Analysis and optimization of assembly precision-cost model based on 3D tolerance expression

Sun, Wei; Mu, Xiaokai; Sun, Qingchao; Zhi-yong, Sun; Wang, Xiaobang

doi:10.1108/aa-10-2017-137

Cited by 13 publications

(7 citation statements)

References 26 publications

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“…The tolerance of the closed-loop of the assembly dimension chain affects the manufacturing dimension of each part. Thats why, the assembly accuracy constraints are generated (Sun et al , 2018).…”

Section: Precision Constraintsmentioning

confidence: 99%

Knowledge creation and application of optimal tolerance distribution method for aircraft product assembly

Miah

Zhang

Chand

2021

AEAT

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Purpose This paper aims to illustrate the tolerance optimization method based on the assembly accuracy constrain, precession constrain and the cost of production of the assembly product. Design/methodology/approach A tolerance optimization method is an excellent way to perform product assembly performance. The tolerance optimization method is adapted to the process analysis of the hatch and skin of an aircraft. In this paper, the tolerance optimization techniques are applied to the tolerance allocation for step difference analysis (example: step difference between aircraft cabin door and fuselage outer skin). First, a mathematical model is described to understand the relationship between manufacturing cost and tolerance cost. Second, the penalty function method is applied to form a new equation for tolerance optimization. Finally, MATLAB software is used to calculate 170 loops iteration to understand the efficiency of the new equation for tolerance optimization. Findings The tolerance optimization method is based on the assembly accuracy constrain, machinery constrain and the cost of production of the assembly product. The main finding of this paper is the lowest assembly and lowest production costs that met the product tolerance specification. Research limitations/implications This paper illustrated an efficient method of tolerance allocation for products assembly. After 170 loops iterations, it founds that the results very close to the original required tolerance. But it can easily say that the different number of loops iterations may have a different result. But optimization result must be approximate to the original tolerance requirements. Practical implications It is evident from Table 4 that the tolerance of the closed loop is 1.3999 after the tolerance distribution is completed, which is less than and very close to the original tolerance of 1.40; the machining precision constraint of the outer skin of the cabin door and the fuselage is satisfied, and the assembly precision constraint of the closed loop is satisfied. Originality/value The research may support further research studies to minimize cost tolerance allocation using tolerance cost optimization techniques, which must meet the given constrain accuracy for assembly products.

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Section: Precision Constraintsmentioning

confidence: 99%

Knowledge creation and application of optimal tolerance distribution method for aircraft product assembly

Miah

Zhang

Chand

2021

AEAT

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“…These modeling and analysis methods provide a rich theoretical basis for the prediction of system assembly accuracy and the comprehensive analysis of tolerance. Based on the SDT theory and homogeneous coordinate transformation theory, Sun et al revealed the influence mechanism of assembly deformation on the overall assembly accuracy of mechanical system [14][15][16]. Some scholars have proposed the theoretical model and method of deviation accumulation control on the assembly path of rotor system [17][18][19].…”

Section: Introductionmentioning

confidence: 99%

A novel collaborative optimization assembly process method for multi-performance of aeroengine rotors

Wen

Zhao

et al. 2023

Int J Adv Manuf Technol

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In the assembly process of aeroengine, the aeroengines have been rejected at pass off test for high vibration of high pressure rotor under the condition of meeting the geometric accuracy. Repeated disassembly and trial assembly will lead to interface damage, which will affect the safety and reliability of the engine. Therefore, a multi-objective collaborative optimization process method for geometric accuracy and dynamic performance is put forward based on the practical engineering problems. In the proposed method, the primal problem is firstly reveals the transfer mechanism of coaxiality and unbalance of rotor system, and the prediction model of the coaxiality and unbalance of the rotor system was established. Then, combined with the high-precision reduced order model of aeroengine high-pressure combined rotor, the system vibration responses under different assembly states are obtained. Finally, a multi-objective collaborative optimization assembly process method considering coaxiality, unbalance and vibration response is obtained. The results show that the collaborative optimization process method considering assembly accuracy and dynamic performance is the optimal assembly strategy, which can reduce the vibration amplitude of the key nodes of the rotor system while ensuring high assembly accuracy, and achieve the low-level vibration of the rotor system.

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“…Some scholars have also focused on the economic benefits associated with robot design. Sun et al (2018) proposed an assembly precision-cost model and analyzed it with a horizontal machining center as an example, which reduced the cost by 16.83% while satisfying the assembly precision. Miah et al (2022) analyze the tolerance allocation for the step difference between the aircraft cabin door and the outer skin of the fuselage.…”

Section: Introductionmentioning

confidence: 99%

Assembly precision design for parallel robotic mechanism based on uncertain hybrid tolerance allocation

Xu¹,

Tao²,

Gao³

et al. 2023

RIA

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Purpose The coupling impact of hybrid uncertain errors on the machine precision is complex, as a result of which the designing method with multiple independent error sources under uncertainties remains a challenge. For the purpose of precision improvement, this paper focuses on the robot design and aims to present an assembly precision design method based on uncertain hybrid tolerance allocation (UHTA), to improve the positioning precision of the mechanized robot, as well as realize high precision positioning within the workspace. Design/methodology/approach The fundamentals of the parallel mechanism are introduced first to implement concept design of a 3-R(4S) &3-SS parallel robot. The kinematic modeling of the robot is carried out, and the performance indexes of the robot are calculated via Jacobian matrix, on the basis of which, the 3D spatial overall workspace can be quantified and visualized, under the constraints of limited rod, to avoid the singular position. The error of the robot is described, and a probabilistic error model is hereby developed to classify the hybrid error sensitivity of each independent uncertain error source by Monte Carlo stochastic method. Most innovatively, a methodology called UHTA is proposed to optimize the robot precision, and the tolerance allocation approach is conducted to reduce the overall error amplitude and improve the robotized positioning precision, on the premise of not increasing assembly cost. Findings The proposed approach is validated by digital simulation of medical puncture robot. The experiment highlights the mathematical findings that the horizontal plane positioning error of the parallel robotic mechanism can be effectively reduced after using UHTA, and the average precision can be improved by up to 39.54%. Originality/value The originality lies in UHTA-based precision design method for parallel robots. The proposed method has widely expanding application scenarios in industrial robots, biomedical robots and other assembly automation fields.

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Analysis and optimization of assembly precision-cost model based on 3D tolerance expression

Cited by 13 publications

References 26 publications

Knowledge creation and application of optimal tolerance distribution method for aircraft product assembly

Knowledge creation and application of optimal tolerance distribution method for aircraft product assembly

A novel collaborative optimization assembly process method for multi-performance of aeroengine rotors

Assembly precision design for parallel robotic mechanism based on uncertain hybrid tolerance allocation

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