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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
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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
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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”
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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
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MONTAŽNI PROCES: STRUKTURE &
OPERACIJE MONTAŽNI UREĐAJIOPERACIJE MONTAŽNI UREĐAJII KOMPONENTE
OBLIKOVANJE KATALOG
nestandardni standardni
INTEGRACIJA SUSTAVA
PRILAGODBA KONSTRUKCIJEPRILAGODBA KONSTRUKCIJE UREĐAJA I KOMPONENTI
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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
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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)
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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
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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
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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
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DFA
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Production Pilot
• PILOTLine
• PILOTYield
• PILOTCell
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• 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
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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
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• 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
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• 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
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25
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32
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35
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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 )
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Varijante inicijalne orijentacije proizvoda
Hi6Hi4
Hi3Hi5
Hi2
Hi3
xz – vodoravna ravnina
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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. ...
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iii. Primjer varijantnog rješenjamontažnoga sustava
Hi5
Hi3
100 mm
75 mm
Hi2Hi7
Hi2
xz – horizontalna ravnina75 mm
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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
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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
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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.
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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
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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