Modeling Variation Propagation of Multi-Station Assembly Systems With Compliant Parts

2003 ◽  
Vol 125 (4) ◽  
pp. 673-681 ◽  
Author(s):  
Jaime Camelio ◽  
S. Jack Hu ◽  
Dariusz Ceglarek
Keyword(s):  
Space Representation ◽  
Assembly Process ◽  
State Space Representation ◽  
Automotive Body ◽  
Compliant Assembly ◽  
Variation Propagation ◽  
Sources Of Variation ◽  
Dimensional Variation ◽  
Compliant Parts ◽  
And Performance

Products made of compliant sheet metals are widely used in automotive, aerospace, appliance and electronics industries. One of the most important challenges for the assembly process with compliant parts is dimensional quality, which affects product functionality and performance. This paper develops a methodology to evaluate the dimensional variation propagation in a multi-station compliant assembly system based on linear mechanics and a state space representation. Three sources of variation: part variation, fixture variation and welding gun variation are analyzed. The proposed method is illustrated through a case study on an automotive body assembly process.

Modeling Variation Propagation of Multi-Station Assembly Systems With Compliant Parts

2001 ◽  
Author(s):  
Jaime A. Camelio ◽  
S. Jack Hu ◽  
Dariusz J. Ceglarek
Keyword(s):  
Space Representation ◽  
State Space Representation ◽  
Automotive Body ◽  
Compliant Assembly ◽  
Variation Propagation ◽  
Sources Of Variation ◽  
Dimensional Variation ◽  
Compliant Parts ◽  
And Performance

Abstract Products made of compliant sheet metals are widely used in automotive, aerospace, appliance and electronics industries. One of the most important challenges for the assembly process of such compliant parts is the assembly dimensional quality, which affects product functionality and performance. This paper develops a methodology to evaluate the dimensional variation propagation in a multi-station compliant assembly system based on linear mechanics and a state space representation. Three sources of variation are analyzed, part variation, fixture variation and weld gun variation. The proposed method is illustrated through a case study on automotive body assembly.

Integration of in-plane and out-of-plane dimensional variation in multi-station assembly process for automotive body assembly

2019 ◽  
Vol 234 (6) ◽  
pp. 1690-1702
Author(s):  
Vahid Jandaghi Shahi ◽  
Abolfazl Masoumi
Keyword(s):  
Transfer Function ◽  
Sheet Metal ◽  
Assembly Process ◽  
Assembly Operation ◽  
Automotive Body ◽  
Variation Propagation ◽  
Out Of Plane ◽  
Dimensional Variation ◽  
Plane Direction ◽  
Assembly Operations

Automotive body assembly systems contain multiple operations in multi-station processes. One of the most critical challenges for such manufacturing systems is dimensional quality, which is affected by the accumulation and propagation of variation caused by manufacturing imperfections. However, sheet metal part compliancy behavior makes the variation modeling method extremely intricate when both rigid (in-plane) and compliant (out-of-plane) variations are considered. This paper develops a more accurate variation propagation model to describe dimensional variation of sheet metal assembly in multi-station assembly system through involving both the variation types simultaneously as well as the impacts of assembly operations on each other. In this methodology, three sources of deviations—non-ideal parts, fixture errors, and assembly operations effects—are taken into account. The variation generated in every assembly operation (placing, clamping, fastening, and releasing steps) and the variation propagation through station-to-station interaction (repositioning) are analyzed by the transfer function mechanism. In the in-plane direction, the stream of variation analysis is adopted to obtain the rigid transfer function to describe the position and orientation relationships between part and assembly element errors. For the simulation of part deformation during the assembly process in the out-of-plane direction, the compliant transfer functions are extracted by variation response methodology. A nested state space model is used to integrate the overall assembly variation by updating part geometry after each assembly operation. The capability of proposed method is illustrated through a case study on an automotive body side assembly process.

Variation Analysis for Compliant Assembly

2000 ◽  
Author(s):  
S. Jack Hu ◽  
Yufeng Long ◽  
Jaime Camelio
Keyword(s):  
Sheet Metal ◽  
Assembly Line ◽  
Assembly Process ◽  
Variation Analysis ◽  
Assembly Lines ◽  
Compliant Assembly ◽  
Single Station ◽  
Dimensional Variation ◽  
Sheet Metal Assembly

Abstract Assembly processes for compliant non-rigid parts are widely used in manufacturing automobiles, furniture, and electronic appliances. One of the major issues in the sheet metal assembly process is to control the dimensional variation of assemblies throughout the assembly line. This paper provides an overview of the recent development in variation analysis for compliant assembly. First, the unique characteristics of compliant assemblies are discussed. Then, various approaches to variation modeling for compliant assemblies are presented for single station and multi-station assembly lines. Finally, examples are given to demonstrate the applications of compliant assembly variation models.

Fault Failure Diagnosis for Compliant Assembly Structures Using Statistical Modal Analysis

2006 ◽  
Author(s):  
Prakash ◽  
D. Ceglarek ◽  
M. K. Tiwari
Keyword(s):  
Modal Analysis ◽  
Failure Diagnosis ◽  
Industrial Case Study ◽  
Mapping Procedure ◽  
Compliant Part ◽  
Compliant Assembly ◽  
Dimensional Variation ◽  
Compliant Parts ◽  
Deformation Modes

This paper develops a new diagnostics methodology for N-2-1 fixtures used in assembly processes with compliant parts. The developed methodology includes: (i) the predetermined CAD-based dimensional variation fault patterns model; (ii) data-based dimensional variation fault model; and (iii) the fault mapping procedure isolating the unknown fault. The CAD-based variation fault pattern model is based on the piece-wise linear bi-partitioning of compliant part into deformed (faulty) and un-deformed regions. Data-based dimensional variation fault models are based on the statistical modal analysis (SMA) which allow to model part deformation with varying number of deformation modes. It is proved in the paper that these independent deformation modes are equivalent to the CAD-based faults models obtained in (i). The fault mapping procedure allows to diagnose the unknown fault by comparing the unknown fault variation pattern obtained from the SMA model with one of the predetermined CAD-based fault patterns. One industrial case study from an automotive roof framing assembly illustrates the proposed method.

scholarly journals Assembly Variation Analysis of Aircraft Panels under Part-to-part Locating Scheme

2019 ◽  
Vol 2019 ◽  
pp. 1-15 ◽  
Author(s):  
Xia Liu ◽  
Luling An ◽  
Zhiguo Wang ◽  
Changbai Tan ◽  
Xiaoping Wang ◽  
...  
Keyword(s):  
Elastic Deformation ◽  
Assembly Process ◽  
Variation Analysis ◽  
Kinematic Theory ◽  
Statistical Variation ◽  
Variation Propagation ◽  
Fixed Part ◽  
Compliant Parts ◽  
Aircraft Panels

A typical aircraft panel is the assembly consisting of a multitude of thin and lightweight compliant parts. In panel assembly process, part-to-part locating scheme has been widely adopted in order to reduce fixtures. By this locating scheme, a part is located onto the pre-fixed part/subassembly by determinant assembly (DA) holes, and temporary fasteners (e.g., spring pin) are used for joining these DA hole-hole pairs. The temporary fasteners can fasten DA hole-hole pairs in the axial and radial directions of DA holes. The fastening in the radial directions is realized by the expansion of temporary fasteners. Although the usage of temporary fasteners helps reduce the positional differences between hole-hole pairs, their clamping forces thereby may lead to elastic deformation of compliant parts/subassemblies. Limited research has been conducted on such elastic deformation produced by temporary fastener and its influence on assembly dimensional quality. This paper proposes a novel rigid-compliant variation analysis method for aircraft panel assembly, incorporating the deformation in part-to-part locating process. Based on the kinematic theory and linear elasticity deformation assumption, the variation propagation through the locating process, as well as the entire assembly process of an aircraft panel, is formulated. Then, the statistical variation analysis is performed with Monte Carlo (MC) simulation. Finally, the proposed method is validated by a case study. The result shows the deformation in the part-to-part locating process significantly impacts the assembly variations, and our method can provide a more accurate and reliable prediction.

scholarly journals Design Evaluation of Multi-station Assembly Processes by Using State Space Approach

2002 ◽  
Vol 124 (3) ◽  
pp. 408-418 ◽  
Author(s):  
Yu Ding ◽  
Dariusz Ceglarek ◽  
Jianjun Shi
Keyword(s):  
State Space ◽  
Process Design ◽  
State Space Model ◽  
System Level ◽  
Space Representation ◽  
System Response ◽  
Design Evaluation ◽  
Assembly Process ◽  
Sensitivity Indices ◽  
Variation Propagation

This paper considers the problem of evaluating and benchmarking process design configuration in a multi-station assembly process. We focus on the unique challenges brought by the multi-station system, namely, (1) a system level model to characterize the variation propagation in the entire process, and (2) the necessity to describe the system response to variation inputs at both global (system level) and local (station level and single fixture level) scales. State space representation is employed to recursively describe the propagation of variation in such a multi-station process, incorporating process design information such as fixture locating layout at individual stations and station-to-station locating layout change. Following the sensitivity analysis in control theory, a group of hierarchical sensitivity indices is defined and expressed in terms of the system matrices in the state space model, which are determined by the given process design configuration. Implication of these indices with respect to variation control is discussed and a three-step procedure of applying the sensitivity indices for selecting a better design and prioritizing the critical station/fixture is presented. We illustrate the proposed method using the group of sensitivity indices in design evaluation of the assembly process of an SUV (Sport Utility Vehicle) side panel.

Variation Propagation Analysis on Compliant Assemblies Considering Contact Interaction

2006 ◽  
Author(s):  
Kang Xie ◽  
Lee Wells ◽  
Jaime A. Camelio ◽  
Byeng D. Youn
Keyword(s):  
Linear Response ◽  
Reduction Method ◽  
Linear Process ◽  
Manufacturing Processes ◽  
Assembly Process ◽  
Dimension Reduction Method ◽  
Propagation Analysis ◽  
Variation Propagation ◽  
Non Linear ◽  
Dimensional Variation

Dimensional variation is inherent to any manufacturing process. In order to minimize its impact on assembly products is important to understand how it propagates through the assembly process. Unfortunately, manufacturing processes are complex and in many cases highly non-linear. Traditional assembly models have represented assembly as a linear process. However, assemblies that include the contact between their components and tools show a highly non-linear response. This paper presents a new assembly methodology considering the contact effect. In addition, an efficient to predict output response is presented. The enhance dimension reduction method (eDR) is used to accurately and efficiently predict the statistical response of the assembly to variation on the input parameters.

Modeling Variation Propagation Based on State Space and its Application to Dimensional Variation Prediction in Shipbuilding

2011 ◽  
Vol 291-294 ◽  
pp. 2889-2892
Author(s):  
Xiang Rui Liu ◽  
Zhi Ying Zhang
Keyword(s):  
State Space ◽  
Assembly Process ◽  
Accuracy Control ◽  
Dimensional Control ◽  
Shipbuilding Industry ◽  
Locating Error ◽  
Variation Propagation ◽  
Dimensional Variation ◽  
Block Construction ◽  
Stream Model

Dimensional control is one of the most important challenges in shipbuilding industry. In order to predict assembly dimensional variation in block construction of shipbuilding, a variation stream model based on state space is presented in this paper, which can be further applied to accuracy control. Both locating error and welding deformation are taken into consideration in this model, and variation propagation mechanisms and accumulative rule in the assembly process are analyzed, then, a model is developed to describe the variation propagation throughout the assembly process, finally, an example of flat block construction is given to provide this method is effective and useful.

scholarly journals Design Evaluation of Multi-Station Assembly Processes by Using State Space Approach

2002 ◽  
Author(s):  
Yu Ding ◽  
Dariusz Ceglarek ◽  
Jianjun Shi
Keyword(s):  
State Space ◽  
Process Design ◽  
State Space Model ◽  
System Level ◽  
Space Representation ◽  
System Response ◽  
Design Evaluation ◽  
Assembly Process ◽  
Sensitivity Indices ◽  
Variation Propagation

This paper considers a problem of evaluating and benchmarking process design configuration in a multi-station assembly process. We focus on the unique challenges brought by the multi-station system: (1) a system level model to characterize the variation propagation in the entire process, (2) the necessity to describe the system response to variation inputs at both global (system level) and local (station level and single fixture level) scales. State space representation is employed to recursively describe the propagation of variation in such a multi-station process, incorporating process design information such as fixture locating layout at individual stations and station-to-station locating layout change. Following the sensitivity analysis in control theory, a group of hierarchical sensitivity indices is defined and expressed in terms of the system matrices in the state space model, which are determined by the given process design configuration. Implication of these indices with respect to variation control is discussed and a three-step procedure of applying the sensitivity indices to selecting a better design and prioritizing the critical station/fixture is presented. We illustrate the proposed method using the group of sensitivity indices in design evaluation of the assembly process of a SUV (Sport Utility Vehicle) side panel.

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