Browse Topic: Flexible manufacturing systems

Items (87)
Find
Capability-Driven Adaptive Task Distribution for Flexible Multi-Human-Multi-Robot (MH-MR) Manufacturing Systems2020-01-13034/14/2020
Collaborative robots are more and more used in smart manufacturing because of their capability to work beside and collaborate with human workers. With the deployment of these robots, manufacturing tasks are more inclined to be accomplished by multiple humans and multiple robots (MH-MR) through teaming effort. In such MH-MR collaboration scenarios, the task distribution among the multiple humans and multiple robots is very critical to efficiency. It is also more challenging due to the heterogeneity of different agents. Existing approaches in task distribution among multiple agents mostly consider humans with assumed or known capabilities. However human capabilities are always changing due to various factors, which may lead to suboptimal efficiency. Although some researches have studied several human factors in manufacturing and applied them to adjust the robot task and behaviors. However, the real-time modeling and calculation of multiple human capabilities and real-time adaptive task distribution in flexible MH-MR manufacturing according to human capabilities are still challenging due to the complexity of human capabilities and heterogeneous multi-agent interactions. To address these issues, this paper first proposes a practical modeling approach to model and calculate the capabilities of different humans in real-time using some measurable performance indices. Based on these capabilities, this paper furthermore mathematically models the MH-MR manufacturing process and proposes a capability-driven adaptive task distribution approach with genetic algorithm based solutions to distribute different tasks to humans and robots online. The proposed adaptive approaches are validated through different MH-MR manufacturing tasks and the experimental results show that the approaches can significantly improve the manufacturing efficiency in terms of the time cost and the number of accomplished tasks than existing approaches in the presence of different time-varying human capabilities. Detailed results and statistical comparisons are presented to illustrate the effectiveness and advantages of the proposed solutions.
Zhang, Shaobo, Jia, Yunyi
Unsettled Technology Domains in Robotics for Automation in Aerospace ManufacturingEPR201901012/20/2019
Cost reduction and increasing production rates are driving automation of aerospace manufacturing. Articulated serial robots may replace bespoke gantry automation or human operations. Improved accuracy is key to enabling operations such as machining, additive manufacturing (AM), composite fabrication, drilling, automated program development, and inspection. New accuracy standards are needed to enable process-relevant comparisons between robotic systems. Accuracy can be improved through calibration of kinematic and joint stiffness parameters, joint output encoders, adaptive control that compensates for thermal expansion, and feedforward control that compensates for hysteresis and external loads. The impact of datuming could also be significantly reduced through modeling and optimization. Highly dynamic end effectors compensate high-frequency disturbances using inertial sensors and reaction masses. Global measurement feedback is a high-accuracy turnkey solution, but it is costly and has limited capability to compensate dynamic errors. Local measurement feedback is a mature, affordable, and highly accurate technology where the robot is required to position or align relative to some local feature. Locally clamped machine tools are an alternative approach that can utilize the flexibility of industrial robots while also enabling high-quality machined surfaces. Hybrid high-accuracy control strategies will be required for many processes. NOTE: SAE EDGE™ Research Reports are intended to identify and illuminate key issues in emerging, but still unsettled, technologies of interest to the mobility industry. The goal of SAE EDGE™ Research Reports is to stimulate discussion and work in the hope of promoting and speeding resolution of identified issues. SAE EDGE™ Research Reports are not intended to resolve the issues they identify or close any topic to further scrutiny.
Muelaner, Jody
A Guide to Collaborative Robot SafetyTBMG-343855/1/2019
The ability of collaborative robots to share tasks with humans and flexibly adapt to new requirements can provide high returns on investment in a wide variety of industrial applications. Manufacturers employ these robots to reap the benefits of integrated safety features that allow them to work with or close by humans and boost productivity for a wide variety of repetitive tasks.
Demonstration of Transformable Manufacturing Systems through the Evolvable Assembly Systems Project2019-01-13633/19/2019
Evolvable Assembly Systems is a five year UK research council funded project into flexible and reconfigurable manufacturing systems. The principal goal of the research programme has been to define and validate the vision and support architecture, theoretical models, methods and algorithms for Evolvable Assembly Systems as a new platform for open, adaptable, context-aware and cost effective production. The project is now coming to a close; the concepts developed during the project have been implemented on a variety of demonstrators across a number of manufacturing domains including automotive and aerospace assembly. This paper will show the progression of demonstrators and applications as they increase in complexity, specifically focussing on the Future Automated Aerospace Assembly Phase 1 technology demonstrator (FA3D). The FA3D Phase 1 demonstrated automated assembly of aerospace products using precision robotic processes in conjunction with low-cost reconfigurable fixturing supported by large volume metrology. This was underpinned by novel agent-based control for transformable batch-size-of-one production. The paper will conclude by introducing Phase 2 of the Future Automated Aerospace Assembly Demonstrator - currently in development - that will translate the Evolvable Assembly Systems research to a higher technology readiness level and address the challenges of scalable and transformable manufacturing systems.
Sanderson, David, Turner, Alison, Shires, Emma, Chaplin, Jack, Ratchev, Svetan
Automated Guided Vehicles for Small Manufacturing Enterprises: A Review05-11-03-00249/17/2018
Automated guided vehicle systems (AGVS) are the prominent one in modern material handling systems used in small manufacturing enterprises (SMEs) due to their exciting features and benefits. This article pinpoints the need of AGVS in SMEs by describing the material handling selection in SMEs and enlightening recent technological developments and approaches of the AGVS. Additionally, it summarizes the analytical and simulation-based tools utilized in design problems of AGVS along with the influence of material handling management and key hurdles of AGVS. The current study provides a limelight towards making smart automated guided vehicles (AGVs) with the simplified and proper routing system and favorable materials and more importantly reducing the cost and increasing the flexibility.
Kumbhar, Surajkumar Goraksha, Thombare, Rachana B., Salunkhe, Amitkumar B.
Understanding Smart Machines: How They Will Shape the FutureTBMG-288635/1/2018
Powered by smart machines, the new industrial revolution is changing how machine builders design, and how manufacturers operate today and in the future. To remain competitive and profitable, plants and machines will have to be smarter: better connected, more efficient, more flexible, and safe.
Cobots and Industrial Robots Choose the Right Robot for the JobTBMG-288094/1/2018
Automating manufacturing processes is a complex issue, with no one-size-fits-all solution. Robots range from insect-like microrobots to industrial robots powerful enough to move automotive chassis or airplanes. Toward the lower end of the spectrum is a class of robots referred to as collaborative robots (or cobots) because they are designed to share a workspace with human workers.
Using Thermoplastic Composites for Aerospace Applications17AERP12_0412/1/2017
Recent advancements in composite production and processing are making thermoplastics a viable option in a wider array of aerospace applications. Traditionally, aerospace manufacturers have turned to composites for their significant weight reductions and cost savings compared with conventional aerospace materials, such as aluminum. Thermoset composites have been the composite of choice in recent years for their perceived high quality, commercialized pricing, more mature manufacturing process and well-established supply chain. They found application in diverse areas, including primary structural applications. Thermoplastics, in contrast, have been considered a costlier option and were mainly used in small semi-structural applications, such as clips and brackets.
Using Thermoplastic Composites for Aerospace ApplicationsTBMG-2795212/1/2017
Recent advancements in composite production and processing are making thermoplastics a viable option in a wider array of aerospace applications.
Advanced Machining and Automation Reduce Medical Device Tubing CostsTBMG-2785411/1/2017
In order to stay competitive in today’s medical device marketplace, it is imperative that companies continually invest in the latest technologies to ensure that they produce the highest quality metal tubing products, while also reducing costs. To meet these demands, full-service contract manufacturing operations must also be vertically integrated to handle complex medical device tubing projects.
High-Accuracy Articulated Mobile Robots2017-01-20959/19/2017
The advent of accuracy improvement methods in robotic arm manipulators have allowed these systems to penetrate applications previously reserved for larger, robustly supported machine architectures. A benefit of the relative reduced size of serial-link robotic systems is the potential for their mobilization throughout a manufacturing environment. However, the mobility of a system offers unique challenges in maintaining the high-accuracy requirement of many applications, particularly in aerospace manufacturing. Discussed herein are several aspects of mechanical design, control, and accuracy calibration required to retain accurate motion over large volumes when utilizing mobile articulated robotic systems. A number of mobile robot system architectures and their measured static accuracy performance are provided in support of the particular methods discussed.
Jackson, Timothy
A Novel Fixturing Solution for Handling Complex-Shaped Components2017-01-20829/19/2017
Many components used in the aerospace industry are complex-shaped, without symmetric axes and parallel surfaces. Fabricating and repairing these components often require fixturing system to support manufacturing processes such as drilling, surface finishing, inspections and assembly. Currently available fixturing systems can be divided into dedicated and flexible fixtures. Among these, the flexible fixtures are suitable for rapidly changing fabricating processes and handling several complex-shaped components using same fixturing system. Background research suggested that the pin type fixturing system is the predominant design used in such applications to fix complex-shaped components. In pin type fixturing systems, force is applied to a single point of contact. This increases the pressure applied to the work piece and possibility of damaging these components. Further, conventional pins use rigid designs, which cannot adapt to the shape of the work piece. This reduces the applicable clamping force and the increases the possibility of slipping. This paper describes a fixturing system to address these problems by developing a distributed force fixing method with conformance to complex shapes. Proposed fixturing system uses jamming granular materials with negative pressure. A flexible rubber container fill with granular material is attached to the tip of a modified pin. When the container touches the work piece it conforms to the shape of the work piece. Then the rubber container vacuumed, which rigidifies the container and fix the shape, through granular jamming. Series of experiments were carried out to decide the best suited granular material in terms of highest holding force with best adaptability to a complex surface. Experiments were carried out using eight different low cost locally sourced materials. According to the experimental results proposed system successfully provide required holding forces to manipulate complex shaped components.
Jayaweera, Nirosh, Kulasekera, Asitha, Maduranga, Posindu, Kasun, Thilina, Seekkuarachchi, Prabodh, Sampath, Janaka
Automation and Robotics - The Trend Towards Cyber Physical Systems in Agriculture Business2017-01-19325/10/2017
The digital transformation offers Europe tremendous opportunities of more efficient production using Cyber Physical Systems (CPS), which will enable new concepts for future farming systems. The very fast development of information and communication technologies is driving the evolution of mobile machines into cyber-physical systems with virtually no limitations for communication. Automation is the most important trend in the development of agricultural mobile machines due to the open potential of efficiency increases at all levels (machine, process and farm operation). CPS technologies are going to deliver solutions at the system and enterprise level by supporting real time and strategic decisions while enabling much higher system transparency and controllability within the sustainability tri-angle.
Herlitzius, Thomas
Bringing New Vision to Laser Material Processing SystemsTBMG-268995/1/2017
The use of modern laser technology has become standard in industrial manufacturing thanks to its speed, accuracy and effectiveness. Lasers are used to engrave parts, electronic printed circuit boards or chip cards. They perforate packaging; structure semiconductor wafers; drill, cut and weld plastics or metals; and create highly complex structures via 3D printing.
High Accuracy Mobile Robotic System for Machining of Large Aircraft Components2016-01-21399/27/2016
A mobile robotic system is presented as a new approach for machining applications of large aircraft components. Huge and heavy workshop machines are commonly used for components with large dimensions. The system presented in this paper consists of a standard serial robot kinematics and a mobile platform as well as a stereo camera system for optical measurements. Investigations of the entire system show that the mechanical design of the mobile platform has no significant influence on the machining accuracy. With mobile machines referencing becomes an important issue. This paper introduces an optical method for determining the position of the mobile platform in relation to the component and shows its accuracy limits. Furthermore, a method for increasing the absolute accuracy of the robots end-effector with help of stereo camera vision is presented. This publication shows that the mobile robotic system yields an efficient possibility for advanced machining processes of large-scaled aircraft structures in the Factory of the Future.
Susemihl, Hendrik, Moeller, Christian, Kothe, Simon, Schmidt, Hans Christian, Shah, Nihar, Brillinger, Christoph, Wollnack, Jörg, Hintze, Wolfgang
Manufacturing the Next Generation of Connected and Electrified Vehicle2016-01-02964/5/2016
Increasing electrification of the vehicle as well as the demands of increased connectivity presents automotive manufacturers with formidable challenges. Automakers and suppliers likely will encounter three practices that will influence how they develop and manufacture highly connected vehicles and future e-mobility platforms: 1) hierarchical production processes in fixed footprints that do not share data freely; 2) lack of real-time, in-line quality inspection and correction processes for complex miniaturized electronic components; and 3) floor to enterprise resource and execution systems that can collect, analyze and respond to rapidly changing production needs. While the automotive manufacturing industry has implemented sensors, robotics and computerized automation for decades, these systems largely are organized in a hierarchical fashion within individual data silos, and often in a closed, hard-wired network environment largely disconnected from IT and enterprise service-based networks. To complicate matters, automotive and industrial standard manufacturing equipment is still largely constrained by a large installed base of legacy workflow, equipment and standards. This paper explores some possible directions how automakers and suppliers will need to change and what considerations they will need to account for with respect to data into order to manufacture the next generation of connected and electrified vehicles.
Minarcin, Monika
A Linkage Based Solution Approach for Determining 6 Axis Serial Robotic Travel Path Feasibility2016-01-03364/5/2016
When performing trajectory planning for robotic applications, there are many aspects to consider, such as the reach conditions, joint and end-effector velocities, accelerations and jerk conditions, etc. The reach conditions are dependent on the end-effector orientations and the robot kinematic structure. The reach condition feasibility is the first consideration to be addressed prior to optimizing a solution. The ‘functional’ work space or work window represents a region of feasible reach conditions, and is a sub-set of the work envelope. It is not intuitive to define. Consequently, 2D solution approaches are proposed. The 3D travel paths are decomposed to a 2D representation via radial projections. Forward kinematic representations are employed to define a 2D boundary curve for each desired end effector orientation. The feasible region for all orientations is determined by the use of Boolean intersections of the boundary curves or by overlapping valid regions in which points are placed. Combining the tool path and functional work space regions allow designers to readily visualize regions of concern. A KUKA and Comau robot are used to illustrate the methodology.
Urbanic, R.J., Hedrick, R., Djuric, Ana M.
Robots and Humans - Let the Collaboration BeginTBMG-244284/1/2016
A collaborative robot is essentially an industrial robot with additional safety capabilities. These safety features include:
Executive Perspectives: RoboticsTBMG-242933/1/2016
CHETAN KAPOOR Senior Director of Technology Innovation Yaskawa America, Motoman Robotics Division Miamisburg, OH
Comau enters the small-robot segment with Racer315MEIP12_2312/1/2015
Small robots are beginning to handle tasks inside automotive production facilities that require human-like dexterity. “The primary reason for smaller robots gaining traction in the automotive industry, especially in the assembly area, are advances in end effector technology (the device at the end of a robotic arm), tactile sensing capabilities, and overall precision,” said Alex Shikany, Director of Market Analysis for the Robotic Industries Association (RIA) in Ann Arbor, MI.
Buchholz, Kami
Robotic Drilling and Countersinking on Highly Curved Surfaces2015-01-25179/15/2015
Electroimpact has developed a novel method for accurately drilling and countersinking holes on highly convex parts using an articulated arm robotic drilling system. Highly curved parts, such as the leading edge of an aircraft wing, present numerous challenges when attempting to drill normal to the part surface and produce tight tolerance countersinks. Electroipmact's Accurate Robot technology allows extremely accurate positioning of the tool point and the spindle vector orientation. However, due to the high local curvature of the part, even a small positional deviation of the tool point can result in a significantly different normal vector than expected from an NC program. An off-normal hole will result in an out of tolerance countersink and a non-flush fastener. A compliant contact pad with normality feedback is commonly used to locally normalize to a work part but in the case of highly curved parts, a flat contact pad has too small of a contact area with the panel to allow accurate local normalization. Electroimpact has developed a pneumatically actuated four-point lander on a compliant contact pad with normality feedback. This development, along with Electroimpact's Accurate Robot technology allows for automated drilling and countersinking on parts that have previously been unachievable with robotic drilling systems.
Holt, Sean, Clauss, Rider
Towards Self-Adaptive Fixturing Systems for Aircraft Wing Assembly2015-01-24939/15/2015
The aim of this work was to develop a new assembly process in conjunction with an adaptive fixturing system to improve the assembly process capability of specific aircraft wing assembly processes. The inherently complex aerospace industry requires a step change in its capability to achieve the production ramp up required to meet the global demand. This paper evaluates the capability of adaptive fixtures to identify their suitability for implementation into aircraft wing manufacturing and assembly. To understand the potential benefits of these fixtures, an examination of the current academic practices and an evaluation of the existing industrial solutions is highlighted. The proposed adaptive assembly process was developed to account for the manufacturing induced dimensional variation that causes significant issues in aircraft wing assembly. To test the effectiveness of the adaptive assembly process, an aircraft wing assembly operation was replicated on a demonstrator test rig. The experimental case study is described and positive initial test data is presented. The demonstrator achieved assemblies that were 0.129 mm and 0.114 mm from the actual target. These initial tests show that a repeatable process is obtainable, but a further increase in accuracy is required. Future work will be bring the system to a higher maturity level to allow for implementation into aircraft assembly processes.
Vaughan, Dan, Branson, David, Bakker, Otto Jan, Ratchev, Svetan
Implementing the Hybrid Lean-Agile Manufacturing System Strategically in Automotive Sector2015-01-90835/1/2015
In order to strike a balance between cost and availability, the present study presents the strategic implementation of the hybrid lean-agile manufacturing system. The proposed implementation is based on literature review and statistical analysis. The study presents short term and long term proposed plans for implementing this newly developed system in a sustainable way. It shows how the strategic facet of the hybrid lean-agile manufacturing system addresses the key manufacturing competitive dimensions. The paper presents as well a cost-benefit analysis in comparison with the lean manufacturing system and agile manufacturing system based on the net present value. The study shows that the expectedly most efficient among the manufacturing systems is the Hybrid Lean-Agile Manufacturing System with normalized comparative improvement of about 58% and 42%, respectively. The study concludes through a statistical sample that about one third of the variation in successfully dealing with the sources of competitive advantage in automotive sector can be explained by adopting the strategic facet of the hybrid lean-agile manufacturing system. The study is limited to the automotive manufacturing sector. The paper would be of interest to the seekers for efficient manufacturing systems such as lean manufacturing practitioners and agile manufacturing practitioners.
Elmoselhy, Salah A.
Enhancing Automotive Wire Harness Manufacturing Through Digital Continuity2015-01-02384/14/2015
Manufacturing companies are benefiting from technology in most key areas of the flow from design through manufacture. This applies to the wire harness industry which is a key element of the modern automotive industry. Wire harness manufacturing engineering, however, is a critical path function that is under severe pressure and yet has been under-served by technology. In some respects it has become the weak link in the chain. Recent innovations in commercial off-the-shelf (COTS) technology are set to change this situation. Software applications are now available to deliver transformational manufacturing engineering automation as well as being able to integrate with technology in other areas of the process. This will enable a digitally continuous data flow that can remove excessive cost, time, and pressure - while helping manufacturers meet the increasing demands of the industry.
Smith, Nick
Hybrid Lean-Agile Manufacturing System Strategic Facet in Automotive Sector2014-01-91041/1/2015
The lean production system has been successful in the cost-based winning order criterion markets. However, the automotive market has been volatile and the new criterion of winning orders has been availability, which has called for an agile system. The present paper argues that because of fierce competition the current automotive market winning order criterion is now a blend of cost and availability. It shows how a hybrid lean-agile system can strategically meet such a challenging criterion. The study presents the drivers, attributes and providers in lean manufacturing, agile manufacturing, and hybrid lean-agile manufacturing systems. It investigates how the strategic facet of the proposed hybrid lean-agile manufacturing system addresses the six manufacturing competitive dimensions. It presents as well the hybrid lean-agile manufacturing key performance indicators. The strategic facet of the proposed hybrid lean-agile manufacturing system has been validated through industrial case studies in automotive sector. A cost-benefit ratio qualitative analysis has been conducted on the proposed system and the benefits outweigh corresponding costs resulting in positive present value.
Elmoselhy, Salah A.
Aerospace Engineering: November 5, 201414AERD1111/5/2014
Adaptive trimming of composite parts Some of the techniques used in the Adaptive Manufacturing System are normal aerospace processes. The unique and enabling process is the scanning and adaptive trimming.
Adaptive Manufacturing System2014-01-22739/16/2014
The ever increasing use of composites for aircraft components presents opportunities for new ways to process these parts. There are myriad benefits for use of composites in achieving aircraft performance goals. However, composites come with unique challenges as well. Some of these challenges impact the ability to produce accurate parts. Traditionally, such parts have been trimmed only while clamped in dedicated rigid tools that secure the part in the nominal shape. This results in significant investment in tooling design, production, maintenance, storage and, handling. As an alternative, PaR has developed its Adaptive Manufacturing System that incorporates a Robotic Fixture and Precision Motion Machine with an Integrated Process Head. The Robotic Fixture allows the entire family of parts to be managed with one fixture that remains within the machine footprint. The fixture is programmed to command 38 individual robots to assume appropriate poses and end effector configurations to accommodate over 400 different parts in the family that range in length from 0.5 to 20 meters. Once the part(s) is loaded in the fixture, the system automatically scans the part to determine the actual location and contour, as presented to the machine. The actual measurements are compared against reference data, which defines the nominal condition. This allows the machine to automatically develop adaptive tool paths that trim the part, so that the part will be the right size when constrained to its nominal condition. Trimming is done with abrasive waterjet, using multiple different catchers to accommodate different accessibility conditions. A spindle is also integrated into the same head as the waterjet and laser scanners, to accommodate hole drilling and edge chamfering. After the trimming operations are complete, the system washes and dries the part. A subsequent geometric inspection is performed using either a probe in the spindle, or the laser scanners. The inspection uses DMIS programming and results in an inspection report to go with the completed part. This paper will further describe the challenges and technology implemented in the development of this system.
Cunov, James, Habermann, Charles J.
GM Implements Flexible Assembly System and Controls to Reduce WorkflowTBMG-1886912/1/2013
At the GF6 six-speed, front-wheel transmission line at General Motors Powertrain in Toledo, OH, a new front-wheel-drive transmission line for smaller, more fuel-efficient vehicles such as the Chevy Malibu and Chevy Cruze is currently ramping up to its initial goal of 2,200 units per day. A closer look reveals the method used to program this line, implement changeover, stage the workpiece flow, perform all machining and secondary operations, and assemble the finished transmissions.
Mobile Automated Robotic Drilling, Inspection, and Fastening2013-01-23389/17/2013
The versatility of the accurate robot has been increased by coupling it with a mobile platform with vertical axis. The automation can be presented to fixed aircraft components such as wings, fuselage sections, flaps, or other aircraft assemblies requiring accurate drilling, inspection, and fastening. The platform accommodates a tool changer, ride along coupon stand, fastener feed system, and other systems critical for quality automated aircraft assembly. The accurate robot's flexibility is increased by a floor resynchronization system. The indexing system is replaced by an automated two-camera onboard vision system and miniature targets embedded in the factory floor, with accuracy comparable to cup and cone alternatives. The accurate robot can be deployed by casters, curvilinear rail, or air bearings.
Gray, Troy, Orf, Daniel, Adams, Greg
Automated Removal of Prepreg Backing Paper - A Sticky Problem2013-01-22899/17/2013
Automated solutions for manufacturing composite products based on prepreg often imply Automatic Fiber Placement or Automatic Tape Laying. These systems are generally associated with huge investments. For certain manufacturing applications it is interesting to investigate alternatives to find simpler and less costly automation. One example of an automated system could be the use of a standard industrial robot to pick single prepreg plies from an automated cutting machine and stack them to form a plane laminate. This paper is based on a case illustrating a product from the aircraft manufacturing industry. The case will demonstrate a pick and place concept on a general level and illustrate challenges that must be solved. The challenge selected to be the main focus for this paper is an automated process for backing paper removal. A literature review of different gripping technologies reveals several interesting technologies, and the most promising are tested for backing paper removal. The tests show that an automated removal process can be designed by using standard vacuum grippers in combination with mechanical clamping grippers. In order to lift the backing paper with a vacuum gripper an initial separation between the backing paper and prepreg is needed. This separation is most easily mechanically induced by bending the material. The proposed solution for automatic backing paper removal can be integrated in a manufacturing cell for manufacturing of the studied product.
Björnsson, Andreas, Lindback, Jan-Erik, Johansen, Kerstin
Evaluation of Electromagnetic Forming Behavior of Automotive Aluminum Alloy Sheet2013-01-01313/25/2013
In this study, electromagnetic forming behavior of automotive aluminum alloy sheet was evaluated. The 5J32 aluminum alloy sheets with thickness of 1.0mm was utilized. The electromagnetic forming system (EMFS) with maximum energy capacity of 120kJ was used with the helix type coil and open die cavity in order that the targeted hemi elliptical protrusion were freely formed. Forming shape, heights and springback amounts after forming were investigated with increasing the initial voltage. The hemi elliptical protrusion was formed without failure up to 9.0kV and was failed at 9.5kV. As increasing the input voltages, the forming heights and the springback of the hemi elliptical protrusion were increased.
Kim, Daeyong, Kim, Ji Hoon, Lee, Myoung-Gyu
Applied Accurate Robotic Drilling for Aircraft Fuselage2010-01-18369/28/2010
Once limited by insufficient accuracy, the off-the-shelf industrial robot has been enhanced via the integration of secondary encoders at the output of each of its axes. This in turn with a solid mechanical platform and enhanced kinematic model enable on-part accuracies of less than +/−0.25mm. Continued development of this enabling technology has been demonstrated on representative surfaces of an aircraft fuselage. Positional accuracy and process capability was validated in multiple orientations both in upper surface (spindle down) and lower surface (spindle up) configurations. A second opposing accurate robotic drilling system and full-scale fuselage mockup were integrated to simulate doubled throughput and to demonstrate the feasibility of maintaining high on-part accuracy with a dual spindle cell.
Devlieg, Russell, Szallay, Todd
A Framework for the Fusion of Multiple Metrology Sources for Measurement Assisted Assembly2009-01-311911/10/2009
Measurement assisted assembly is one of the key emerging technologies in airframe manufacture. The use of metrology to assist with the assembly process can significantly reduce the cost and complexity of the required fixtures as well as reducing manual labor input and assembly time. Most of the existing systems use a single metrology system but this paper describes the development and deployment of a network based system that allows the deployment of multiple metrology systems to support either a single task or multiple tasks simultaneously.
Webb, P., Ye, C., To, M., Al-Thraa, S., Kayani, A.
Influence of Sharing Bus on Real-Time Networked Control Systems Performance2007-01-269211/28/2007
A major trend in modern aerospace and automotive systems is to integrate computing, communication and control into different levels of the vehicle and/or its supervision. A well fitted architecture adopted by this trend is the common bus network architecture. A Networked Control System (NCS) is called when the control loop is closed through a communication network. The presence of this communication network introduces new characteristics (sharing bus, delays, jitter,etc) to be considered at design time of a control system. This work focuses on the effect of sharing bus between the control system and the other devices connected to the bus foreigner to control. These last devices are called interferences. We intented to show, through simulations, the influence of sharing bus on real time control systems performance. To compare effects, we choose the CanBus protocol where the medium access control is event driven; and the TTP protocol where the medium access control is time driven. In the future, we intent to extend this study to the Attitude and Orbit Control System (AOCS) of Multi-Mission Platform (MMP) satellite in its nominal operation mode.
Valdivia, Rolf Henry Vargas, Souza, Marcelo Lopes de Oliveira e
Quantitatively Augmented QFD-HOQ2007-01-37058/5/2007
Quality Function Deployment (QFD) is a process to translate the Voice of the Customer (VOC) into the technical will of the enterprise. QFD is an integral step in the flowdown of customer requirements into the product system, subsystem(s), components and manufacturing processes. The House of Quality (HOQ) is a fundamental element of the QFD process, which provides a framework to relate customer attributes to engineering characteristics at the product architecture level. This paper presents the advantages and limitations of the symbols and weighting schemes used in constructing the relationship matrix in the classical House of Quality of the Quality Function Deployment process. The selection of the weighting scheme for function flowdown during the early design phase impacts the prioritization of engineering characteristics. A simple example using an nxn matrix is provided to illustrate the impact. A methodology is proposed to augment QFD-HOQ with principles used in vector matrix algebra and Analytical Hierarchical Process (AHP) to enable the selection of the right engineering characteristics.
Jikar, Vivek K., Cudney, Elizabeth A., Smith, Eric D., Ragsdell, Kenneth M., Paryani, Kioumars
Simulation at the Heart of an Automated Aerospace Manufacturing Process2006-01-31509/12/2006
The traditional use of simulation software in aerospace manufacturing applications has been as a pre-production tool for the validation of tool paths and the generation of robot programs. Once the process has been proven via simulation, the data is then transferred to the machine or robot and the production process executed. This is a linear approach in which the virtual and real systems are operated independently and in a serial manner. The current capabilities of offline programming (OLP) and simulation systems when combined with appropriate hardware in a flexible manufacturing environment now allow them to be used right at the heart of a manufacturing process, as an integral part of the manufacturing route. In a flexible manufacturing cell such as that developed at the University of Nottingham for the automated assembly and riveting of large aerostructures, a key driver is the need to reduce or eliminate complex and costly jigs and fixtures for part positioning. The use of simple non-precise support structures results in variation in the spatial relationship between the robot and the part or assembly. These variations are inherent in the nature of the parts, as a result of the additive manufacturing process and from the use of robots. The part position and orientation variation must be measured and accounted for in the robot program and the combination of a non-contact real-time metrology system and an OLP system linked together in a flexible cell allows this to happen as part of the manufacturing process. This results in a much closer coupling between the virtual part of the manufacturing process and the real part. This paper will describe the embedding of the simulation system at the heart of the robotic assembly and riveting cell at the University of Nottingham and will outline the ways in which the capabilities of the simulation system can be utilized to produce an innovative and highly flexible manufacturing system for the production of aerospace assemblies with significant geometrical variations.
Eastwood, S., Webb, P.
A Neuro-Fuzzy Approach to a Machine Vision-based Parts Inspection Problem2006-01-03784/3/2006
This paper describes a research project whose objective is to improve the parts inspection component of the automotive manufacturing process through the application of neuro-fuzzy systems. The basic methodology is to circulate case studies of industrial inspection problems among 5 universities and challenge the researchers to find more robust analysis algorithms. This paper presents initial work on one of the case studies whose subject is the application of a machine vision-based system to identify missing fasteners in a cross-car beam.
Norman, Thomas, Surgenor, Brian, Killing, Jonathan, Mechefske, Chris, Bone, Gary, Demirli, Kudret, Sun, Qiao, Xi, Fengfeng
Automotive Engineering International 2005-12-01AUTODEC0512/1/2005
Assembly by design The latest product development software offers new tools to improve the body engineering process and deliver flexible manufacturing capability. Measure twice, cut once The old carpenter's axiom is doubly true in the expensive realm of motorsport, where simulations provide a more cost-effective way to test ideas than trial-and-error. 2005 technology in review AEI editors look back at some of the most significant engineering and innovation stories of the past year. The new steels Lessons learned on where, when, why, and how to use new higher-strength materials is an information-sharing mandate of high order. Nissan showcases advanced technology The underlying philosophy of the company's "Orchard Concept" R&D strategy is to direct its strengthened resources to "real, specifc technological innovation in the car that you see on a showroom floor," providing performance and functions that exceed customer expectations. Wire trimming Technology advances, especially the increased use of networking, are helping to reduce vehicle wire count and bulk. Gaining momentum Buoyed by much improved quality and customer satisfaction, Hyundai looks to move upmarket, develop its own hybrid vehicles, and invest in the future.
Flexible Automated Riveting and Assembly of Fuselage Skin Panels2003-01-29549/8/2003
This paper describes the current state of development of a highly flexible assembly and auto-riveting system based around multiple robots and compact and innovative riveting and assembly end-effectors. The riveting end-effectors are capable of drilling, countersinking, sealing and upsetting operations. The assembly end-effectors are re-configurable and can handle ant stringer or frame on a Bombardier Aerospace CRJ700 fuselage panel. The cell is also equipped with non-contact metrology systems that are used to compensate for compliance and remove the requirement for large and complex fixtures. The riveting system has been fully evaluated and a number of test coupons submitted for testing. Detailed analysis of these has proved that the resulting riveted joints are of production quality. The final system will be non-product specific allowing a single cell to produce a number of different aircraft components.
Webb, Philip, Eastwood, Sara, Chitiu, Alex, Fayad, Carole, McKeown, Colm
Digital Laser Vision in the Aerospace Industry2003-01-29579/8/2003
This paper is a case study of a successful application of a particular type of machine vision system to an aerospace manufacturing operation. The task for the vision system is to find holes very accurately. The system performs this task using a novel combination of laser triangulation and grayscale area analysis. Using a custom sensor, incorporating a high resolution digital camera, structured and unstructured illumination, together with advanced image processing algorithms has resulted in a measurement system which has excellent accuracy and repeatability.
Beattie, Bob
OEM production systems enable flexibilityAUTOJAN03_031/1/2003
Building multiple models on the same production line is a Japanese innovation-one that U.S. automakers are hurrying to implement. Ford Motor Co. is using its most valuable property, the F-Series pickup truck, to launch its flexible manufacturing program in North America beginning with the 2004 model year. The first fully flexible plant for Ford in America will be the Norfolk Assembly Plant, launch site for the redesigned 2004 F-150. General Motors Corp. already has a flexible plant in operation: the new Lansing Grand River plant, where the Cadillac CTS currently is produced. The SRX goes into production there this summer, with more models planned. Chrysler Group has the capability to add or change models with minimal disruption at four plants. With the 2004 model year Chrysler Pacifica, for the first time it will build multiple models off different platforms at the same facility, namely the Windsor Assembly Plant in Canada beginning early this year.
Ponticel, Patrick
Use of Electromagnetic and Vacuum Forces on Aircraft Assembly2002-01-263010/1/2002
Decades ago our innovative grandfathers developed the first automated riveting machines based on hard automation using kinematics and tools attached to a C-frame. The C-frame serves multiple functions: First, it holds the upper and lower tools in fixed positions relative to each other; second, it translates upper active tooling forces to the lower tool; and third, it embraces the part placed between the upper and lower tool. C-frames and newly developed yoke, ring and gantry machines, used for low level (first, second) fuselage and wing assembly are growing in size to exorbitant proportions to satisfy requirements of larger and larger structures. High costs are dictated by massive kinematics and complex controls that provide stability, precision, and process speed. All this is mainly needed because we have to carry mechanical forces around the part, from upper to lower tool along the C-frame, gantry, yoke, bridge, etc. There are several other forces in nature (i.e. gravity, electricity, magnetism, pressure, vacuum, heat, atomic, friction, etc.) which can be considered and applied to machine design to achieve optimum and reliable results for minimal investments in machinery and floorspace. Analyzing alternative forces in search of more innovative assembly systems specifically for high level assembly where “embracing” parts (fuselage barrels, wing boxes) is no alternative, electromagnetic and vacuum forces were down-selected as the most promising option. The specific characteristics of magnetic flux capable of penetrating a part provides an ideal technique for generating clamping forces during drilling, fastener feeding, and the upsetting process. Electromagnet generating clamping force is easily integrated with a multi-function end effector moving on rails along structural joints performing fastening in sync with an internal tool. Vacuum systems capable of generating forces on part surfaces using suction cups and/or vacuum chambers, have the capability to attach/hold assembly systems on aircraft structures by part non intrusive means. Utilization of these new technologies in aircraft assembly enables the development of new innovative light-weight, flexible assembly systems, targeting high level fuselage and wing assembly. Principles and technologies needed for generating electromagnetic and vacuum forces for a prototype assembly system are discussed in this paper.
Sarh, Branko
Agent Based Scheduling in Production System2001-01-322510/1/2001
The objective in a flexible manufacturing system is an optimal system resources scheduling. The production scheduling of such system may be resolved by a set of individual agents, which can work parallel and their coordination may bring a more effective way to find an optimal solution. Criteria for the optimal solution may be created on the time or economical (cost) basis but each may have a different priority depending on each situation. In this paper we will analyse an approach to find a feasible schedule of all products, which could minimize their costs and satisfy all constrains jointed with each product.
Frankovic, B., Dang, T. T., Moeller, K.
The Presence of Bifurcation in a Closed-Loop Discrete Control of a Flexible Benchmark Plant analised from the Jury Stability Criterion2001-01-39633/5/2001
Many interesting phenomena occur when the discrete control is applied over a flexible structure like the aliasing and hidden oscillations. In this work a particular phenomenon called our attention because was a bit strange: increasing the sampling period of a discrete proportional plus derivative closed-loop control (by Tustin or Bilinear method) over a harmonic oscillator (our flexible benchmark plant) we noted that happened regions of stability and instability. Initially we imagined that from some high value of sampling period this control system would instable and it stay instable. This work study analytically this phenomenon and show graphically this bifurcation.
Tredinnick, Marcelo R. A.C., de O. e Souza, Marcelo Lopes, Gadelha de Souza, Luiz C.
Applying Construction Automation Research to Extraterrestrial Building Projects2000-01-24657/10/2000
In this paper, the authors give a brief overview of past construction automation research, including practical applications, and report on current efforts which attempt to increase efficiency, flexibility, autonomy, and architectural quality into the automated erection of habitable spaces. Current research includes genetic programming-enhanced design, the use of shape grammars for automatic layout of parametric spaces, the use of kit-of-parts concepts for quantified assembly, and concepts for efficient packing and shipping of building components and construction robots for automated deployment onsite. The paper concludes with a discussion of possibilities for applying terrestrial automated construction research and design concepts to building processes in hostile environments. A building type is proposed for the initial construction or extension of the First Mars Outpost, which includes preliminary discussions and design studies on parametric pneumatic building modules, site preparation and placement, and robotic construction equipment.
Howe, A. Scott, Howe, Jeffrey W.
The Production System Design and Deployment Framework1999-01-16445/11/1999
This session keynote paper presents a framework for designing and deploying production systems. The framework enables the communication and determination of objectives and design solutions from the highest level to the lowest level of a manufacturing enterprise. The design methodology ensures that the physical implementation, called Design Parameters (DPs), meets the objectives or Functional Requirements (FRs) of the production system design. This paper presents a revolutionary approach to determine the objectives and the implementation of a “lean” production system design for a manufacturing business as guided by the design axiom of independence.
Cochran, David S.
Human Centered Manufacturing: a Necessity for Enhancing Productivity and Competitiveness1999-01-16054/20/1999
This paper argues in favor of a human-centered (anthropocentric) approach to modern manufacturing. The bases for these arguments are: (a) worker deskilling and creativity issues, (b) economics, and (c) unresolved problems in automation, such as software reliance and costs. Detailed arguments are avoided owing to space limitations. Finally, some issues confronting human-centered manufacturing are raised.
Mital, Anil, Pennathur, Arun
The Lean and Agile Manufacturing Model1999-01-16114/20/1999
The Lean and Agile Manufacturing Simulation Model simulates the concepts of lean and agile manufacturing. A “live” working factory model is used to contrast the operating styles between a typical “mass production” plant and a “lean” production plant. Participants work as a team to plan, fabricate, manufacture, assemble, and ship two types of products using three common manufacturing processes - Traditional Mass Production (Push), Just-In-Time Manufacturing (Pull), and Cellular Manufacturing (Cell). Model functions include; warehousing, fabrication, WIP storage, assembly, inspection, accounting and shipping utilizing a miniature factory model, complete with tools, fixtures, materials and shop floor paperwork transactions. The model initially utilizes a traditional Material Requirements Planning (MRP) based scheduling approach to operate the factory. Through the application of lean production concepts, participants learn how to re-engineer the factory by applying various lean and agile techniques that include: Visual Factory Techniques Design For Manufacturing (DFM) One-Piece Work Flow Just-In-Time Delivery Integrated Supply Chain Logistics Key Performance Measures & Controls
Frech, Steven, Piciacchia, Roy
Wing Assembly System for British Aerospace Airbus for the A3209821519/15/1998
British Aerospace needed an automated wing riveting system for fastening the A320 wing sections. The E4000 Wing Riveting System was designed and installed at their Airbus factory in Chester, UK and is now in production. It uses a five axis solid yoke with workheads on each end of the yoke. It accurately installs both rivets and lockbolts over the entire wing panel, including offset areas.
Zieve, Peter, Smith, Andrew
Wing Manufacturing: Next Generation9856017/31/1998
Due to the part size and technological limitations of the available assembly equipment, traditional wing manufacturing has consisted of a three stage process. Parts are first manually tacked together in an assembly jig, They are then removed from the jig, rotated horizontally and craned into an automated fastening machine. Finally they are removed from the fastening machines and craned to a third station where the manual tacks are removed and the parts are prepped for final wing box assembly. With the advent of electromagnetic riveting (EMR) and the traveling yoke assembly machine this traditional approach has been replaced with single station processing. Wing panels and spars can now be automatically tacked together under continuous clamp up in their assembly jigs using EMR. This eliminates the requirement for disassembly, debur and cleaning required with the manual process. While the wing panels and spars remain rigidly held in their flying configuration by the assembly jig they are fastened with an articulated yoke. Tool tables are mounted to the bottom of a solid yoke to insure opposing head alignment. Assembly jigs are lined end to end to allow one machine to service multiple stations and further enhance productivity. In addition to efficiency improvements this new process improves product quality. The elimination of multiple crane moves and the manual tracking process greatly reduces the potential in process damage to the components. Since the parts are held rigidly in their assembly jigs during the entire fastening process, final panel and spar definitions are improved. Further, the use of EMR riveting has been demonstrated to provide superior fatigue to conventional process. Two recent case studies of this approach are presented. The E4000 assembly system went into production on the A320 program in early 1998. The E5000 spar assembly system, ASAT4, goes into production in mid 1998. These two system are evolutions of earlier systems introduced on the Airbus A340 and Boeing 767 programs respectively. These two systems include a number of new enhancements over past systems and demonstrate approaches to both high and low rate aircraft production.
Hartmann, John, Zieve, Peter
Items per page:
1 – 50 of 87