Industry case study: rapid prototype of mountain bike frame section

Collins, Paul K.; Leen, Robert; Gibson, Ian

doi:10.1080/17452759.2016.1222563

Cited by 22 publications

(25 citation statements)

References 2 publications

Supporting

Mentioning

Contrasting

Unclassified

Order By: Relevance

“…For this reason, analysts forecast that the global high-end bicycle market will grow with a compound annual growth rate (CAGR) of 4.82% during the period 2017-2021 according to the report from Research and Markets Ltd. It is known that high-end bikes demand a high quality of bike frame [1][2][3][4][5][6][7]. Unfortunately, frame QC still relies on the Vernier caliper, the plug gauge, the cylindrical gauge, and the thread gauge, etc.…”

Section: Introductionmentioning

confidence: 99%

Achievement of Accurate Robotic Arm-based Bike Frame Quality Check Using 3D Geometry Mathematical Model

Lin

Wang

et al. 2019

Applied Sciences

View full text Add to dashboard Cite

Currently, the bike frame quality check (QC) mostly relies on human operation in industry. However, some drawbacks such as it being time-consuming, having low accuracy and involving non-computerized processes are still unavoidable. Apart from these problems, measured data are difficult to systematically analyze for tracking sources of product defects in the production process. For this reason, this paper aims to develop a 3D geometry mathematical model suitable for bicycle frames QC using robotic arm-based measurement. Unlike the traditional way to find coefficients of a space sphere, the proposed model requires only three check point coordinates to achieve the sphere axis coordinate and its radius. In the practical work, the contact sensor combined with the robotic arm is used to realize the compliance items measurement in shaft length, internal diameter, verticality, parallelism, etc. The proposed model is validated based on both mathematic verification and actual bike frame check.Appl. Sci. 2019, 9, 5355 2 of 17 material handling, welding, thermal spraying, assembly, palletizing, drilling, and painting, etc. [18][19][20][21]. For instance, a platform based on a robotic arm using three degrees of freedom (DoF) principle was proposed to estimate the calibration parameters of microelectromechanical systems (MEMS) [22]. It can be placed indifferent positions for collecting a dataset of points evenly distributed. This case implies that the measurement technique using robotic arms may provide a good solution for the bike frame QC process. System Description System StructureThe proposed system structure of bike frame quality check is shown in Figure 1a, consisting of subsystems such as robotic arm, graphical user interface (GUI), programmable logic controller (PLC), contact sensor, mathematical model, database, and workbench. Each subsystem is responsible to carry out a specific task, described as follows. (1) Robotic arm can carry the contact sensor and move it to the check points. Therefore, the coordinates of check points can be found based on the robotic arm coordinate system. (2) The contact sensor can feedback a digital signal to the robotic arm immediately once it touches the surface of the check points. (3) PLC is to control the rotating disk to rotate the bike frame 90 • for the robotic arm to reach every check point. (4) Graphical user interface (GUI) provides a friendly user interface for users to input data and display a real-time measurement outcome.(5) Mathematical model presents a geometry algorithm that can effectively integrate the sphere formula with the inner product of normal vector to find four parameters in the sphere formula using only three measured points. Accordingly, the center coordinate of check point and its diameter can be calculated accurately and simply. (6) A database using MySQL is used to store the measured data and export measurement data report. (7) The workbench shown in Figure 1b is designed to sustain all hardware devices. It contains: (1) a fixing frame, (2) A rotating disk, ...

show abstract

Section: Introductionmentioning

confidence: 99%

Achievement of Accurate Robotic Arm-based Bike Frame Quality Check Using 3D Geometry Mathematical Model

Lin

Wang

et al. 2019

Applied Sciences

View full text Add to dashboard Cite

show abstract

“…This has led to the ability to have a patient specific cast that allows the patient to return to their everyday life with reduced impact on their abilities to live their everyday life. Other areas that have been looking at similar aspects of additive manufacturing for similar reasons, is sports technology (Collins 2016). With the ability to rapidly make changes and design a durable part that is of a complex geometry that could otherwise not be produced is allowing the industry the ability to create components that are optimized for their application.…”

Section: Introductionmentioning

confidence: 99%

Design of a Patient Specific, 3D printed Arm Cast

Fitzpatrick¹,

Mohanned²,

Collins³

et al. 2017

KEG

View full text Add to dashboard Cite

3D printing is a manufacturing technique by which the material is added layer by layer to create a physical three-dimensional object. This manufacturing technique had primarily found uses in academic and commercial sectors for prototyping and product realization purposes. However, more recently the home consumer market has seen a surge in low cost printers bringing this capability to the masses. More recently 3D printing has seen considerable interest from the clinical sector, where alongside the synergistic use with medical imaging data, a whole generation of patient specific implantable technologies, splints/casts and resection guides can be created. Predominantly, clinical applications have focused on the use of 3D printing for bone replacement, however with the advent of more sophisticated multi-material printers, interest has now begun to move to applications in orthotics and orthopedic casting.This study is to review and evaluate the feasibility of designing and realizing a more patient specific orthopedic cast to surpass current limitation with traditional fiberglass/plaster casts, through the use of advanced 3D modelling and printing techniques. To directly compare the efficacy of the traditional and 3D printed casts, we shall investigate critical parameters such as the time for manufacture, the overall weight of the final product, the accuracy off the cast relative to the patient’s unique anatomy and additional user-centric metrics (comfort, aesthetics, etc.). The design examined made use of advanced mesh structures throughout the bulk of the cast, such that the device would require less material (by weight) during fabrication, could allow for tunable weight and mechanical properties and allow for air penetration to the person skin, thereby reducing discomfort due to prolonged moisture exposure (chaffing, bad smells, etc.). As the primary focus of this study is the design and product realization phases and we shall not assess metrics relating to patient recover time or experience.Overall it was found that the 3D printed cast was significantly lighter, with improved water repellent and air circulation properties, as compared to a traditional cast. Through the use of high precision design/manufacturing techniques, the final device could be accurately reproduced to match the test patient’s unique anatomy, thereby optimizing the orientation of the patient’s bones during post fracture recovery. It was however found that the manufacturing time for the 3D printed cast was slower than traditional casting methods owing to the additional time during the design phase. In future work we aim to address this limitation and to devise a streamlined methodology such that a generic cast design can be adapted to patient specific anatomical data through parametric design algorithms.Ultimately, it was found that through the use of advanced design techniques, patient specific data and 3D printing, a custom orthopedic cast could be realized and with significant potential to augment current use of this technology for surgical intervention and improve patient outcomes. The use of advanced manufacturing in the medical field will likely enable more patient specific/user-centric treatment in the near future.

show abstract

“…The industry is seeing a shift, with more small and medium enterprises having access to tools that were out of reach (in terms of cost and expertise required) in the past (Collins, Leen and Gibson, 2016). The methods explored in this research will compare new entry level tools and processes with traditional professional tools.…”

Section: Introductionmentioning

confidence: 99%

Shape optimisation of a snowboard binding highback. A case study of generative design process comparison

Leen¹

2017

KEG

Self Cite

View full text Add to dashboard Cite

<div>FEA software is traditionally expensive to purchase, takes a high level of technical skill and understanding and requires users to dedicate years to develop specialist skills. With the increasing popularity of more user-friendly, elementary software packages such as Fusion360, more cost effective and efficient processes can be developed and harnessed, especially by SME’s and designers that don’t have the ability to purchase expensive software packages. One particular FEA element that has recently begun transitioning from highly specialised to more readily available is ‘generative design’ and ‘shape optimisation.' Shape optimisation has only been able to be utilised by large corporations with large research and development budgets. This case study looks at exploring and optimising the methods involved in generative design for product development and it’s aimed at facilitating practises for small to medium enterprises (SME’s).The work described in this paper presents a study using a snowboard binding highback component which was reverse engineered using 3D scanning. A blank model, free of any discerning features was created from the scan and then used as the platform for the generative design phase. This process was completed using easily accessible software (Fusion 360) as well as high-end professional software (Ansys 16). A comparison between the two workflows analyses the resultant model outcomes and outlines efficiencies regarding processing time, technical skill, and latent difficulties of the entry-level process for generative design of the snowboarding high back.This paper aims to demonstrate and describe an optimisation model for generative design and shape optimisation during entry-level product development.</div>

show abstract

Industry case study: rapid prototype of mountain bike frame section

Cited by 22 publications

References 2 publications

Achievement of Accurate Robotic Arm-based Bike Frame Quality Check Using 3D Geometry Mathematical Model

Achievement of Accurate Robotic Arm-based Bike Frame Quality Check Using 3D Geometry Mathematical Model

Design of a Patient Specific, 3D printed Arm Cast

Shape optimisation of a snowboard binding highback. A case study of generative design process comparison

Contact Info

Product

Resources

About