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.

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.

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.

Lubrication of Aluminium Sheet Metal within the Automotive Industry

2005 ◽  
Vol 6-8 ◽  
pp. 551-558 ◽  
Author(s):  
M. Meiler ◽  
H. Jaschke
Keyword(s):  
Sheet Metal ◽  
Raw Materials ◽  
Body Parts ◽  
Assembly Process ◽  
Paint Shop ◽  
Production Chain ◽  
Aluminium Sheet ◽  
Automotive Body ◽  
Advantages And Disadvantages ◽  
Dry Film

The production of automotive body parts and panels is a very complex process, starting with the raw materials and ending in the paint shop. Due to the fact that aluminium sheet metal has to be lubricated before forming, all of the following processes have to be considered. Lubricants, such as oils, dry-film lubricants or recently introduced hotmelts have to protect the material’s surface, reduce friction whilst drawing the panels and should not compromise further treatments [1]. Different types of lubricants show different characteristics. This difference is especially noticeable when comparing liquid and dry-film lubricants. As dry-film lubricants do not run off the blanks’ surface and are distributed homogeneously, they show different tribological properties compared to conventional liquid lubricants. The effect on friction of aluminium sheet metal is shown through several basic experiments [2, 3]. In addition, the paper shows the effect of further operations within the production chain. The advantages and disadvantages not only for drawing, but also for assembly lines and the painting process are described in this paper. Assembly issues are carried out on stability testings of riveted and clinched assemblies. These trials show how the assembly process is affected by different proceedings. The fact that every car body has to be completely free of grease before painting, signifies the necessity to get lubrication off the car body’s surface before painting. The interactions between lubrication and paint shop are shown on typical process parameters. Most typical characteristics considering bonding and riveting were tested out on a hood assembly of the current BMW 7-series. In addition to that, experiences made in the press shop at BMW’s Dingolfing plant were figured out and carried over to a long-term strategy of pre-lubrication of aluminium sheet metal. This includes adhesive compatibility as well as the above mentioned assembly process.

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.

Dimensional Error Compensation in Compliant Assembly Processes Using Virtual Assembly Training

2008 ◽  
Author(s):  
Kang Xie ◽  
Jaime A. Camelio ◽  
L. Eduardo Izquierdo
Keyword(s):  
Optimal Control ◽  
Sheet Metal ◽  
Error Compensation ◽  
Feedforward Control ◽  
Virtual Assembly ◽  
Control Action ◽  
Variation Propagation ◽  
Iterative Sampling ◽  
Assembly Operations

Dimensional variation propagation and accumulation in multistage manufacturing processes are among the most important issues that affect quality. Although robust design and statistical process quality control help to reduce the effects of these problems, neither of these two methods can be used for instant variation reduction during assembly operations. This paper introduces a complete methodology for error compensation in compliant sheet metal assembly processes. The proposed methodology can be divided in two steps: (1) an off-line error control-learning module using virtual assembly models, and (2), an in-line control implementation using a feedforward control strategy. The off-line learning method focuses on determining the optimal control actions or corrections to a set of predefined deviations. Specifically, it utilizes a newly developed iterative sampling method based on Kriging fitting to efficiently determine an optimal control action. The in-line feedforward control uses measurements of incoming assembly components to select an appropriate pre-learned control action. Two case studies are presented; first, a mathematical case study is used as the empirical proof for the feasibility of the iterative sampling and fitting algorithm. Second, a simulation-based case study is used to illustrate the effectiveness of the proposed methodology to improve dimensional quality in assembly operations of compliant sheet metal parts.

Process-Based Assembly Technical Annotation Management in 3D Assembly Instruction

2013 ◽  
Vol 717 ◽  
pp. 742-748
Author(s):  
Jun Hao Geng ◽  
Xi Tian Tian ◽  
Bin Yang
Keyword(s):  
Time Sequence ◽  
Assembly Process ◽  
Antenna Feed ◽  
Assembly Quality ◽  
Satellite Antenna ◽  
Assembly Operation ◽  
Assembly Time ◽  
3D Assembly ◽  
Management Method ◽  
Assembly Operations

In order to instruct on-site workers to accomplish the assembly job fast and exactly, improve the assembly quality and efficiency, we proposed a management method for assembly technical annotation in 3D assembly instruction. This method maps 3D technical annotations to assembly operation and assembly time based on time sequence granularity, achieves the goal of showing assembly technical annotations based on assembly process. We demonstrated the effectiveness of this method with a satellite antenna feed components assembly process instance. The instance shows that this method can mark assembly technical annotations based on assembly process, and show the annotations in time sequence but not in assembly space. This will help on-site assembly workers to understand the assembly order fast and unambiguously, finish the assembly operations correctly.

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.

Compliant assembly variation analysis of sheet metal with shape errors based on primitive deformation patterns

2017 ◽  
Vol 232 (13) ◽  
pp. 2334-2351 ◽  
Author(s):  
Yunyong Li ◽  
Yong Zhao ◽  
Haidong Yu ◽  
Xinmin Lai
Keyword(s):  
Sheet Metal ◽  
Propagation Model ◽  
Surface Shape ◽  
Mode Analysis ◽  
Assembly Process ◽  
Variation Analysis ◽  
Compliant Assembly ◽  
Variation Propagation ◽  
Shape Errors ◽  
Deformation Patterns

In the compliant assembly of sheet metal, the performance of the product is highly related to the shape errors of surface. Therefore, variation analysis is generally required to reveal the influence principle of the components’ manufacturing variations on the surface shape errors of the product. The traditional compliant assembly variation analysis methods were used to build a variation propagation model based on characteristic points between parts and product without considering shape errors. In this paper, a new method based on primitive deformation patterns considering shape errors is proposed. The primitive deformation patterns of part can be obtained by natural mode analysis of ideal part, and the primitive deformation patterns of product can be calculated by the dynamic substructure method. The initial shape errors of part are decomposed into the individual contributions of primitive deformation patterns. Considering the force equilibrium relationship in assembly process, a variation propagation model is built based on the primitive deformation patterns between parts and product. This model reveals variation propagation in assembly process by the basic element of dimension error field (deformation patterns), which is convenient for evaluating the assembly quality. A case study on a panel parts assembly process is presented to demonstrate the proposed variation analysis method. The results show the effectiveness and accuracy of the proposed method compared with the method of finite element analysis conducted in commercial software ABAQUS.

Variation Propagation Analysis on Compliant Assemblies Considering Contact Interaction

2007 ◽  
Vol 129 (5) ◽  
pp. 934-942 ◽  
Author(s):  
Kang Xie ◽  
Lee Wells ◽  
Jaime A. Camelio ◽  
Byeng D. Youn
Keyword(s):  
Contact Interaction ◽  
Thermal Deformation ◽  
Linear Process ◽  
Assembly Process ◽  
Physical Processes ◽  
Propagation Analysis ◽  
Variation Propagation ◽  
Highly Nonlinear ◽  
Dimensional Variation

Dimensional variation is inherent to any manufacturing process. In order to minimize its impact on assembly products it is important to understand how the variation propagates through the assembly process. Unfortunately, manufacturing processes are complex and in many cases highly nonlinear. Traditionally, assembly process modeling has been approached as a linear process. However, many assemblies undergo highly complex nonlinear physical processes, such as compliant deformation, contact interaction, and welding thermal deformation. This paper presents a new variation propagation methodology considering the compliant contact effect, which will be analyzed through nonlinear frictional contact analysis. Its variation prediction will be accurately and efficiently conducted using an enhanced dimension reduction method. A case study is presented to show the applicability of the proposed methodology.

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