Collaborative Product Assembly Design and Assembly Planning. Methodologies and Applications

205 Pages·2011·6.109 MB·English

by  C. Lu, J.Y.H. Fuh and Y.S. Wong (Auth.)

Collaborative Product Assembly
Design and Assembly Planning
Collaborative Product
Assembly Design and
Assembly Planning
Methodologies and applications
C L , J Y H F
ONG U ERRY ING SI UH
Y S W
AND OKE AN ONG
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First published 2011, Woodhead Publishing Limited
© C. Lu., J. Y. H. Fuh and Y. S. Wong, 2011
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Woodhead Published ISBN 978 0 85709 053 9
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List of fi gures, tables and lists
Figures
1.1 Collaborative assembly design 3
3.1 Feature-based hierarchical co-assembly
representation 36
3.2 Structure of assembly features 38
3.3 Assembly consisting of three parts 40
3.4 Assembly feature between Part 1 and Part 2 40
3.5 Assembly feature between Part 1 and Part 3
(Condition 1) 41
3.6 The design modifi cation results (1) 42
3.7 Assembly feature between Part 1 and Part 3
(Condition 2) 42
3.8 The design modifi cation results (2) 43
3.9 XML fi le defi ning the assembly information
of each feature in Part 2 48
3.10 Parsing result of XML fi le (in Figure 3.9)
when <featureID> ‘201’ and ‘202’ are modifi ed 49
3.11 XML fi le defi ning the assembly information
of each feature in Part 1 50
3.12 Parsing result of the XML fi le in Figure 3.11 51
3.13 Flowchart of whole XML fi les parsing process 51
3.14 The proposed system framework 52
3.15 Simplifi ed gearbox assembly displayed in
design Client 1 54
3.16 Some features of each part 55
3.17 Part 1 in design Client 1 56
xi
Collaborative Product Assembly Design and Assembly Planning
3.18 XML fi le 1 56
3.19 XML fi le 2 57
3.20 Java Applet browsed in Client 1 for submitting
design modifi cation information 57
3.21 Web page 1 58
3.22 Web page 2 58
3.23 Part 2 in design Client 2 59
3.24 Part 3 in design Client 3 60
3.25 Modifi ed Part 2 in design Client 2 60
3.26 The design modifi cation propagation
triggered by modifi cation of F and F 61
11 12
3.27 Updated gearbox assembly in design Client 1 62
4.1 Geometric deviation in six DOFs of the
cylindrical feature 67
4.2 Geometric deviation in restricted DOF of the
cylindrical feature in assembly 68
4.3 Geometric deviation in six DOFs of the
planar feature 69
4.4 Geometric deviation in restricted DOFs of
the planar feature in assembly 69
4.5 Perpendicularity tolerance of planar feature
from datum A 70
4.6 Tolerance zone of a planar feature 70
4.7 Perpendicularity tolerance of cylindrical
feature from datum B 71
4.8 Tolerance zone of the axis of cylindrical feature 72
4.9 Clearance in assembly 73
4.10 Probability of normal distribution 74
4.11 Normally distributed clearance zone 76
4.12 Peg-hole mating condition 1a 77
4.13 Clearance zone 1a 77
4.14 Peg-hole mating condition 2a 78
4.15 Clearance zone 2a 79
4.16 Rectangular key-hole mating condition 1b 80
xii
List of fi gures, tables and lists
4.17 Clearance zone 1b 81
4.18 Geometric deviation around Z axis 81
4.19 Possible maximum δz 82
4.20 Rectangular key-hole mating condition 2b 83
4.21 Clearance zone 2b 83
4.22 Assembly consisting of 12 parts 87
4.23 Tolerance design in Part 1 88
4.24 Tolerance design in Part 2 88
4.25 Tolerance design in Part 4 89
4.26 Tolerance design in Part 3 89
4.27 Assembly sequence 1 90
4.28 Concentricity in Part 3 94
4.29 Distance between O and O 97
2ʹ 3ʹ
4.30 Distance between O and O 97
4 4ʹ
4.31 A drive assembly consisting of 21 parts 101
4.32 Tolerance design of Part 5 102
4.33 Tolerance design of Part 20 103
4.34 Tolerance design of Part 12 104
4.35 Tolerance design of Part 16 104
4.36 Tolerance design of Part 4 105
4.37 Tolerance design of Part 1 105
5.1 Non-dominated solutions in a two-objective
optimization problem 111
5.2 Search directions toward Pareto frontier 112
5.3 Optimized search directions toward Pareto
frontier 113
5.4 Linear membership functions to derive
the fuzzy weights 115
5.5 Order Crossover procedure 119
5.6 Insertion mutation procedure 120
5.7 Assembly consists of seven parts 125
5.8 Evolving steps of the fi tness function for
a solution 129
5.9 An assembly consisting of 22 parts 130
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Collaborative Product Assembly Design and Assembly Planning
5.10 Part 1 131
5.11 Part 2 131
5.12 Part 3 132
5.13 Part 4 132
5.14 Fuzzy weight parameter input dialog box 133
5.15 Fitness value in different generations in
four tests 141
6.1 Redesign guidelines from the assembly
planning results 151
6.2 Limited assembly orientation of Part 2 to Part 1 156
6.3 Redesigned Part 13a and Part 13b in assembly 157
6.4 Assembly with one assembly orientation change 158
6.5 Assembly without assembly orientation change 158
6.6 Original design of Part 14 160
6.7 Redesigned Part 14 160
6.8 Redesigned assembly operation type 162
6.9 Original design of Part 13 162
6.10 Redesigned Part 13 162
7.1 System framework for collaborative assembly
planning 166
7.2 The workfl ow of collaborative assembly
planning 169
7.3 A motor table assembly 175
7.4 User login 176
7.5 Part selection for sub-assembly 2 176
7.6 Feasibility check on sub-assembly task
assignment 178
7.7 Part reselection for sub-assembly 2 178
7.8 Feasibility check on sub-assembly task
reassignment 179
7.9 Parameter selection for sub-assembly No. 1 180
7.10 Assembly planning results showing evolved
non-dominated solutions 181
7.11 Assembly sequence of a non-dominated solution 181
xiv
List of fi gures, tables and lists
Tables
4.1 The dimension and tolerance of each feature
in assembly 90
5.1 Tool type and operation type of each part in
the assembly 135
5.2 GA parameters in test 1 135
5.3 Twenty trial results in test 1 135
5.4 Test results of a trial in test 1 136
5.5 GA parameters in test 2 136
5.6 Fuzzy weight parameters in test 2 136
5.7 Twenty trial results for fuzzy weights setting
with Δμ (cid:2) Δμ (cid:2) 0.3 137
1 2
5.8 Test results of a trial in test 2 138
5.9 Fuzzy weight parameters in test 3 138
5.10 Twenty trial results for fuzzy weights setting
with Δμ (cid:2) Δμ (cid:2) 0.5 138
1 2
5.11 Test results of a trial in test 3 139
5.12 Fuzzy weight parameters in test 4 139
5.13 Twenty trial results for fuzzy weights setting
with Δμ (cid:2) Δμ (cid:2) 0.8 140
1 2
5.14 Test results of a trial in test 4 140
5.15 Tool type and operation type of each part
in the assembly 143
5.16 Twenty trial results for four tests 143
5.17 Test results of a trial in test 4 143
Lists
3.1 XML format defi ning design parameters of
each feature in a Part 45
3.2 XML format defi ning the assembly information
of each feature in a Part 47
xv
Acknowledgements
The authors would like to thank Dr Glyn Jones, the managing
director of Chandos Publishing, for his invitation to submit
the book proposal, and his kind advice and support for this
work.
The authors are grateful for the support of the School of
Mechatronics Engineering of the University of Electronic
Science and Technology of China, and the Department of
Mechanical Engineering of the National University of
Singapore in the writing of the book. Many thanks to our
university colleagues for their direct and indirect assistance
and contributions to the content and development of the
manuscript.
In particular, the authors greatly appreciate their family
members for their spiritual encouragement and emotional
support.
C. Lu, Chengdu, P.R. China
J. Y. H. Fuh, Singapore
Y. S. Wong, Singapore
xvii
Preface
Product assembly design and assembly planning are two
important steps during product development. Effective and
rapid assembly design and assembly planning can obviously
shorten the product development life cycle, reduce the
development cost, and thereby help manufacturers to
enhance profi t. With the fast development of Internet and
computer technologies, the traditional assembly design and
assembly planning have evolved to collaborative assembly
design and assembly planning in an Internet-enabled working
environment to speed up the product development process.
Therefore, research to facilitate and realize collaborative
assembly design and assembly planning in an Internet-
enabled environment has attracted much attention in the
past decade. Based on the research work of the authors in the
past few years, this book presents several newly developed
methodologies and applications for collaborative assembly
design and assembly planning to improve the effi ciency of
product development in a collaborative design environment.
This book targets researchers in the academy and engineers
in industry who want to know more about the collaborative
product development technologies. It can also serve as a
reference book for graduate students researching product
design and assembly.
xix