Computer aided fixture design: Recent research and trends

Widely used in manufacturing, fixtures have a direct impact upon product manufacturing quality, productivity and cost, so much attention has already been paid to the research of computer aided fixture design (CAFD) and many achievements in this field have been reported.In this paper, a literature survey of computer aided fixture design and automation over the past decade is proposed. First, an introduction is given on the fixture applications in industry. Then, significant works done in the CAFD field, including their approaches, requirements and working principles are discussed. Finally, some prospective research trends are also discussed.     

Case based reasoning method for computer aided welding fixture design

This paper presents a case-based reasoning (CBR) method for welding fixture design, a critical issue in the manufacturing of large and complicated equipment. However, previous fixture design research has mainly focused on machining fixtures rather than welding fixtures. In this paper, an approach of data abstraction for fixture design information representation is proposed, first to systemize and manage myriads of fixture related resources, e.g., past fixture design solutions, fixture units depository. Based on this approach, a multi-level CBR method for welding fixture design is then presented. This method could help designers, by referencing previous design cases, to make a conceptual fixturing solution quickly and, finally, finish the detailed solution of fixture design.     

Development of an Internet-enabled interactive fixture design system

Fixture design is a complex and an intuitive process. An efficient fixture design system is essential to cut costs and reduce the product lead-time. In today's manufacturing landscape, various computer-aided systems exist to aid the various stages of manufacturing. A fixture design system should be able to transfer information with the various other systems to bring about a seamless product design and manufacturing environment. A fixture design system should also be portable on different operating platforms. This paper addresses the development of an Internet-enabled interactive fixture design system. The Internet and the use of XML as a file format provide a means for the transfer of information and knowledge between the various computer-aided manufacturing systems. The system has been implemented using Java and is based on a three-tier Thin Client-Fat Server architecture. This ensures the platform independent performance of the system. A locating scheme independent interactive fixture design method has also been developed in this work for detailed fixture design.     

A feature-based fixture design methodology for the manufacturing of aircraft structural parts

In fixture design for the manufacturing of aircraft structural parts, there are various challenges and serious problems in industry, such as difficulty in design knowledge capture and reuse, and the arbitrary or non-standard nature of design, which influence the efficiency and quality of fixture design. This paper proposes a feature-based fixture design methodology in which previous fixture design cases and design rules are described in association with features and thus the design knowledge is integrated with geometric information of aircraft structural parts, which are the main concern of this project. In this methodology, machining features of the structural parts and their associated attributes are identified by feature recognition technique from the 3 dimensional (3D) part models defined based on model-based definition (MBD) technique. The feature-based part information models are then established and are used to retrieve previous fixture design cases and design rules stored in the knowledge base. Fixture designers will choose the appropriate retrieved design cases as the starting point for new fixture design or use previous designs to assess his/her current design. In this way the process of new fixture design can be improved. In the current stage of the research, a prototype feature-based fixture design system based on CATIA for the manufacturing of aircraft structural parts has been developed and used by a large airplane manufacturer.     

Design and planning problems in flexible manufacturing systems: a critical review

This review paper describes the state-of-the-art research on flexible manufacturing systems (FMS) design and planning issues. The emphasis is on presenting research results coming out of the current FMS literature that help the FMS manager in setting up a highly efficient manufacturing system. In addition to that, it discusses relevant research contributions after 1986, that were not part of any of the previous survey papers on operations research models for FMSs. Also, applications of combinatorial optimization approaches to FMS planning problems are adequately exposed in the paper.     

Fixture knowledge model development and implementation based on a functional design approach

The development of a knowledge model applied to fixture design is a complex task. The main purpose of such model is the development of a knowledge-based application to assist fixture designers. It comprises a detailed specification of the types and structures of data involved in the execution of the inference process needed to create a fixture solution for machining a raw part. A development method together with a knowledge model for automating fixture design is proposed. The development was divided into three parts: Design Process Model, definition of Top-level functional functions and Product Knowledge Model. Adopting a functional design approach, the fixture design solution was created in two levels: functional and detailed. The functional level is based on fixture functional elements and the detailed one is based on fixture commercial elements. The definitions and concepts used in the application are specified in several Units of Knowledge (UoK) that comprises the Fixture Knowledge Model. Common Knowledge Analysis and Design Structuring (CommonKADS), Methodology and software tools Oriented to KBE Applications (MOKA), Integrated DEFinition for Function Modelling (IDEF0) and Unified Modelling Language (UML) are the methodologies and techniques used in the proposed method. Finally, a prototype KBE application for fixture design was developed.     

Development of an automated flexible fixture for planar objects

A three fingered automated flexible fixturing system has been developed to fixture planar objects in a machining process. The fixturing system consists of two computer numerically controlled (CNC) modules, an auxiliary mechanism and a fixturing algorithm. This fixture is designed on the idea of the minimum number of fingers needed to immobilise an object. The fixturing algorithm is developed on the concept of the maximal inscribed circle in a polygon. It offers the flexibility to reconfigure the fingers of the system to accommodate workpieces of different shapes and sizes. A prototype of the system has been successfully built and tested, showing satisfactory performance in mechanical design and automatic control over the configurations of the fingers. Examples are given of the application of the system with objects of different shapes. The system is shown to be flexible, reconfigurable and automatic, capable of fixturing planar objects of different shapes and sizes in the machining process.     

Automated fixture configuration for rapid manufacturing planning

The wide adoption of agile manufacturing systems has necessitated the design and use of fixtures or work holding devices that have in-built flexibility to rapidly respond to part design changes. Despite the availability of reconfigurable fixtures, practical fixture configuration largely remains an experience driven manual activity to enable customization for varying workpiece geometry, and most automated solutions do not scale well to accommodate such variation. In this paper, we address the problem of rapidly synthesizing a realistic fixture that will guarantee stability and immobility of a specified polyhedral work-part. We propose that the problem of automated fixture layout may be approached in two distinct stages. First, we determine the spatial locations of clamping points on the work piece boundary using the principles of force and form closure, to ensure immobility of the fixtured part under external perturbation. In particular, we show that the candidate restraints mapped to the six dimensional vector space of wrenches (force–moment pairs) may be hashed in a straightforward manner to efficiently generate force closure configurations that restrain part movement against large external wrenches. When clamps are allowed to exert arbitrarily high reaction forces on the part, the spatial arrangement of the clamping locations ensures the part is in form closure. On generating force/form closure configurations, the chosen locations are matched against a user-specified library of reconfigurable clamps to synthesize a valid fixture layout comprising clamps that are accessible and collision free with each other and the part. Additionally, in the case of determining machining setups the clamps are chosen to avoid collisions with the moving cutting tool. We demonstrate fast algorithms to perform both location selection and fixture matching, and show several results that underscore the practical application of our solution in automated manufacturing process planning.     

Multi-objective optimal fixture layout design

This paper addresses a major issue in fixture layout design to determine and evaluate the acceptable fixture designs based on multiple quality criteria and to select an optimal fixture with appropriate trade-offs among multiple performance requirements. The performance objectives considered are related to the fundamental requirements of kinematic localization and total fixturing (form-closure). Three performance objectives are defined as the workpiece localization accuracy and the norm and dispersion of the locator contact forces. The paper focuses on multi-criteria optimal design with a hierarchical approach. An efficient interchange algorithm is extended and used for different practical cases, leading to proper trade-off strategies for performing fixture synthesis. Examples are given to illustrate empirical observations with respect to the proposed approach and its effectiveness.     

Variant design for mechanical artifacts: A state-of-the-art survey

Variant design refers, to the technique of adapting existing design specifications to satisfy new design goals and constraints. Specific support of variant design techniques in current computer aided design systems would help to realize a rapid response manufacturing environment. A survey of approaches supporting variant design is presented. Capabilities used in current commercial computer aided design systems are discussed along with approaches used in recent research efforts. Information standards applicable to variant design are also identified. Barriers to variant design in current systems are identified and ideas are presented for augmentation of current systems to support variant design.     

Flexible tool support for accessibility evaluation

The increasing need to check Web site accessibility has stimulated interest in tools to aid the various activities involved. While some tools for this purpose already exist, we believe that there is a demand for making their support more flexible. In particular, there is often a need for validation of multiple sets of guidelines, repairing Web pages and providing better reports for the evaluators. In this paper, we discuss such issues and how we have addressed them in the design of MAGENTA, our new tool for supporting inspection-based evaluation of accessibility and usability guidelines.     

Concurrent manufacturing of parts and tools for the sheet-metal industry

The manufacturing of complex bent parts can be supported effectively by computer-aided planning methods. Software systems are already available for unfolding, laser cutting and bending sequence determination. The paper focuses on methods that support the design of non-standard bending tools and the flexible manufacturing of such tools using laminated object modelling (LOM) technology. The developed system allows for concurrent planning and manufacturing of bending parts and tools. Within the framework of this system, neural networks are applied for automated tool design.     

面向并行工程的组合夹具辅助设计系统设计与开发

提出了一种基于Web的计算机辅助夹具设计系统原型,并采用基于UML的ICONIX开发过程实现,通过用例图、对象类图、Robustness图和顺序图明确了系统对象类的功能、关联以及协同关系．     

基于实例设计的夹具CAD研究

文章结合某企业航空发动机典型零件的工装夹具CAD,通过对传统夹具设计过程的分析,指出了将基于实例的设计技术进行夹具CAD的可行性。同时,通过对基于实例推理的分析,研究了如何将基于实例的设计技术应用到夹具设计中,并提出了基于实例设计的夹具CAD系统结构,解决了如何进行夹具设计实例的描述、组织、调整等关键问题,实现了基于实例的夹具CAD系统。     

An integrated methodology for fixture design

In this paper, a methodology to perform fixture design as an integrated aspect of process planning is proposed. A three-phase methodology for the fixture design activity has been developed. The three phases include predesign analysis (phase I), functional analysis (phase II), and productivity improvement (phase III). In phase I, the product design information is studied, and initial fixture design aspects are developed. In phase II, the clamping and location aspects of fixture design are addressed for the given initial process sequence and product design information. Phase III involves studying ways to increase the productivity including using simultaneous machining approaches, multiclustering, use of specialized jigs, etc.     

Fuzzy-set-based approach for concurrent constraint set-up planning

Material removal processes are integral parts of many manufacturing systems. They are either primary machining processes or an important part of preparing toolings for subsequent forming and moulding processes. Manufacturing process planning identifies the type of material removal processes and the machining parameters, cutting tools and fixtures needed to generate the features on a part. Previous research in manufacturing process planning has concentrated mainly on the role of features, in the derivation of the associated process and fixture plans. Many computer-aided process planning (CAPP) and computer-aided fixture planning (CAFP) systems derive process and fixture plans from the features on a part, on the basis that these features are context-free. However, manufacturing operations are interdependent processes. In the author's computer-aided set-up planning (CASP) system, a different perspective is adopted. Feature relations form the core of the conceptual structure. These features relations, which are often imprecise, are used in deriving set-up plans. The feature relations, which may be due to geometrical constraints, tolerance requirements, etc., are modelled using fuzzy sets and fuzzy relations. This paper presents the various feature relations considered in the present system and proposes a practical planning algorithm for set-up planning.     

Automatic assembly path planning for wiring harness installations

The automotive industry of today is becoming more focused on electrified and hybrid solutions, where both conventional combustion engines and battery supplied electrical engines need to fit in an already densely packed vehicle. Many quality problems are related do flexible parts. In particular, the assembly of electric cables and wiring harnesses is difficult due to its concealed routing, multiple branching points, weights and the flexibility in the material. To avoid late detection of assembly problems, the assembly aspect must be considered early during conceptual design and production preparation with respect to both feasibility and ergonomics. Development of automatic path planning methods in virtual manufacturing tools supporting deformable parts is therefore highly motivated.     

Manufacturing networks in the era of digital production and operations: A socio-cyber-physical perspective

The performance of manufacturing networks relies on interactions. Digitalization supports an evidence-based understanding of partners’ idiosyncrasies and behaviours, so that proper decision-making takes place. Indeed, context uncertainty and flexible problem solving demand human involvement in cyber-physical systems. Therefore, to materialize systems efficiency along with flexibility and robustness, human aspects and limitations need to be properly considered in the planning and control of manufacturing networks. This vision paper aims to address distributed decision-making in digital and integrated manufacturing networks under a socio-cyber-physical systems perspective. Therefore, this exploratory study presents a narrative review of current research literature, followed by a research framework proposition. Manufacturing and control research communities need to embrace a convergent vision addressing (i) how manufacturing networks can be planned and controlled in the future, (ii) which are the proper decision-making methods and approaches, as well as (iii) which are the technology drivers fostering new research opportunities with practical impact. In this context, the proposed framework indicates potential research avenues and offers an agenda for future work.     

The application of information systems for the design and operation of flexible machining cells

The use of information systems in manufacturing applications has dramatically changed over the last few years. The design and implementation of somewhat dated relational databases has been replaced by the generation of information models, that can be simultaneously used for the development of information systems and satisfy their integration requirements. Over the last ten years the authors have been involved in a series of research programmes focusing on the design and operation of flexible machining cells. The use of information systems has been a central theme and the enabling technology to achieve a number of novel design concepts and operational strategies for such cells. The initial research was based on the utilization of relational databases to integrate a variety of modelling and design tools. However, the additional effort required to integrate such databases to manufacturing software tools, in the form of developing file translators, information gateways and interfac es, has made the authors adopt a new approach. With this approach the information requirements are represented in a neutral format within a data model, using a formal data specification language developed by the Standards for the Exchange of Product (STEP) committee. This paper describes these changes in the design and implementation of information systems in manufacturing applications, and provides an initial view of future research requirements.     

Modeling and Visualization for a Production Planning Decision Support System

This paper describes the process of decision support systems development for the optimization of the aggregate production planning problem for an important manufacturer of applicances in Chile. This work is part of a more general research effort, whose purpose is to build a generator of software applications for logistic problems in industry, based on optimization models. We take advantage of powerful tools and approaches for the modeling stage, and for building systems with user friendly interfaces and good data management capabilities. The production planning problem is formulated as a mixed integer programming model, which is solved using CPLEX. The system is currently being used by the company for their decision processes in manufacturing.