Stream-of-Variation (SOVA) Modeling II: A Generic 3D Variation Model for Rigid Body Assembly in Multistation Assembly Processes

[+] Author and Article Information
Wenzhen Huang

Department 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

Zhenyu Kong

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

Dariusz Ceglarek

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

J. Manuf. Sci. Eng 129(4), 832-842 (Mar 27, 2007) (11 pages) doi:10.1115/1.2738953 History: Received August 14, 2006; Revised March 27, 2007

A 3D rigid assembly modeling technique is developed for stream of variation analysis (SOVA) in multi-station processes. An assembly process is modeled as a spatial indexed state transition dynamic system. The model takes into account product and process factors such as: part-to-fixture, part-to-part, and inter-station interactions, which represent the influences coming from both tooling errors and part errors. The incorporation of the virtual fixture concept (Huang, Proc. of 2006 ASME MSEC) and inter-station interaction leads to the generic, unified SOVA model formulation. An automatic model generation technique is also developed for surmounting difficulties in modeling based on first principles. It enhances the applicability in modeling complex assemblies. The developed SOVA methodology outperforms the current simulation based techniques in computation efficiency, not only in forward analysis of complex assembly systems (tolerance analysis, sensitivity analysis), but it is also more powerful in backward analysis (tolerance synthesis and dimensional fault diagnosis). The model is validated using industrial case studies and series of simulations conducted using standardized industrial software (3DCS Analyst).

Copyright © 2007 by American Society of Mechanical Engineers
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Figure 1

Generic 3-2-1 fixture layout in GCS

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Figure 2

Coordinate transformation between mating planes

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Figure 3

Deviation from reorientation

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Figure 4

Deviation accumulation on part J at station i

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Figure 5

An assembly process with N stations

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Figure 6

Case study for validation

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Figure 7

PLP layout and shift schemes

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Figure 8

Floor-pan assembly in three assembly stations

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Figure 9

Relative error comparison SOVA versus 3DCS

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Figure 10

Relative errors in ND33 truck cab assembly analysis (3DCS versus SOVA)




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