An Automated Flexible Fixture System for Mass Customization

Abstract

The need for mass customisation is growing as customer demand for customised products increases. Mass customisation is the production of custom products at mass-produced rates. Current fixture technology does not possess the flexibility required for mass customisation. It was determined, through research, that if mass customisation is to be achieved, a fixture system is required that possesses the following attributes: it accommodates a large variety of part families and geometries; it has automated setups and setup changeovers; it has a semi-automated fixture design; and it provides adaptive feedback during machining processes. A fixture system, known as an automated flexible fixture system (AFFS), was developed that met these requirements. The AFFS was researched, designed, manufactured, and tested. The tests involved determining the AFFS's response to changes in cutting conditions. The AFFS's response to the tests indicated that it behaved normally, for the most part, with higher feed rates and spindle speeds generally yielding higher or more vibrational frequency bands. Further development is required before the AFFS meets commercial standards. However, as a proof of concept it was successful. This paper presents the developed AFFS in more detail. OPSOMMINGDie behoefte aan grootskaalse op bestelling aangepaste vervaardigde produkte is aan die toeneem. Die bestaande hegstuktegnologie beskik nie oor die vermoë om hiervoor voorsiening te maak nie. Dit is bepaal, deur navorsing, dat ʼn hegstuksisteem wat die volgende eienskappe besit benodig word om grootskaalse op bestelling vervaardiging te bewerkstellig: dit moet ʼn groot verskeidenheid van onderdeel-soorte en -vorms akkommodeer, dit moet van geoutomatiseerde opstellings en opstelling veranderings beskik, dit moet uit ʼn semi-geoutomatiseerde hegstukontwerp bestaan en dit moet voorsienning maak vir aanpasbare terugvoer tydens die masjinering proses. ʼn Hegstuksisteem is ontwikkel wat aan hierdie vereistes voldoen. Dié sisteem is nagevors, ontwerp, vervaardig en getoets. Tydens die toetse is die sisteem se reaksie op veranderinge in die masjineringstoestande bepaal. Die sisteem se reaksie tydens die toetse het getoon dat dit meestal normaal reageer het, met hoër voer-en spilsnelhede wat in die algemeen meer vibrasie bandwydtes lewer. Verdere ontwikkeling is nodig voordat die sisteem kommersiële standaarde haal. As ʼn bewys van konsep was dit egter suksesvol. Hierdie artikel bespreek die sisteem in detail.

Development of Flexible Fixtures with Incomplete Locating: Connecting Rods Machining Case Study

“…Overall, the proposed methodology continues recent strategies in the development of flexible fixtures [33], increases the reliability of the automated flexible fixture systems for mass production [34], improves methods for flexible fixture design in the automotive industry [35], extends recent developments in reconfigurable fixture design [36], and improves simulation approaches in fixture design [37].…”

Simulation-Based Study of the Resilience of Flexible Manufacturing Layouts Subject to Uncertain Demands of Product Variants

“…To capture these relationships, let us denote a machine-type matrix, MT = [mtjk], where mtjk = 1 if machine mj belongs to machine type tk (otherwise, mtjk = 0). Notably, the framework model in Figure 1 does not include fixtures, the importance of which should not be underestimated in manufacturing systems [50,51]. In the context of product variety (or mass customization), flexible fixtures are particularly relevant and can be classified into two types: traditional and modern [52].…”

“…Notably, the framework model in Figure 1 does not include fixtures, the importance of which should not be underestimated in manufacturing systems [50,51]. In the context of product variety (or mass customization), flexible fixtures are particularly relevant and can be classified into two types: traditional and modern [52].…”

Design Sustainability of Reconfigurable Machines

“…This implies that one RM would have been used, but in order to create a sufficient application of the developed model, four RMs were considered. The AFFS is a reconfigurable type of flexible fixture that can be reconfigured to accommodate different part geometries and rapidly provide automatic set-up and changeovers during operation [32]. The RAF is designed as major enabling equipment in a RAS to rapidly position the frames of a workpiece while other components are assembled to it.…”