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Article
Publication date: 11 May 2020

Enrique Gallegos-Nieto, Hugo I. Medellin-Castillo, Yan Xiu-Tian and Jonathan Corney

This study aims to present a new haptic-enabled virtual assembly system for the automatic generation and objective assessment of assembly plans. The system is intended to be used…

213

Abstract

Purpose

This study aims to present a new haptic-enabled virtual assembly system for the automatic generation and objective assessment of assembly plans. The system is intended to be used as an assembly planning tool along the product development process.

Design/methodology/approach

The generation of product assembly plans is based on the analysis of the assembly movements and operations performed by the user during the virtual assembly execution, and the objective assessment of product assembly is based on the definition and computation of new proposed assembly metrics.

Findings

To evaluate the system, a case study corresponding to the assembly of a mechanical component is presented and analyzed. The results demonstrate that the proposed system is an effective tool to plan and evaluate different product assembly strategies in a more practical and objective approach than existing assembly planning methods.

Research limitations/implications

Although the virtual assembly execution time is larger than the real assembly execution time, the assembly planning and evaluation results provided by the system are valid. However, the development of higher performance collision detection algorithms is needed to reduce the simulation time.

Originality/value

The proposed virtual assembly system is able to not only simulate and automatically generate assembly plans but also objectively assess them from the virtual assembly task execution. The introduction and use of several assembly performance metrics to objectively evaluate assembly strategies in virtual assembly also represents a novel contribution.

Details

Assembly Automation, vol. 40 no. 4
Type: Research Article
ISSN: 0144-5154

Keywords

Available. Content available
Article
Publication date: 1 December 2005

Jonathan Corney

83

Abstract

Details

Assembly Automation, vol. 25 no. 4
Type: Research Article
ISSN: 0144-5154

Keywords

Available. Content available
Article
Publication date: 1 December 2003

Jonathan Corney

339

Abstract

Details

Assembly Automation, vol. 23 no. 4
Type: Research Article
ISSN: 0144-5154

Keywords

Available. Content available
Article
Publication date: 1 December 2005

Jonathan Corney

876

Abstract

Details

Assembly Automation, vol. 25 no. 4
Type: Research Article
ISSN: 0144-5154

Keywords

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Article
Publication date: 1 December 2005

Robert Bogue

To describe a new vision‐based co‐ordinate measuring machine (CMM) developed in France by ActiCM, which has undergone successful trials with car maker Renault.

600

Abstract

Purpose

To describe a new vision‐based co‐ordinate measuring machine (CMM) developed in France by ActiCM, which has undergone successful trials with car maker Renault.

Design/methodology/approach

The vision‐based CMM uses intelligent vision devices (IVDs) which are mounted on a robot arm. Each IVD has two high‐definition CCD cameras, a visible LED illumination source and a white light projector. Up to eight sensors can work simultaneously on the same part which the IVDs' cameras can image from two different and known positions. These two views are then geometrically manipulated by the device software using photogrammetry to extract 3D data.

Findings

Trials at a Renault car production plant have shown that the system can validate a car's body shape in significantly less time than is possible with conventional CMMs. The time for a 2,000‐element validation has been reduced from around 10 to 2 h, with a dimensional accuracy of 300 μm.

Originality/value

This illustrates that vision‐based CMMs are able to reduce dramatically the time taken to validate a car's body shape whilst maintaining the same accuracy as conventional CMMs.

Details

Assembly Automation, vol. 25 no. 4
Type: Research Article
ISSN: 0144-5154

Keywords

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Article
Publication date: 1 December 2005

Deon de Beer, Gerrie Booysen, Ludrick Barnard and Michèle Truscott

The paper examines whether additive manufacturing can deliver durable injection‐moulding tools – fast, reliable, accurate and economic. Researchers from the Central University of…

1084

Abstract

Purpose

The paper examines whether additive manufacturing can deliver durable injection‐moulding tools – fast, reliable, accurate and economic. Researchers from the Central University of Technology, Free State (CUT), South Africa, are involved in rapid prototyping (RP) applications‐based research, simultaneously using results to support small‐ and medium‐sized enterprises (SMEs) on a national basis – both with contract research and technology transfer[1]. SMEs in South Africa involved in product development, are often hampered by economies of scale. Many new products simply disappear in the product development valley of death, partly due to manufacturing costs and limited product development budgets. RP has been used extensively by Technimark, one of the CUT's industrial partners, to evaluate and verify designs in various design stages. To remain competitive in the global market, Technimark and the CUT often have to apply RP directly as the manufacturing method. The paper discusses the use of RP to support (accelerated) limited production of moulded plastic parts.

Design/methodology/approach

The hypothesis is to use additive manufacturing for direct production of injection‐moulding tooling, subject to time, cost and quality constraints.

Findings

A case study where both development costs as well as lead‐time forced our industrial partner to trial Alumide as a tooling medium is discussed.

Originality/value

The paper introduces a new rapid tooling material, which may be of cost and time benefit to the product development and plastic injection‐moulding fraternity.

Details

Assembly Automation, vol. 25 no. 4
Type: Research Article
ISSN: 0144-5154

Keywords

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Article
Publication date: 1 December 2005

Joel Quincieu, Chris Robinson, Brent Stucker and Todd Mosher

This paper illustrates an effective application of rapid prototyping (RP) to produce a high definition polymer model of a satellite structure prior to final machining of the…

1859

Abstract

Purpose

This paper illustrates an effective application of rapid prototyping (RP) to produce a high definition polymer model of a satellite structure prior to final machining of the aluminum panels. The benefits when using this type of model in the design and assembly stages of satellite fabrication make clear that RP can and should play an important role in the design and fabrication of small satellite structures.

Design/methodology/approach

Selective laser sintering was utilized to produce a full‐scale model of a novel modular small satellite structure. This model was then used as a tool for quality control, fit check, assembly process verification, mock‐up, and as a model for manufacturing tooling design.

Findings

This case study illustrates that the use of RP to create a model early in the design cycle is beneficial from a cost and time perspective even when applied to a product which will be produced in a quantity of one. In addition, the merits of RP mesh well with modular designs and for applications where assembly and test tooling is required to validate the quality of a product.

Practical implications

This paper illustrates an effective use of RP in the satellite fabrication industry. The benefits described are generally applicable to other complex systems which need design validation early in the design cycle.

Originality/value

There are few examples of the effective application of RP to produce models, but not the final product, of a complex structure in the satellite and other industries where small lot production occurs.

Details

Assembly Automation, vol. 25 no. 4
Type: Research Article
ISSN: 0144-5154

Keywords

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Article
Publication date: 1 December 2005

Gregory J. Gibbons and Robert G. Hansell

The aim of this study is to demonstrate the benefit of design flexibility afforded by the Arcam free‐form fabrication process in the direct manufacture of injection mould inserts…

1314

Abstract

Purpose

The aim of this study is to demonstrate the benefit of design flexibility afforded by the Arcam free‐form fabrication process in the direct manufacture of injection mould inserts with complex cooling channel configurations and the process efficiency and quality gains achieved through using such inserts.

Design/methodology/approach

The manufacturing process of a flood cooled injection mould insert using the Arcam EBM S12 layered manufacturing process is presented. The insert is then evaluated against two other inserts (one un‐cooled and one traditionally baffle cooled (BC)) in the manufacture of test components, with the temperature of the insert and components recorded. The process conditions were adjusted (reduced cooling time) to increase the core and component temperatures to identify the operational limits of the inserts. Thermal imaging was employed to visualize the thermal distribution within the BC and flood cooled (FC) inserts.

Findings

The cooling efficiency of the FC insert was found to be significantly higher than that of the other two inserts, and the homogeneity of the heat distribution of the FC insert was more even than the BC insert. It was possible to manufacture non‐deformed components using the FC insert with zero cooling time (ejection immediately after removal of holding pressure), this was not possible with the BC insert.

Research limitations/implications

Provides a basis for the development of more efficient and thermally homogeneous inserts through the Arcam EBM process.

Practical implications

Provides a technology/process for the manufacture of highly efficient core inserts for injection moulding, offering the industry a competitive advantage through the potential for time and cost savings and higher quality components.

Originality/value

This is the first direct comparison of an Arcam EBM manufactured insert with complex cooling geometries against traditionally cooled inserts, particularly novel is the thermal imaging analysis of the cooling efficiency and distribution.

Details

Assembly Automation, vol. 25 no. 4
Type: Research Article
ISSN: 0144-5154

Keywords

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Article
Publication date: 1 December 2005

Ralf Becker, Andrzej Grzesiak and Axel Henning

Rapid manufacturing processes provide designers, mechanical and process engineers with a lot of chances and opportunities. It is necessary to show them, how their work and their…

2056

Abstract

Purpose

Rapid manufacturing processes provide designers, mechanical and process engineers with a lot of chances and opportunities. It is necessary to show them, how their work and their processes will change due to these new technologies.

Design/methodology/approach

Rapid manufacturing offers the chance to use the additive manufacturing processes to produce not just prototypes but advanced functional parts in small and medium quantities that can utilise a lot of design advantages that are provided by the process. We consult, as a German applied research institute, independent companies, helping them to introduce new product development and manufacturing processes, rethink the design of their products and to be aware of the advantages of upcoming manufacturing technologies.

Findings

Finds that a lot of products of today and especially of tomorrow could be produced by the new rapid manufacturing processes today and at competitive costs, if their design was adapted carefully using the new possibilities. New categories of products will come up too.

Research limitations/implications

The acceptance of rapid manufacturing as a new production technology is still limited by the available manufacturing systems. The number of released materials is still small and the accuracy of the parts and the building speed is still not exactly rapid. The mindset of the decision makers and of the R&D departments has to be radically changed. There is a lot of development going on, so the situation will change…

Originality/value

Aspects of a visionary scenario for future productions and products are shown and some examples are demonstrated based on a customised robot gripper.

Details

Assembly Automation, vol. 25 no. 4
Type: Research Article
ISSN: 0144-5154

Keywords

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Article
Publication date: 1 December 2005

S.H. Masood and W.Q. Song

Presents development and characterisation of a new metal/polymer composite material for use in fused deposition modelling (FDM) rapid prototyping process with the aim of…

4033

Abstract

Purpose

Presents development and characterisation of a new metal/polymer composite material for use in fused deposition modelling (FDM) rapid prototyping process with the aim of application to direct rapid tooling. The work represents a major development in reducing the cost and time in rapid tooling.

Design/methodology/approach

The material consists of iron particles in a nylon type matrix. The detailed formulation and characterisation of the thermal properties of the various combinations of the new composites are investigated experimentally. Results are compared with other metal/polymer composites used in rapid tooling.

Findings

The feedstock filaments of this composite have been produced and used successfully in the unmodified FDM system for direct rapid tooling of injection moulding inserts. Thermal properties are found to be acceptable for rapid tooling applications for injection moulding.

Originality/value

Introduces an entirely new metal based composite material for direct rapid tooling application using FDM RP system with desired thermal properties and characteristics. This will reduce the cost and time of manufacturing tooling inserts and dies for injection moulding.

Details

Assembly Automation, vol. 25 no. 4
Type: Research Article
ISSN: 0144-5154

Keywords

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