Stream-of-Variation Modeling—Part I: A Generic Three-Dimensional Variation Model for Rigid-Body Assembly in Single Station Assembly Processes

[+] Author and Article Information
Wenzhen Huang

Dept. of Mechanical Engineering, University of Massachusetts, Dartmouth, MA 02747whuang@umassd.edu

Jijun Lin

Engineering Systems Division, School of Engineering, Massachusetts Institute of Technology, Cambridge, MA 02139-4307jijunlin@mit.edu

Michelle Bezdecny

 GE Global Research Center, Niskayuna, NY 12309bezdecny@research.ge.com

Zhenyu Kong

School of Industrial Engineering and Management, Oklahoma State University, Stillwater, OK 74078james.kong@okstate.edu

Dariusz Ceglarek

Department of Industrial and Systems Engineering, University of Wisconsin-Madison, Madison, WI 53706darek@engr.wisc.edu

J. Manuf. Sci. Eng 129(4), 821-831 (Feb 28, 2007) (11 pages) doi:10.1115/1.2738117 History: Received August 14, 2006; Revised February 28, 2007

A stream-of-variation analysis (SOVA) model for three-dimensional (3D) rigid-body assemblies in a single station is developed. Both product and process information, such as part and fixture locating errors, are integrated in the model. The model represents a linear relationship of the variations between key product characteristics and key control characteristics. The generic modeling procedure and framework are provided, which involve: (1) an assembly graph (AG) to represent the kinematical constraints among parts and fixtures, (2) an unified method to transform all constraints (mating interface and fixture locators etc.) into a 3-2-1 locating scheme, and (3) a 3D rigid model for variation flow in a single-station process. The generality of the model is achieved by formulating all these constraints with an unified generalized fixture model. Thus, the model is able to accommodate various types of assemblies and provides a building block for complex multistation assembly model, in which the interstation interactions are taken into account. The model has been verified by using Monte Carlo simulation and a standardized industrial software. It provides the basis for variation control through tolerance design analysis, synthesis, and diagnosis in manufacturing systems.

Copyright © 2007 by American Society of Mechanical Engineers
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Figure 1

Examples of kinematics joints: (a) generalized fixture layout, (b) 3-2-1 fixture scheme

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Figure 2

Assembly chain in a single station

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Figure 3

Examples of kinematics joints

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Figure 4

Case study for validation

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Figure 5

(a) Relative errors of SOVA versus MC and (b) relative error of SOVA model versus 3DCS

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Figure 6

Mating feature plane at arbitrary position and orientation

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Figure 7

(a) Rotation as a vector and (b) rotation in coordinate systems B and D

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Figure 8

Point definition at mating planes




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