Towards computer-aided configuration design for the life cycle

In modern design, life-cycle concerns such as recycling and service are receiving increased attention. The configuration design phase, where the product and component structure is established, is of particular importance when designing for the life cycle. In this paper, the foundation for a CAD system supporting configuration design for the life cycle is presented. A prototypical CAD system, called CODA (Configuration Design of Assemblies), is under development based on this foundation. A discussion on the supported product and component representation is given, followed by a portrayal of some of the capabilities to support life-cycle design. Specifically, requirements are identified for the information needed to support design for assembly, disassembly, service, recycling, and reuse. A case study involving the (re)design of a hand-held tape recorder with respect to improved disassemblability and recyclability is utilized to highlight some of the capabilities of the current system. With the new product and component representation embodied in CODA, improved support over current CAD systems is provided for configuration design and life-cycle design assessments.     

An assembly oriented design framework for product structure engineering and assembly sequence planning

The paper describes a novel framework for an assembly-oriented design (AOD) approach as a new functional product lifecycle management (PLM) strategy, by considering product design and assembly sequence planning phases concurrently. Integration issues of product life cycle into the product development process have received much attention over the last two decades, especially at the detailed design stage. The main objective of the research is to define assembly sequence into preliminary design stages by introducing and applying assembly process knowledge in order to provide an assembly context knowledge to support life-oriented product development process, particularly for product structuring. The proposed framework highlights a novel algorithm based on a mathematical model integrating boundary conditions related to DFA rules, engineering decisions for assembly sequence and the product structure definition. This framework has been implemented in a new system called PEGASUS considered as an AOD module for a PLM system. A case study of applying the framework to a catalytic-converter and diesel particulate filter sub-system, belonging to an exhaust system from an industrial automotive supplier, is introduced to illustrate the efficiency of the proposed AOD methodology.     

Disassembly analysis through time estimation and other metrics

This paper examines the problem of assessing product ease of disassembly for recycling in light of the broader issue of manufacturability evaluation. The disassembly time estimation method outlined here is shown to provide one of several needed metrics for use during product design. Moreover, the ability to estimate process time provides the foundation upon which other metrics can be developed. The evaluation based on disassembly time is demonstrated on an electric drill example, and the difficulties associated with generating other disassemblability metrics are discussed.     

A PDES/STEP-based model and system for concurrent integrated design and assembly planning

Product data exchange and interfacing between different CAD/CAM systems are of great importance to the development of concurrent integrated design environments and computer integrated manufacturing systems. This paper presents a STEP-based method and system for concurrent integrated design and assembly planning. An integrated object model for mechanical systems and assemblies is first defined by a hierarchy of structure, geometry and feature. The structure is represented as a component-connector or joint multi-level graph with both hierarchical functional and assembly relations. These hierarchical relation models are then used for uniformly describing their causal relations both for assembly level and feature based single part level. The generic product assembly model is organized according to STEP, using mostly the entities of integrated resources and partly self-defined entities, which are necessary for design and assembly planning. Based on the generic product assembly model, STEP-based strategies and agent concepts are used for agent-based concurrent integration of design and assembly planning. A prototype system, consisting of a CAD system, a product modeling system, an assembly planning system, and an assembly evaluation system is developed, in which product data can be exchanged between these subsystems. Details about the implementation of the system are addressed. The integrated design and assembly planning system can support the introduction of a new product. The results of assembly planning are feedback to the stage of assembly design to improve on the design. A case study is carried out for assembly-oriented design of a gearbox, to illustrate the proposed approach and to validate the developed system.     

A framework for an automotive body assembly process design system

This paper describes a framework for an automotive body assembly process design system. It is a computer-aided intelligent system that can automatically generate the optimal joint types and assembly sequences for the best dimensional quality. The backbone of this system is the Case-Based Reasoning (CBR) methodology, which works by searching through a case library created from previous designs whose identifying features resemble the current case. Algorithms for initial solution generation, dimension chain generation, joint design selections, assembly sequence generation, and tolerance analysis and optimization are developed. Based on the framework, a software tool called Body Build Advisor, or BBA, is developed. The software allows process designers to analyze candidate assembly schemes and achieve the best assembly process design prior to having detailed knowledge of geometry of the parts, and thus is ideal for architectural process design. In addition, the system has the advantage of an open structure that can be easily modified and adapted to accommodate existing assemblies and to suggest areas for improvement.     

A framework for collaborative top-down assembly design

This paper presents a new system framework for collaborative top-down assembly design. Different from current computer-aided design (CAD) systems, the framework allows a group of designers to collaboratively conduct product design in a top-down manner. In our framework, a multi-level and distributed assembly model is adopted to effectively support collaborative top-down assembly design. Meanwhile, fine-granularity collaborative design functionalities are provided. First, the coupled structural parameters involved in the distributed skeleton models of the product can be collaboratively determined by the correlative designers based on fuzzy and utility theory. Second, agent based design variation propagation is achieved to ensure the consistency of the multi-level and distributed assembly model during the whole design process. Third, collaborative design of assembly interfaces between the components assigned to different designers is supported. The prototype implementation shows that our framework works well for supporting practical collaborative top-down assembly design.     

Designing educational software with students through collaborative design games: The We!Design&Play framework

In this paper, we present a framework for the development of collaborative design games that can be employed in participatory design sessions with students for the design of educational applications. The framework is inspired by idea generation theory and the design games literature, and guides the development of board games which, through the use of adequate stimuli, rules and props, facilitate students in extracting and expressing their needs, desires and prospects regarding future educational software. To evaluate the proposed framework three studies were conducted. The first study aimed at the design of a web learning platform with the participation of 62 undergraduate higher education students in 13 design sessions; in the second study, a structured design approach was employed (12 sessions, 54 students) with the same design objective for comparison reasons; in the third study, the framework was deployed for the design of an electronic assessment application so as to examine its applicability in different learning domains (8 design sessions, 28 students). Students were very positive regarding both their participation and experience with the design games, and the needs elicited. The games favored a quick, broad exploration of the design space and facilitated the elicitation of numerous diverse needs and ideas, almost twice as many as produced by the structured approach. They also facilitated the creation of an informal atmosphere and limited the effects of common social influences on idea generation, such as social loafing, evaluation apprehension and production blocking. The three studies indicated that the proposed framework may simplify the development and employment of effective and efficient participatory design sessions in educational settings.     

Collaboration Among Designers: Analysing an Activity for System Development

Workplace studies provide an important input to system development, yet there is no straightforward way of translating empirical results into requirements. This study contributes to the development of methods by reporting an activity theory based approach consisting of (i) field observations, (ii) modelling and (iii) a specific task analysis for system requirements. The research informed the further development of the Build-it system, a multi-user system designed to support co-located interaction between designers in engineering and architecture, and other stakeholders such as clients, operators, or inhabitants. The background research was conducted in four engineering companies and comprised of meeting observations, a questionnaire on design collaboration (n=94) and the analysis of 20 artefacts. The findings indicate that collaboration is of critical importance to the design process, and at least some of the tasks in engineering design could be supported by a system like Build-it. The task analysis for system requirements involved potential users from engineering but extended the scope to other domains, namely architecture and chemical process engineering (n=22). In all three domains a multi-user system like Build-it would be advantageous; however, the specific requirements varied more than expected. The study critically reflects on the use of generic concepts and the process of conducting research for the purpose of understanding work for design.     

Design for manufacture and design for ‘X’: concepts,applications, and perspectives

The implementations of design for assembly and design for manufacture (DFM) led to enormous benefits including simplification of products, reduction of assembly and manufacturing costs, improvement of quality, and reduction of time to market. More recently, environmental concerns required that disassembly and recycling issues should be considered during the design stages. The effort to reduce total life-cycle costs for a product through design innovation is becoming an essential part of the current manufacturing industry. Therefore, researchers begin to focus their attention on design for environment, design for recyclability, design for life-cycle (DFLC), etc. These studies are sometimes referred to as Design for X (DFX). Since the late 1990s, hundreds of papers have been published pertaining to DFX applications in manufacturing. Most of them are widely distributed over many different disciplines and publications. This makes it very difficult for one to locate all the information necessary for the application of DFX in manufacturing. A paper that can help researchers and practitioners applying this emerging technology is highly desirable. The objective of this paper is to present the concepts, applications, and perspectives of ‘DFX’ in manufacturing, thus providing some guidelines and references for future research and implementation.     

A design environment for laminated fiber-reinforced thick composite materials

The research described herein concerns the integration of several components of engineering software using a relational database. More specifically, a conceptual finite element material preprocessing system for laminated fiber-reinforced thick composite materials is studied. In this computer-aided analysis (CAA) system, a materials database is integrated with several software components, including commercially available finite element analysis (FEA) programs and preprocessors, and tools for the design of laminated composite materials. The system focuses on assembling, manipulating and using composite materials data, resulting in the transfer of 2-D and 3-D composite materials property data into a finite element analysis program. The system is life-cycle in nature, supporting a composite through testing, analysis and design. it offers great versatility in its ability to use raw ply data from any source, design layups, and generate laminate properties and FEA materials data files. Despite the fact that such integrated systems are not new in many domains, they have not been successfully introduced to the redlm of composite materials analysis and design. This outcome is due largely to the nature of the materials themselves and the overhead they bring to the development of a successful life-cycle model.     

Ontology-based assembly design and information sharing for collaborative product development

To realize a truly collaborative product design and development process, effective communication among design collaborators is a must. In other words, the design intent that is imposed in a product design should be seized and interpreted properly; heterogeneous modeling terms should be semantically processed both by design collaborators and intelligent systems. Ontologies in the Semantic Web can explicitly represent semantics and promote integrated and consistent access to data and services. Thus, if an ontology is used in a heterogeneous and distributed design collaboration, it will explicitly and persistently represent engineering relations that are imposed in an assembly design. Design intent can be captured by reasoning, and, in turn, as reasoned facts, it can be propagated and shared with design collaborators. This paper presents a new paradigm of ontology-based assembly design. In the framework, an assembly design (AsD) ontology serves as a formal, explicit specification of assembly design so that it makes assembly knowledge both machine-interpretable and to be shared. An Assembly Relation Model (ARM) is enhanced using ontologies that represent engineering, spatial, assembly, and joining relations of assembly in a way that promotes collaborative assembly information-sharing environments. In the developed AsD ontology, implicit AsD constraints are explicitly represented using OWL (Web Ontology Language) and SWRL (Semantic Web Rule Language). This paper shows that the ability of the AsD ontology to be reasoned can capture both assembly and joining intents by a demonstration with a realistic mechanical assembly. Finally, this paper presents a new assembly design information-sharing framework and an assembly design browser for a collaborative product development.     

并行环境下广义装配设计的集成框架

提出了以装配建模和变量设计为核心,以装配规划与仿真,装配分析和公差分析与综合等为支撑的广义装配设计的集成框架,该框架能在并行工程的环境下对产品设计进行信息集成和设计过程集成,形成自上而下的,各支撑系统模块间相互依存,相互评价的设计循环,从而提高产品的一次设计成功率。     

Intelligent design and planning of manual assembly workstations: A neuro-fuzzy approach

The design of manual assembly workstations, as with most forms of designs, is highly iterative and interactive. The designer has to consider countless constraints and solutions for contradictory goals. In order to assist the designer in design process, it is required to develop a new intelligent methodology and system. This paper develops a neuro-fuzzy hybrid approach to intelligent design and planning of manual assembly workstations. Problems, related to workstation layout design, planning, and evaluation, are discussed in detail. A fuzzy neural network is used to predict the ranges of anatomical joint motions and to design or adjust workstations and tasks. The neuro-fuzzy computing scheme is integrated with operator's posture analysis and evaluation. For training and test purposes, experiment is carried out to simulate assembly tasks on a multi-adjustable assembly workstation equipped with a flexible PEAK motion measurement and analysis system. The trained neural network is capable of memorizing and predicting the joint angles associated with a range of workstation configurations. Thus, it can also be used for the design/layout and on-line adjustment of manual assembly workstations. Thus, the developed system provides a unified, computational intelligent framework for the design, planning and simulation of manual assembly workstations.     

Extending the Ecological Interface Design process—Integrated EID

This article aims to extend the traditional Ecological Interface Design (EID) process. With the rapid pace of digitalization in technological systems, there is a need for a design process that can handle the systemic design goals and the experiential basis of interaction. Currently, the traditional EID is well-positioned to address these challenges. However, methodologically, it needs to be substantiated to make it accessible for designers, designing for novel arenas, such as Industry 4.0. Further, substantiating the design process will help designers, engineers, and human factors researchers with an accessible pathway that links the design brief to the final interface form. Therefore, this article delves into the “design” basis in the work of the Risø group and other prominent EID researchers and practitioners. In addition, it draws from a variety of themes in the discipline of design that addresses methodology. In particular, key insights are drawn from the design methods movement (1960s—); design, communication, and complexity from the Ulm school of design, 1953–1968; cognitive research conducted on designers and design activities; and finally, interaction design and communication design processes and models. All of these insights have been used syncretically to create the new integrated EID (iEID) process. This new design process consists of nine stages divided into three phases of divergence, transformation, and convergence, converting the initial design brief to the final interface. The steps of iEID are demonstrated using the example of interface design for a “digital twin” in the manufacturing sector.     

Enhancing disassembly and recycling planning using life-cycle analysis

Both the general public and governmental agencies highly prioritize resource optimization (energy and material) and environmental issues such as ozone, acid rain and global warming in the life-cycle context. Disassembly and recycling are also increasingly important in most industrial countries due to the significant increase in the quantity of used products being discarded. Disassembly of used products has been recognized as necessary to make recycling economically viable in current state-of-the-art reprocessing technology. This emerging trend requires incorporating environmental considerations into design strategies. This study presents a graph-based heuristic method for disassembly analysis of end-of-life products, which incorporates the Eco-Design concept. Product components and their assembly relationships from the bill of material BOM are adopted to split the graph into sub-graphs denoting modular sub-assemblies. The life-cycle analysis LCA is then used to analyze disassembly trees, from which a disassembly sequence can be derived. Designers can use the analytical results to evaluate the dis-assemblability and recyclability of products when they are designed.     

Knowledge intensive Petri net framework for concurrent intelligent design of automatic assembly systems

The integration of design and planning of flexible assembly system has been recognized as a tool for achieving efficient assembly in a production environment that demands assembly with a high degree of flexibility. This paper proposes a concurrent intelligent approach and framework for the design of robotic flexible assembly systems. The principle of the proposed approach is based on the knowledge Petri net formalisms, incorporating Petri nets with more general problem-solving strategies in AI using knowledge-based system techniques. The complex assembly systems are modeled and analyzed by adopting a formal representation of the system dynamic behaviors through knowledge Petri net modeling from the specifications and the analysis of those models. A template is first defined for a knowledge Petri net model, and then the models for assembly system individuals are established in the form of instances of the template. The design of assembly systems is implemented through a knowledge Petri net-based function–behavior–structure model. The research results show that the proposed knowledge Petri net approach is applicable for design, simulation, analysis and evaluation, and even layout optimization of the flexible assembly system in an integrated intelligent environment. The integration of assembly design and planning process can help reduce the development time of assembly systems.     

Integration of the STEP-based assembly model and XML schema with the fuzzy analytic hierarchy process (FAHP) for muti-agent based assembly evaluation

Assemblability analysis and evaluation plays a key role in assembly design, operation analysis and planning. In this paper, we propose an integrated intelligent approach and framework for evaluation of assemblability and assembly sequence for electro-mechanical assemblies (EMAs). The approach integrates the STEP (STandard for the Exchange of Product model data, officially ISO 10303)-based assembly model and XML schema with the fuzzy analytic hierarchy process for assembly evaluation. The evaluation structure covers not only the geometric and physical characteristics of the assembly parts but also the assembly operation data necessary to assemble the parts. The realization of the integration system is implemented through a multi-agent framework. Through integration with the STEP-based product modeling agent system, CAD agent system and assembly planning agent system, the developed assembly evaluation agent system can effectively incorporate, exchange, and share concurrent engineering knowledge into the preliminary design process so as to provide users with suggestions for improving a design and also helping obtain better design ideas. The applications show that the proposed approach and system are feasible. Received: July 2004 / Accepted: January 2006     

Automated sizing of automotive steering ball joints in parametric CAD environment using expert knowledge and feature-based computer-assisted 3D modelling

Ball joints used in the steering systems of vehicles are exposed to fluctuating loads, which can cause fatal accidents in case of failure. The design of ball joints is an iterative and time-consuming process. Even though the automotive industry is preparing for the era of autonomous self-steering vehicles, parts such as ball joints were not designed using a fully automated parametric design methodology. Recently, parametric design of automotive ball joints based on variable design methodology using knowledge and feature-based computer-assisted-3D modelling methods was studied. However, these studies do not give details of the interactive sizing process within the part and assembly module to determine the final dimensions for avoidance of fatigue failure.This work provides methods and discusses details of the configurable sizing of a ball joint assembly under the boundaries of the developed “parametric design platform”. The platform closes the software gap for the automated reconfiguration and sizing of the ball joint assembly using a three-dimensional (3D) modelling technique. The platform can parametrically change part, material, feature, geometry, assembly and dimension features in a programmable environment. It can also reconfigure the ball joint assembly model considering various structured data conforming to technical standards and reasoning mechanisms with “engineering and geometrical relations” provided in this work, and data gathering along the life cycle of a product. Parameterised 3D solid models and a knowledge base of ball joints are stored in a database, and then an evaluation process within the platform that is capable of sizing ball joints for infinite fatigue-life has been established to verify sizing. It demonstrates the practicability and validity of the automated sizing of a steering ball joint within a configurable design environment and with minimum human expert knowledge and interaction.     

Supporting management and maintenance of manufacturing knowledge in design automation systems

Many companies base their business strategy on customized products. To enable a high level of product adaptation in an engineer-to-order approach companies invest time and resources to develop design automation systems. Initially, when implementing a design automation system, the focus is on successfully developing a system that generates design variants based on different customer specifications (i.e. the execution of system embedded knowledge and system output). However, in the long run, two important aspects are the management and maintenance of the knowledge that governs the designs. Further, the increasing emphasis on deploying a holistic view of a product’s properties and functions implies an increasing number of life-cycle requirements. The knowledge to adapt the product to fulfil these requirements should also be used and consequently incorporated into the knowledge-base, allowing for correct decisions to be made. In a system for automated variant design, the implications on the product of these life-cycle requirements have to be expressed as algorithms, production rules and/or computational statements to be intertwined with the design calculations. The number of requirements can be significantly large, and the knowledge scattered over different application systems used for the realisation of the design automation system. This makes it difficult to manage and maintain the system as the product life-cycle environment changes and evolves.In this article, the focus is on the requirements related to manufacturing. For that, an approach for the modelling of manufacturing requirements, supporting both knowledge execution and information management, in systems for automated variant design is introduced. The approach has been applied and refined when developing a design automation system in cooperation with a company to demonstrate and verify the approach’s usability.     

Exploring teachers' use of TPACK in design talk: The collaborative design of technology-rich early literacy activities

Research shows the benefits of collaborative design activity by teachers are that in their conversations (design talk) they develop technological pedagogical content knowledge (TPACK). While more and more teachers engage in collaborative design, little is known about how they use TPACK during design. The main question of this study was: “What is the nature of design talk of a group of teachers during the design of technology-rich early literacy activities?” Using a holistic case study on design talk, the analysis focused on the topics that were under discussion and how these topics were discussed. Three phases of coding were applied: (a) how design represents any of the seven domains of TPACK knowledge (Pedagogical, Content, Technological, Technological Pedagogical, Technological Content, Pedagogical Content or Technological Pedagogical Content Knowledge); (b), how design talk represented three aspects of reasoning (external priorities, practical concerns and existing orientations); and (c), and what levels of inquiry are reached (no-depth; sharing ideas; analyze; and plan). Findings indicate that design talk reflects moments in which teachers reach deeper levels of inquiry. Findings also indicate that TPACK was mostly linked to expressing practical concerns. However when engaging in deeper inquiry, teachers existing orientations featured more prominently in the conversations. External priorities hardly seemed to play any role in design talk. Also, when addressing TPACK or PCK, design talk mostly reflects practical concerns. Pedagogy was addressed not as a single knowledge domain, rather in conjunction with the other two domains. Practical implications are discussed regarding how to support teachers during collaborative design.