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RESEARCH PAPERS

Three-Dimensional Assembly Synthesis for Robust Dimensional Integrity Based on Screw Theory

[+] Author and Article Information
Byungwoo Lee

Product Realization Lab, GE Global Research, Niskayuna, NY 12309leeb@research.ge.com

Kazuhiro Saitou1

Department of Mechanical Engineering, University of Michigan, Ann Arbor, MI 48109-2125kazu@umich.edu

1

Author to whom correspondence should be addressed.

J. Mech. Des 128(1), 243-251 (Oct 24, 2004) (9 pages) doi:10.1115/1.1904048 History: Received May 10, 2004; Revised October 24, 2004

This paper presents a three-dimensional (3D) extension of our previous work on the synthesis of assemblies whose dimensional integrity is insensitive to the dimensional variations of individual parts. Assuming that assemblies can be built in the reverse sequence of decomposition, the method recursively decomposes a given product geometry into two subassemblies until parts become manufacturable. At each recursion, joints are assigned to the interfaces between two subassemblies to ensure the two criteria for robust dimensional integrity, in-process dimensional adjustability, and proper part constraints. Screw theory is utilized as a unified 3D representation of the two criteria. A case study on an automotive space frame is presented to demonstrate the method.

Copyright © 2006 by American Society of Mechanical Engineers
Topics: Manufacturing , Screws
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References

Figures

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Figure 1

Two box designs (a) without and (b) with adjustable height during assembly (see Ref. 1)

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Figure 2

Two box designs (a) without and with (b) proper constraints (see Ref. 1)

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Figure 3

Assembly sequences (a) without and (b) with in-process adjustability (modified from (Ref. 2)

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Figure 4

Assembly sequences where two dimensions are adjusted (a) at one step and (b) independently at two steps (modified from Ref. 2)

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Figure 5

Assembly sequences (a) without and (b) with proper constraints (see Ref. 1)

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Figure 6

(a) Product geometry of a beam based product and (b) its configuration graph

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Figure 7

An example of joint library for 3D beam based assemblies consisting of lap, butt, and lap-butt

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Figure 8

Representation of a screw using screw coordinates

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Figure 9

Lap (a) and lap-butt joint (b) of a beam based model and the local coordinate frames for twists

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Figure 10

A binary decomposition in product geometry (left) and configuration graph (right)

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Figure 11

Joint types assigned to the subconfigurations in Fig. 1. The “L→” represents a lap joint from a lower-index node to a higher-index node.

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Figure 12

A partial AND/OR graph of the 2D rectangular box in Fig. 1

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Figure 13

A frame structure with eight KCs

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Figure 14

(Top) Joint types for frame sturcture and (bottom) their graphical representation

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Figure 15

Half of optimal AND/OR graph of assembly synthesis for the product geometry in Fig. 1

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Figure 16

All assembly designs existing in the optimal AND/OR graph shown in Fig. 1, where corresponding assembly sequences can be found

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Figure 17

Passenger area of an automotive space frame

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Figure 18

Three optimal assembly designs synthesized for the automotive frame in Fig. 1

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Figure 19

A partial optimal AND/OR graph of assembly synthesis for the automotive space frame in Fig. 1

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