Modelling, simulation and optimisation of the technological processes of assembly

Olaf Ciszak, Marcin Suszyński

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ISBN/ISSN:

978-83-7775-635-5

DOI:

Wydawnictwo:

Wydawnictwo Politechniki Poznańskiej

Rok wydania:

2021

Liczba stron:

144

XML:ISBN/ISSN:

ONIX MARC21

Bibliografia:

Ciszak, Olaf; Suszyński, Marcin. Modelling, simulation and optimisation of the technological processes of assembly. Red. . : Wydawnictwo Politechniki Poznańskiej, 2021, 144 s. ISBN 978-83-7775-635-5

Bibliografia refWorks:

RT Book, Whole

SR Electronic(1)

A1 Ciszak, O.

A1 Suszyński, M.

T1 Modelling, simulation and optimisation of the technological processes of assembly

PB Wydawnictwo Politechniki Poznańskiej

YR 2021

SN 978-83-7775-635-5

Bibliografia BibTex:

@Book{ 268541, author = "Ciszak, Olaf and Suszyński, Marcin", editor = "", title = "Modelling, simulation and optimisation of the technological processes of assembly", publisher = "Wydawnictwo Politechniki Poznańskiej", year = "2021", address = "", isbn = "978-83-7775-635-5" }

Bibliografia endNote:

TY - BOOK

AU - Ciszak, Olaf

AU - Suszyński, Marcin

ED -

TI - Modelling, simulation and optimisation of the technological processes of assembly

PB - Wydawnictwo Politechniki Poznańskiej

CY -

PY - 2021

SN - 978-83-7775-635-5

ER -

Netografia (standard APA):

Ciszak, Olaf; Suszyński, Marcin. Modelling, simulation and optimisation of the technological processes of assembly [baza danych online] : Wydawnictwo Politechniki Poznańskiej, 2021 [dostęp: 07 07 2024]. Dostęp w Ibuk Libra: https://libra.ibuk.pl/reader/modelling-simulation-and-optimisation-of-the-technological-processes-olaf-ciszak-marcin-suszynski-268541.

manual and robotic assembly, algorithms for recording structures and optimization of assembly planning processes

Technological processes of manual and robotic assembly are becoming an increasingly important issue in todays competitive market. Therefore, effective methods and models for their implementation should be investigated. Solving problems related to ...

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ISBN/ISSN:

978-83-7775-635-5

DOI:

Wydawnictwo:

Wydawnictwo Politechniki Poznańskiej

Rok wydania:

2021

Liczba stron:

144

XML:ISBN/ISSN:

ONIX MARC21

Definitions and symbols8
1. Introduction 11
2. Technological process of assembly 14
2.1. Role and importance of assembly in the technical preparation of production15
2.2. Designing the technological assembly process18
2.3. Integrated assembly model22
2.4. Automation and robotisation of the technological process of assembly23
2.5. Assembly sequence planning26
2.6. Conclusions36
3. Assembly sequence planning with a directed hypergraph, digraph, state matrix and graph39
3.1. Introduction39
3.2. Base Part Selection40
3.3. From hypergraph to directed graph43
3.4. Matrix representation of the design45
3.5. Assessment of transitions between assembly states47
3.6. Selection of the extreme path in a directed graph49
3.7. Example of an algorithm for ASP52
3.8. Determining the assembly sequence with the use of the Msassembly software55
3.10. Assumptions for a flexible robotic assembly system60
3.9. An example of a flexible robotic assembly system60
3.11. Assembly unit identification system63
3.12. Generation of assembly sequences feasible in terms of design constraints65
3.13. Assembly sequence assessment67
3.14. Conclusions68
4. Example of modelling and simulation of the technological process of assembly of a machining centre69
4.1. Introduction69
4.2. Measurements of labour input required for individual operations70
4.2.1. Timing stages70
4.3. Stages of conducting a working day activity study73
4.4. The technological process of assembly of the machining centre75
4.5. CAD simulation76
4.5.1. Introduction76
4.5.2. CAD System77
4.5.3. Modelling assemblies (products)77
4.5.4. Presentation and documentation of assembly80
4.6 Balancing the final assembly line of the machining centre82
4.7 Modelling and simulation of the technological process of assembly of a machining centre89
4.8 Development of work regulations, methods of communication and the algorithm of the functioning of the information and diagnostic system as part of the active control and supervision of operation of the assembly line94
4.8.1. Assumptions94
4.8.2. System structure96
4.8.3. System operation98
4.9 Simulation tests of the information and diagnostic system and the technological process of assembly of the machining centre; adopting the final structure110
4.9.1. Simulation tests of the information and diagnostic system and the technological process of assembly of the machining centre110
4.9.2. Conclusions118
5. Modelling and simulation of the technological assembly process, taking into account MTBF 120
5.1. Mean Time Between Failures – MTBF120
5.2. The process of assembling the dashboard to the car body121
5.3. Modelling and simulation of the assembly cell for assembling the dashboard to the car body122
5.4. Conclusions125
6. Examination of the efficiency of the assembly cell for the assembly of the main spindle to the turning centre127
6.1. Assembly technology of the main headstock127
6.2. Examination of the labour input required for the assembly operations128
6.3. Operation sequence129
6.4. Modelling and simulation of the assembly cell129
6.5. Conclusions132
7. Summary and conclusions136
References138

1.Introduction

Theprocessofassemblygoesbacktoancienttimes,butpracticallyuntilthemod-

ernageitwascarriedoutsolelythroughmanuallabour,sometimeswiththehelpof

toolsanddevicesenablingthetransferofheavyloads.

Inthebeginningofthe18thcentury,machinepartsstartedtobecombined

basedonpre-matching.Operatorsandassemblersoftenhadtolearnthisprocess

foryears,andthosesufficientlytrainedwereabletoassemblethefinalproduct

fromitsindividualcomponents.Demandapparentlydidnothaveasignificant

impactonthenumberofassemblersand-consequently-thenumberofendprod-

uctsmanufactured.Thedeliverytimewasverylongandthepossibilityofexactly

duplicatingaproductwaslow.Thefirstmajorchangetookplaceatthebeginning

ofthe19thcenturyinthearmamentsindustry,whereindividualpartshadtobe

fullyinterchangeable,withouttheneedtoadjustthem.Thisideawasfirstimple-

mentedbyDanielE.

Whitney,aninventorandentrepreneurworkinginthedefenceindustry.After

receivinganorderfor10,000musketsfortheUSfederalarmoury,hefirstde-

signedthetoolsrequiredtomakewholebatchesofidenticalcomponents.These

interchangeablecomponentsenabledthemassassemblyofmuskets.Whitneywas

alsothefirsttoadopttheproductmodel,whichwasakindofdimensionalstand-

ardusedforverifyingthemanufacturedcomponentspracticallyuntilthebegin-

ningofthe20thcentury,whendimensionaltoleranceswereadoptedintechnical

drawings.Thisenabledtheproductionofcomponentswiththeassumeddimen-

sionaltolerancesinmultipleproductionplants.Italsomadeitpossibletoseparate

themanufacturingprocessofcomponentsfromtheassemblyprocessoftheend

product.Asaresult,thequalificationsneededtomanufactureproductsthatrequire

assemblyweresignificantlylowered.Asregardsmorecomplexproducts,training

unqualifiedoperatorstoworkatindividualstagesoftheassemblyprocesswas

stillalongandarduoustask.Thisgaverisetotheideaofteamwork,wherebyall

theemployeeswerejointlyresponsiblefortheproductassembly,whileeachof

themwasresponsibleforonlyasmallpartoftheprocess.Alltheoperatorhadto

dowasmasterafewtasks,whichmeantitbecameincomparablyeasierandfaster

toachieveahighdegreeofspecialisationandprofessionalism,but-asitturned

outlater-italsoresultedinacertainamountofmonotonyatwork.Abreak-

throughmomentwasFord’slarge-scaleintroductionoftheassemblyline.The

inventordividedtheFord“T”modelinto5,000components,whichwereassem-

bledinafewsimplesteps.

Thiscuttheassemblytimeinhalfandreducedunnecessarydowntimeto

aminimum.Fordalsodescribedthebasicprinciplesofassembly:

-placethetoolsandthemeninthesequenceoftheoperationsothateach

componentpartshalltraveltheleastpossibledistancewhileintheprocess

offinishing,

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Modelling, simulation and optimisation of the technological processes of assembly

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