Knowledge-based approach and system for assembly oriented design,Part I: the approach

Assembly is one of the most important stages for product development. Assembly-oriented design (AOD) is a new approach to designing assemblies, which uses a number of design and analysis tools to help the designer plan out and analyze candidate assembly schemes prior to having detailed knowledge of the geometry of the parts. Using this approach, many assembly schemes can be inexpensively evaluated for their ability to deliver the important characteristics of the final product. This research proposes a knowledge-based approach and develops an expert design system to support top-down design for assembled products. The presentation of research report is divided into two parts: the knowledge-based approach (Part I) and the knowledge-based expert design system (Part II). This paper is the first part of the report (Part I), which mainly proposes a knowledge-based approach and framework for intelligent assembly oriented design. The proposed approach focuses on the integration of product design, assemblability analysis and evaluation, and design for assembly with economical analysis. It differs from the existing approaches adopting the part-first bottom-up modeling technique, in which a hybrid model related to design problem-solving including function–behavior–structure model, feature-based geometric model, and parametric constraint model is used as a comprehensive intelligent framework for assembly modeling and design in a top-down manner from the conceptual level to the detailed level. Through the use of intelligent approach and framework, concurrent engineering knowledge can be effectively incorporated into the assembly design process, and a knowledge-based expert design system can be implemented.     

A spatiotemporal information management framework for product design and assembly process planning reconciliation

This paper introduces an innovative framework for product design and assembly process planning reconciliation. Nowadays, both product lifecycle phases are quasi concurrently performed in industry and this configuration has led to competitive gains in efficiency and flexibility by improving designers’ awareness and product quality. Despite these efforts, some limitations/barriers are still encountered regarding the lack of dynamical representation, information consistency and information flow continuity. It is due to the inherent nature of the information created and managed in both phases and the lack of interoperability between the related information systems. Product design and assembly process planning phases actually generate heterogeneous information, since the first one describes all information related to “what to be delivered” and the latter rationalises all information with regards to “how to be assembled”. In other words, the integration of assembly planning issue in product design requires reconciliation means with appropriate relationships of the architectural product definition in space with its assembly sequence in terms of time. Therefore, the main objective is to provide a spatiotemporal information management framework based on a strong semantic and logical foundation in product lifecycle management (PLM) systems, increasing therefore actors’ awareness, flexibility and efficiency with a better abstraction of the physical reality and appropriate information management procedures. A case study is presented to illustrate the relevance of the proposed framework and its hub-based implementation within PLM systems.     

Geometric skeleton computation enabling concurrent product engineering and assembly sequence planning

This paper introduces a novel modelling approach to geometric skeleton computation enabling concurrent product engineering and assembly sequence planning. Current engineering vision has recently moved towards new modelling and management paradigms to maintain competitive edges all along the product lifecycle. Consistent with concurrent engineering and design for X stakes, this recent shift promotes cross-X and knowledge-intensive philosophies in the product development process, principally focused on lifecycle engineering.The main objective of this research is to integrate assembly process engineering information and knowledge in the early phases of the product development process in a top-down and proactive manner, in order to provide a geometric skeleton-based assembly context for designers. The definition of the product and its related assembly sequence requires both the enhancement and the entire understanding of product relationships between the various product components, and its related assembly rationale. As a consequence, this new modelling approach highlights the need to integrate various stakeholders’ viewpoints involved in the beginning of the product lifecycle. In such a context, earlier work has achieved the early generation of an optimal assembly sequence in the product development process, before the product geometry is completely defined. As a result, previous research has made possible to control and bind the product modelling phase through an assembly oriented product structure.The aim of the proposed approach is to compute and define a geometric skeleton model based on product relational information and the early-defined assembly sequence. The proposed approach–called SKeLeton geometry-based Assembly Context Definition (SKL-ACD)–enables the control of the product modelling phase by introducing skeleton entities consistent with product relationships and assembly sequence planning information. A prototype application within a CAD tool has been developed for aiding geometric skeleton computation and generation. Lastly, an industrial case study is introduced to highlight the feasibility and the relevance of the proposed modelling approach.     

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     

Product relationships management enabler for concurrent engineering and product lifecycle management

The current competitive industrial context requires more flexible, intelligent and compact product lifecycles, especially in the product development process where several lifecycle issues have to be considered, so as to deliver lifecycle oriented products. This paper describes the application of a novel product relationships management approach, in the context of product lifecycle management (PLM), enabling concurrent product design and assembly sequence planning. Previous work has provided a foundation through a theoretical framework, enhanced by the paradigm of product relational design and management. This statement therefore highlights the concurrent and proactive aspect of assembly oriented design vision. Central to this approach is the establishment and implementation of a complex and multiple viewpoints of product development addressing various stakeholders design and assembly planning points of view. By establishing such comprehensive relationships and identifying related relationships among several lifecycle phases, it is then possible to undertake the product design and assembly phases concurrently. Specifically, the proposed work and its application enable the management of product relationship information at the interface of product-process data management techniques. Based on the theory, models and techniques such as described in previous work, the implementation of a new hub application called PEGASUS is then described. Also based on web service technology, PEGASUS can be considered as a mediator application and/or an enabler for PLM that externalises product relationships and enables the control of information flow with internal regulation procedures. The feasibility of the approach is justified and the associated benefits are reported with a mechanical assembly as a case study.     

Integrated knowledge-based Petri net intelligent flexible assembly planning

Automatic assembly planning is recognized as an important tool for reducing manufacturing costs in concurrent product and process development. A novel knowledge-based Petri net (KBPN) is defined, based on the incorporation of expert systems into the usual Petri nets, and used for a unified assembly knowledge representation scheme. A KBPN-approach integrated with a sequence generation algorithm is proposed for the modeling, planning, simulation, analysis and evaluation of the flexible assembly system (FAS). The developed KBPN-based assembly planning system (KAPS) can automatically adjust the deviations between the theoretical planning parameters and the process parameters of real assembly operations to guarantee the best strategies and plans (sequences) for flexible assembly. The research findings are exemplified with a simple assembly to show the effectiveness of the method.     

A hierarchical assembly knowledge representation framework and microdevice assembly ontology

Microdevice assembly knowledge is dispersed in different product development phases, such as assembly design, assembly simulation and assembly process, and a lot of essential knowledge is implicit and heterogeneous. It is difficult for researchers and computer-aided systems to share and reuse different assembly knowledge quickly and accurately, leading to inefficient and inaccurate assembly process planning. To integrate and structurally represent the assembly design knowledge, assembly simulation knowledge and assembly process knowledge of microdevice, this paper proposes a hierarchical assembly knowledge representation framework and develops a microdevice assembly ontology. There are four layers in the framework, including the organizational structure, the structural relationship, the assembly accuracy, and the process characteristics. The assembly design knowledge that is integrated involves the basic properties of the assembly object as well as the spatial, mating, and assembly relationship, etc. Assembly simulation knowledge refers to the permissible range of assembly force and contact force. Knowledge of assembly processes comprises assembly sequence and operating method of the part. The microdevice assembly ontology is developed based on METHONTOLOGY, and implemented with Protégé. The corresponding SWRL rules have been established to inference the implicit knowledge in assembly design. An ignition target assembly knowledge model based on the microdevice assembly ontology is constructed. In the assembly task of the ignition target, engineers can quickly and accurately access the required assembly knowledge from the ignition target assembly knowledge model, thus verifying the integrity and validity of the microdevice assembly ontology.     

An application of design space for assembly process reasoning to utilize current assembly plant resources for new product family members

A successful and profitable product platform strategy requires both product family architecture and assembly process reasoning. New product family member production cost and time can be significantly reduced by utilizing available assembly resources, which can be achieved through systematic assembly process reasoning. A method to utilize existing assembly plant resources, during the development of new product family members, requires comparing feasible assembly processes with exiting assembly plants. The set of feasible assembly sequences for a product family member is modelled by developing an assembly sequence design space, which is combinatorial in nature, and applying constraints on the space. Models that capture effects of constraints on these spaces, explicitly represent feasible regions, and efficiently enumerate designs within this space are investigated. The feasible space is then searched to determine new product assembly sequence that will require minimum change in the current assembly plant. An automotive front structure family is utilized to demonstrate application of the assembly sequence space to perform assembly reasoning to increase exiting assembly plant resource utilization.     

Design for assembly: A challenge for expert systems

Anticipating the increasing use of new and emerging computer technology in product engineering, design for assembly will be achieved effectively by applying advanced data processing technology and data management methods creating an assembly knowledge base and decision support system to close the loop between design, process planning and actual assembly. This paper introduces DFA and describes a strategic and conceptual approach to realise such a decision support system leading to an expert system for Design for Assembly in the near future.     

Knowledge-based approach and system for assembly-oriented design,Part II: the system implementation

Assembly is one of the most important stages for product development. Assembly-oriented design (AOD) is a new approach to designing assemblies, which uses a number of design and analysis tools to help the designer plan out and analyze candidate assembly schemes prior to having detailed knowledge of the geometry of the parts. Using this approach, many assembly schemes can be inexpensively evaluated for their ability to deliver the important characteristics of the final product. This research proposes a knowledge-based approach and develops an expert design system to support top-down design for assembled products. The presentation of research report is divided into two parts: the knowledge-based approach (Part I) and the knowledge-based expert design system (Part II). This paper is the second part of the report (Part II). It will focus on the development of knowledge-based expert design system for assembly oriented design. The knowledge-based assembly oriented design system, i.e., the assembly oriented design expert system (AODES) is constructed to integrate assembly modeling and design, assembly planning, assemblability analysis and evaluation within a concurrent engineering environment. This intelligent system is implemented by integrating object-oriented representation, constraint-based modeling, rule-based reasoning, truth maintenance, and interfacing to database management system and CAD module, in which fuzzy logic based knowledge representation and inference technique are also applied to deal with uncertain data and knowledge in the design process. The developed system differs from the existing systems adopting part-first bottom-up modeling technique, in which a comprehensive intelligent framework is used for assembly modeling and design in a top-down manner from the conceptual level to the detailed level. It is able to help obtain better design ideas, provide users with suggestions so as to create and improve a design, and therefore give users the possibility to assess and reduce the total production cost at an early stage during the design process. Through the use of the system, the concurrent engineering knowledge can be effectively incorporated into the assembly design process in an integrated manner. A case assembly design shows that the intelligent modeling and design system is feasible.     

Using requirement-functional-logical-physical models to support early assembly process planning for complex aircraft systems integration

The assembly line process planning connects product design and manufacturing through translating design information to assembly integration sequence. The assembly integration sequence defines the aircraft system components installation and test precedence of an assembly process. This activity is part of the complex systems integration and verification process from a systems engineering view. In this paper, the complexity of modern aircraft is defined by classifying aircraft system interactions in terms of energy flow, information data, control signals and physical connections. At the early conceptual design phase of assembly line planning, the priority task is to understand these product complexities, and generate the installation and test sequence that satisfies the designed system function and meet design requirements. This research proposes a novel method for initial assembly process planning that accounts for both physical and functional integrations. The method defines aircraft system interactions by using systems engineering concepts based on traceable RFLP (Requirement, Functional, Logical and Physical) models and generate the assembly integration sequence through a structured approach. The proposed method is implemented in an industrial software environment, and tested in a case study. The result shows the feasibility and potential benefits of the proposed method.     

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.     

An object-oriented knowledge based Petri net approach to intelligent integration of design and assembly planning

Artificial intelligence can play an important role in the reduction of manufacturing costs and the enhancement of production efficiency and product quality. In order to assist designers in the early stages of a product development this paper develops an intelligent methodology for integration of design and assembly planning processes, including product design, assembly evaluation and redesign, assembly process planning, design of assembly system and assembly simulation, subjected to both econo-technical and ergonomic evaluations. A new unified class of object-oriented knowledge based Petri nets called OOKPNs, incorporating knowledge based expert systems and fuzzy logic into ordinary place–transition Petri nets, is defined and used for the representation and modeling of the distributed design processes. A prototype intelligent integrated design and assembly planning system (IIDAP) is implemented through distributed blackboard structure with concurrent integration of multiple cooperative knowledge sources and software. It consists essentially of the networked agents and the meta-system, each of which is a knowledge Petri net system with the capabilities of problem solving, learning and conflict resolution, and can be obtained through the inheritance, polymorphism and dynamic binding of instances of OOKPNs. In IIDAP system, both C/C++ language and COOL (CLIPS object-oriented language) are used to incorporate a Petri net tool, a geometric modeling and design tool, a planner and simulator and an evaluation tool. By use of this system, product design and assembly planning can be carried out simultaneously and intelligently in an entirely computer-aided concurrent design and assembly planning system. The design of manufacturable, cost-effective, usable products can therefore be achieved rapidly and flexibly. The developed methodology and system have been successfully applied to assembly design and planning of a micro switch.     

Digital twin-based smart assembly process design and application framework for complex products and its case study

With rapid advances in new generation information technologies, digital twin (DT), and cyber-physical system, smart assembly has become a core focus for intelligent manufacturing in the fourth industrial evolution. Deep integration between information and physical worlds is a key phase to develop smart assembly process design that bridge the gap between product assembly design and manufacturing. This paper presents a digital twin reference model for smart assembly process design, and proposes an application framework for DT-based smart assembly with three layers. Product assembly station components are detailed in the physical space layer; two main modules, communication connection and data processing, are introduced in the interaction layer; and we discuss working mechanisms of assembly process planning, simulation, predication, and control management in the virtual space layer in detail. A case study shows the proposed approach application for an experimental simplified satellite assembly case using the DT-based assembly application system (DT-AAS) to verify the proposed application framework and method effectiveness.     

A knowledge intensive multi-agent framework for cooperative/collaborative design modeling and decision support of assemblies

Multi-agent modeling has emerged as a promising discipline for dealing with decision making process in distributed information system applications. One of such applications is the modeling of distributed design or manufacturing processes which can link up various designs or manufacturing processes to form a virtual consortium on a global basis. This paper proposes a novel knowledge intensive multi-agent cooperative/collaborative framework for concurrent intelligent design and assembly planning, which integrates product design, design for assembly, assembly planning, assembly system design, and assembly simulation subjected to econo-technical evaluations. An AI protocol based method is proposed to facilitate the integration of intelligent agents for assembly design, planning, evaluation and simulation process. A unified class of knowledge intensive Petri nets is defined using the O-O knowledge-based Petri net approach and used as an AI protocol for handling both the integration and the negotiation problems among multi-agents. The detailed cooperative/collaborative mechanism and algorithms are given based on the knowledge objects cooperation formalisms. As such, the assembly-oriented design system can easily be implemented under the multi-agent-based knowledge-intensive Petri net framework with concurrent integration of multiple cooperative knowledge sources and software. Thus, product design and assembly planning can be carried out simultaneously and intelligently in an entirely computer-aided concurrent design and assembly planning 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.     

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.     

基于构件和框架、面向方面的软件产品线开发方法CFB-AOD

本文提出了一种基于构件和框架、面向方面的软件产品线设计方法CFB-AOD(ComponentandFrameworkBased,AspectOrientedDesign)。CFB-AOD关注实际的软件开发过程,致力于在软件产品线的开发过程中融入构件技术、框架技术和面向方面技术,对软件开发特别是软件产品线开发有实际的指导意义。并以北航软件所白盒测试工具产品线QESat为例,介绍了CFB-AOD的实际运用。