A tolerance optimization algorithm was also defined, which functions with the data from the dimensional hierarchization matrix

Keck Planet Finder: Zerodur optical bench mechanical design

The Keck Planet Finder (KPF) is a fiber-fed, high-resolution, high-stability spectrometer in development for the W.M. Keck Observatory. To measure Doppler shifts to 0.5 m/s or better requires some of the optics be stable to 2 nm vertically and 2 nrad in pitch angle throughout a potentially one hour long observation. One traditional approach to this thermal stability problem is to build a metal bench and then control the spectrometer thermal environment to milli-Kelvin levels. An alternative approach used by KPF is to employ a Zerodur bench of extremely low coefficient of expansion (CTE), which relaxes the thermal stability required for the spectrometer assembly. Furthermore, Zerodur optics with integral mounts are used where possible, and are placed in contact with the bench through Zerodur shims. Springs are used to preload the optics and shims within pockets machined into the Zerodur bench. We will describe how this approach has been adapted for each optic (some of which are 450 mm high with a mass of 30 kg), and how the system meets our earthquake survival requirement of 0.92 g. This mounting scheme allows us to avoid using high-CTE metals or adhesives within the optic mounting system, and therefore fully exploit the high thermal stability of the Zerodur optical bench

NASA's Evolutionary Xenon Thruster (NEXT) Ion Propulsion System Information Summary

This document is a guide to New Frontiers mission proposal teams. The document describes the development and status of the NASA's Evolutionary Xenon Thruster (NEXT) ion propulsion system (IPS) technology, its application to planetary missions, and the process anticipated to transition NEXT to the first flight mission

Deep Space Network information system architecture study

The purpose of this article is to describe an architecture for the Deep Space Network (DSN) information system in the years 2000-2010 and to provide guidelines for its evolution during the 1990s. The study scope is defined to be from the front-end areas at the antennas to the end users (spacecraft teams, principal investigators, archival storage systems, and non-NASA partners). The architectural vision provides guidance for major DSN implementation efforts during the next decade. A strong motivation for the study is an expected dramatic improvement in information-systems technologies, such as the following: computer processing, automation technology (including knowledge-based systems), networking and data transport, software and hardware engineering, and human-interface technology. The proposed Ground Information System has the following major features: unified architecture from the front-end area to the end user; open-systems standards to achieve interoperability; DSN production of level 0 data; delivery of level 0 data from the Deep Space Communications Complex, if desired; dedicated telemetry processors for each receiver; security against unauthorized access and errors; and highly automated monitor and control

Shuttle/ISS EMU Failure History and the Impact on Advanced EMU Portable Life Support System (PLSS) Design

As the Shuttle/ISS EMU Program exceeds 35 years in duration and is still supporting the needs of the International Space Station (ISS), a critical benefit of such a long running program with thorough documentation of system and component failures is the ability to study and learn from those failures when considering the design of the next generation space suit. Study of the subject failure history leads to changes in the Advanced EMU Portable Life Support System (PLSS) schematic, selected component technologies, as well as the planned manner of ground testing. This paper reviews the Shuttle/ISS EMU failure history and discusses the implications to the AEMU PLSS

A comprehensive survey of the analytical, numerical and experimental methodologies for dynamics of multibody mechanical systems with clearance or imperfect joints

"Available online 19 December 2017"A comprehensive survey of the literature of the most relevant analytical, numerical, and experimental approaches for the kinematic and dynamic analyses of multibody mechanical systems with clearance joints is presented in this review. Both dry and lubricated clearance joints are addressed here, and an effort is made to include a large number of research works in this particular field, which have been published since the 1960′s. First, the most frequently utilized methods for modeling planar and spatial multibody mechanical systems with clearance joints are analyzed, and compared. Other important phenomena commonly associated with clearance joint models, such as wear, non-smooth behavior, optimization and control, chaos, and uncertainty and links’ flexibility, are then discussed. The main assumptions procedures and conclusions for the different methodologies are also examined and compared. Finally, future developments and new applications of clearance joint modeling and analysis are highlighted.This research was supported in part by the China 111 Project (B16003) and the National Natural Science Foundation of China under Grants 11290151, 11472042 and 11221202. The work was also supported by the Portuguese Foundation for Science and Technology with the reference project UID/EEA/04436/2013, by FEDER funds through the COMPETE 2020 – Programa Operacional Competitividade e Internacionalização (POCI) with the reference project POCI-01-0145-FEDER-006941.info:eu-repo/semantics/publishedVersio

Spatio-temporal adaptive sampling for effective coverage measurement planning during quality inspection of free form surfaces using robotic 3D optical scanner

In-line dimensional inspection of free form surfaces using robotic 3D-optical scanners provide an opportunity to reduce the mean-time-to-detection of product quality defects and has thus emerged as a critical enabler in Industry 4.0 to achieve near-zero defects. However, the time needed to inspect large industrial size sheet metal parts by 3D-optical scanners frequently exceeds the production cycle time (CT), consequently, limiting the application of in-line measurement systems for high production volume manufacturing processes such as those used in the automotive industry. This paper addresses the aforementioned challenge by developing the Spatio-Temporal Adaptive Sampling (STAS) methodology which has the capability for (i) estimation of whole part deviations based on partial measurement of a free form surface; and, (ii) adaptive selection of the next region to be measured in order to satisfy pre-defined measurement criterion. This is achieved by first, modelling spatio-temporal correlations in the high dimensional Cloud-of-Points measurement data by using a dimension reduced space-time Kalman filter; then, dynamically updating the model parameters during the inspection process by incorporating partial measurement data to predict entire part deviations and adaptively choose the next critical region of the part to be measured