PODRŠKA PROJEKTIRANJU AUTOMATSKIH MONTAŽNIH

SUSTAVAhttp://www.fsb.hr/~zkunica/nastava/pms/plan_sw.ppt

i. Uvod

Softver (i hardver) – sredstva objektivizacije znanja, za višu učinkovitost i eksploatibilnost ljudskog (mentalnog) rada

2

Projektiranje automatske montaže i podrška: metodologija, procedure i elementi

Sa stajališta administrativnihRazvojni pristupi

Sa stajališta administrativnih funkcija (MAX, SAP)

OBLIKOVANJEIZRADA

OBLIKOVANJE PROIZVODA

(GENERIRANJE)

PLANA

IZVOĐENJE SKLAPANJA

PROGRAMIRANJE MONTAŽNIH UREĐAJA

OBLIKOVANJE MONTAŽNOGA

SUSTAVA

CAD CAE CAM

CAD-zasnovani Sa stajališta programiranjaSa stajališta montaže

3

Sa stajališta montaže

IMAGINACIJAPROIZVODA

POTREBA

znanje, iskustvo,

CADMATERIJALIZACIJA

PROIZVODA

vri

lucidnost

CADOBLIKOVANJE

SKLAPANJA(CAPP) CAD

ijeme

MONTAŽA(CAM)

e

proizvodnost( ) proizvodnost, ekonomičnost, fleksibilnost, k l ič tPROIZVOD ekologičnost,

“viši ciljevi”

4

PROIZVOD (SKLOP) mehanizam I – putanje sklapanja (ugradbenih elemenata)

MONTAŽNI SUSTAV mehanizam II – gibanja montažnih uređaja i komponenti

nestandardni uređaji i komponente

standardni uređaji i komponente komponentekomponente

5

MONTAŽNI PROCES: STRUKTURE &

OPERACIJE MONTAŽNI UREĐAJIOPERACIJE MONTAŽNI UREĐAJII KOMPONENTE

OBLIKOVANJE KATALOG

nestandardni standardni

INTEGRACIJA SUSTAVA

PRILAGODBA KONSTRUKCIJEPRILAGODBA KONSTRUKCIJE UREĐAJA I KOMPONENTI

6

Okružje za projektiranje montaže treba kombinirati alate distribuirane na dvije razine:

1. pre-alate unutar aktivnosti prethodećim projektiranju montaže,2. CAE post-alat za projektiranje montaže, koji slijedi proces oblikovanja

proizvodaproizvoda.

OBLIKOVANJE DIJELOVA FEA

OBLIKOVANJE SKLOPOVA OBLIKOVANJEMEHANIZAMA

OBLIKOVANJEPROIZVODA

MEHANIZAMA

Projektiranje montaže i aktivnosti oblikovanja proizvoda

PROJEKTIRANJE MONTAŽE

Projektiranje montaže i aktivnosti oblikovanja proizvoda

7

paleta

CA

B

bazni dio

Di k ij ij ti j i d ij t ij dij l (A) t h l šk

xz -vodoravna ravnina

Diskrepancija u orijentiranju: prirodna orijentacija dijela (A), tehnološka orijentacija (B), orijentacija zahtijevana u proizvodu (C)

8

ORIENTATION DEFINITION

ASSEMBLY MODELLINGPART MODELLING

ORIENTATION DEFINITION

PART ASSEMBLY CONFIGURATIONCONFIGURATION

fed (supplied by feeder)natural

fi l (i bl )

naturalfedfi lfinal (in assembly)

undefinedfinallayout (assembly system)undefinedpotential redundancy/conflict

Podrijetla definicije orijentacije

potential redundancy/conflict

9

Procedura projektiranja trebala bi se analizirati kao kombinacija automatski i

ASSEMBLY PLAN GENERATION

p j j jinteraktivno generiranih elemenata.

OPTIONS

Product class

Connectivity Oncheck Off

Automatic generation Onof assembly sequence Off

Automatic generation Onof assembly system layout Off

...

Primjer definicije parametara za generiranje plana

10

ii. Primjeri podrškePODRŠKA PROJEKTIRANJU

AUTOMATSKIH MONTAŽNIH SUSTAVACAE sw tvrtke

(D l i T ti )

j p

AUTOMATSKIH MONTAŽNIH SUSTAVA

Istraživački swStandardi (VDI 2860 )

(Delmia, Tecnomatix, …)

Opći sw Specijalizirani Nepovezani Katalozi

Istraživački sw(znanstveni i razvojni)

Standardi (VDI 2860…)

Opći sw p jintegrirani sw

psw programi

I-DEAS DFMAFESTOProPneu

Katalozi

Proizvođača

CATIA

Ad t

FESTOProDrive

Proizvođača

Unutar softveraSony DAC

AdeptDigital Workcell

AdeptProduction Pilot

FESTOGripper Selection

Posredničkihttp://www part-solutions com

UGS

Production Pilot

COSIMIR

http://www.part-solutions.com

11

DFA

12

13

14

15

Production Pilot

• PILOTLine

• PILOTYield

• PILOTCell

16

• PILOTLineDiscrete Event Simulation

• Line layout of connected cells

• Line balancing

• Optimized line flow

• Maximum line throughput

• Root cause analysis by looking at buffer overflow and starvation,

feeding failures, and assembly task failures

Process Management Toolsg

• Resources (capital equipment, tooling, people)

• CADparts

• Task sequence• Task sequence

• Cycle time distributions

• Process yield distributions

U d fi d• User-defined processes

Line Navigator

• Create multiple line scenarios for comparison

• Revision information

• Merge and view cells developed in PILOT Cell and PILOT Yield

• Promotes simulation model reuse

17

Financial Metrics for Objective Comparison

• Cash flow

• Profit

• Simplepayback

• Net present valuep

• Internal rate of return

• Book value

• Return On Investment (ROI)• Return On Investment (ROI)

Predict Yields

• Use product and process tolerances to compute stack-up leading to

success rate

• Use feeder, tooling, and mover tolerances to compute cell assembly

yield

• Use cell timing to compute line yields

18

19

• PILOTYieldDAC Assembly Scoring

• Import existing files from Sony DAC software and/or add parts to

build an assembly

• Automatically create 3D assembly animation using blocks as

placeholders for parts

• Replace placeholder blocks by actual CAD models

• Edit the approach, mate, and orientation paths for all parts

• Score parts on ease of assembly using time-proven Sony DAC Score parts on ease of assembly using time proven Sony DAC

system

• Enter concepts targeted for assembly and disassembly such as

direction of assembl and like processesdirection of assembly and like processes

• Use built-in flowchart to guide you in determining what makes a

part difficult to feed and pick

• Use built-in questions to guide you to a better design

Study Assembly Feasibility

• Simulate assembly sequence, motion, and timing

• Dynamic GANTT chart during simulation

• Automatic clearance, collision, and penetration detection

• Distance and penetration measurementp

• Dynamic sectioning of assembly

• Instant replay of assembly problems (forward and reverse

simulation slow motion and random access from problem log)

20

simulation, slow motion, and random access from problem log)

• Determine howeasy it is to assemble the product

21

• PILOTCell

Predict Cycle Times

• Design, lay out, program, and test workcell processes including

manual and automated processes, material handling and

packaging, and welding, painting, polishing, and stampingpackaging, and welding, painting, polishing, and stamping

• Robots, CNC machine tools, dedicated automation

• Library of feeders, grippers, conveyors, and more

• Robot off line programming and calibration• Robot off-line programming and calibration

Realistic Simulation

• Physics-based simulation (part bounce and tangle, stable states,

gravity, and gripping)

• Digital I/O and wiring diagrams

22

23

24

25

26

27

28

29

30

31

32

33

34

35

36

37

38

Varijante sustava/varijante proizvoda

Thompsonovi primjeri varijanti živih bića (1917.)

Duererovi (1471.-1528.)primjeri varijanti živih bićap j j

Dva rješenja istog j j gmehanizma (Blanding,

1999.)

39

Varijacije procesa montaže

The assembly process can be represented and modelled using generic i lstructures – generic plans.

The structures show the space and time possibility of the assembly process realisation.

2 3 4 5 6

1 Product

[1, 0, 0, 0, 0] [1, 1, 1, 1, 1] [1, 2, 2, 2, 2] [1, 0, 0, 1, 2]

Some of the structures for a product with six parts (Beneath the graphical presentation of each structure the structure’s numerical code is given.)g )

40

Varijante inicijalne orijentacije proizvoda

Hi6Hi4

Hi3Hi5

Hi2

Hi3

xz – vodoravna ravnina

41

Varijante layouta dijelova Linija(L = 8639,487 mm)

.Hi5

Okrećući stol(D = 1234,212 mm)

Hi4Hi6 Hi3

.

Hi5

z udaljenostHi2

Hi2

z udaljenostHi5-Hi6:

5924,22 mm

Hi3

Hi4

Hi6 42

Tretman identičnih dijelova proizvoda

Rasklopljeni proizvod...

Bez uzimanja u obzir jednakih

Uzimanjem u obzir jednakih (žutih)obzir jednakih

dijelova...jednakih (žutih) dijelova...

Uštede u opremi i prostoru! 43

Varijante proizvođača opreme

ABB IRB 140 FANUC LR Mate 100i AdeptSix 300

Varijante... varijante... itd. ...

44

iii. Primjer varijantnog rješenjamontažnoga sustava

Hi5

Hi3

100 mm

75 mm

Hi2Hi7

Hi2

xz – horizontalna ravnina75 mm

45

Simulacija rasklapanja (redoslijed i putanje, te pozicije dijelova prije sklapanja)

Hi3Hi5

prije sklapanja)

Hi7Hi3Hi5

t 397 Hi2tHi7 = 397 mmtHi5 = 397 mm tHi3 = 265 mm

tHi2 = 265 mm

PogledPogled odozgo

46

Varijanta I

Hi7Hi2

There are four identical pneumatic cylinders. The cylinders push parts from their positions before

Hi3

Hi5

passembly, towards required final positions, to make the assembly.

Hi5The cylinders are pretty long, implying a larger necessary space. The parts come in the assemblyThe parts come in the assembly process in ordered state --magazines.

Assembled product is removed from the assembly spot by a murder hole.

47Double acting cylinder DSNU-25-400P-A

Varijanta IIAl t th th i t IAlmost the same as the variant I. There are also four identical cylinders, but of another type – with shorter strokes. In that way it was possible to place parts closer to the assembly spot (correction of y p (position values obtained by assembly plan).

The cylinders in both variants (I & II) are chosen among many available, and applicable to this specificand applicable to this specific situation.

Double acting cylinder DSW-32-P-B

48

Double acting cylinder DSW 32 P B

Varijanta IIIThe assembly system consists of

Linear module HMP-20-400

The assembly system consists of four identical manipulators, each containing two linear modules,

d h i id ti l iand having identical grippers.

Additionally, there is also a pneumatic cylinder for the part Hi7.

Three manipulators with their grippers carry the parts to the required final positions Therequired final positions. The fourth manipulator takes the part Hi7 and delivers it at the

ti li d hi h hpneumatic cylinder, which pushes the part in its final position within the product.

Since the manipulators have only two DOFs, included pallets

49Parallel gripper HGP-35-10

, pshould be movable (two DOFs).

Varijanta IV

Vacuum gripper VAS-30-1/8-PUR

The variant IV is similar to the variant III, except a robot equipped with a

50

p q ppvacuum gripper is added to the part Hi7, so the cylinder from the variantIII is obsolete.

Varijanta Vj

The variant V is the enhancement of the variants III and IV.

The main difference -- three robots (with four DOFs each) are used in the variant V instead of manipulators in the variants III and IVthe variant V, instead of manipulators in the variants III and IV.

Consequently, movable pallets are no longer needed.

51

Varijanta VIj

Three identical robots from the variant V are replaced with one single robot.

The savings in equipment cost and space are obvious, but assembly cycle will be longer.g

52

Varijanta VIIj

Only one single robot with four DOFs, will assemble the whole product.

Since the part Hi7 requires different gripper than the rest of the parts, the assembly system should involve a possibility of gripper change.

Neglecting the gripper change subsystem, the variant VII carries further cutting of equipment and space costs. However, the assembly cycle

53becomes longer.

Vari

Kriterij rangiranja

Fleksi ProsVari-janta

Oprema ΣProizvod-nost, 60 %

Cijena, 25 %

Fleksi-bilnost, 10 %

Pros-tor, 5

%

I 4 pneumatic cylinders DSNU-25-400P-A, magazines, murder hole 4 5 3 4 4,15

4 i li d DSW 32 P BII 4 pneumatic cylinders DSW-32-P-B, magazines, murder hole 5 5 3 5 4,8

4 manipulators+grippers, pneumatic III

p g pp pcylinder, movable pallets, murder hole

3 3 4 1 3

3 manipulators+grippers

IV

3 manipulators grippers, robot+vacuum gripper, 3 movable pallets, fixed pallet, fixed pallet for assembled products

3 2 5 3 2,95

p

V 4 robots+grippers, 5 fixed pallets 3 1 5 2 2,65

VI 2 robots+grippers 5 fixed pallets 2 3 5 4 2 65VI 2 robots+grippers, 5 fixed pallets 2 3 5 4 2,65

VII single robot, 2 grippers, five fixed pallets 1 4 5 5 2,35

54Usporedba varijanti montažnog sustava

IV. DALJNJI RAD

Detailed variant design of devices, including:

l i d ti i ti f (di ) bli th (di ti d l th )• analysis and optimization of (dis)assembling paths (directions and lengths),

• simulation of assembly operations and assembly techniques (forces, deformable joints - snap fitting )deformable joints snap fitting, ...).

Implementation of assessment criteria.

Automation of the design procedure.

E i t ith t ti f bl l d tExperiments with concurrent generation of assembly plans and systems.

Modelling of CE planning situations and roles (procedures, protocols and data sharing).

Human planner's mental activities and behavior -- conscience and non-Human planner s mental activities and behavior conscience and nonconscience (intuitive) aspects of the planning.

S. Freud& Eric Berne`s transactional analysis55