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Topics Assembly as zero-stress location AKA Exact Constraint, Proper Constraint, or Kinematic Design AKA 3-2-1 assembly
Assembly features as carriers of constraint,
operationalizing the coordinate frames
Non-zero-stress assemblies
Mathematical analysis of constraint
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Assembly = Constraint
Assembly = removal of dof = application of constraint As constraint is applied, degrees of freedom are taken away so that a part gets to where it is supposed to be. When parts are where they are supposed to be, the KCs can be delivered, assuming no variation This is called the nominal design
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KC=Key Characteristic
BODY TO HINGE FLAP1: 6 DOF HINGE FLAP 1 TO HINGE FLAP 2: 5 DOF HINGE FLAP 2 TO DOOR: 6 DOF
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Definitions of Assemblies
Whitehead: An instrument can be regarded as a chain of related parts any mechanism whose function is directly dependent on the accuracy with which the component parts achieve their required relationships.The Design and Use of Instruments and
Accurate Mechanism, by Thomas North Whitehead, 1934
Whitney: An assembly is a chain of coordinate frames on parts designed to achieve certain dimensional relationships called Key Characteristics between some of the parts or between features on those parts. Designing Assemblies,
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statically determinate
properly constrained
kinematic or semi-kinematic ~ 3-2-1
statically indeterminate
over-constrained
You cant just put them together Constraint is a property of the nominal design
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The contact permits some dof to move with respect to each other and prevents motion of other dof. The black ones can move. The red ones cant.
Z Y X
Different kinds of surface pairs permit and prevent motion of different dof
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Degrees of Freedom
An objects location in space is completely specified when three translations (X, Y, Z) and three rotations (. X ,. Y ,. Z) are specified How many DOFs are constrained? z cube on table (x-y plane) .z
cube at floor-wall interface cube at floor-two walls interface ball on table ball at floor-wall interface round peg in blind round hole x y
.x
.y
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Constraint - 1
Proper constraint provides a single value for each of a bodys 6 degrees of freedom This is done by establishing surface contacts with surfaces on another part or parts If less than 6 dof have definite values, the body is
under-constrained If an attempt is made to provide 2 or more values for a dof, then the body is over-constrained because rigid bodies have only 6 dof Any extra needed dof must be obtained by deforming the object
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Constraint - 2
If the X location of the left pin changes, where will the blue plate go?
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LOCATING PIN
LOCATING PIN
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one pair of features multiple features several parts working together, each with its own features
5 1 6 5 1 blind hole pin to hole pin to slot
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Kinematic constraint passes from part to part across the feature joints The degree of constraint can be calculated using Screw Theory Proposed feature designs and KC chains can be examined using Screw Theory to see if they convey the desired amount of constraint and avoid constraint errors
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Constraint - 3
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A closed chain of frames is set up A numerical test is done to see if the chain closes
If, so, the assembly is called fully constrained
Actually, it should be called consistent
Detailed tests for constraint/consistency problems are done by making small shifts and testing for interference Tolerance studies are done the same way Analysis requires detailed geometry Results depend on how the model was built
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Some Examples
C
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Kinematic design seeks to determine locations of parts solely or almost solely by means of geometric compatibility Locked-in stresses are kept so low that they are negligible Exact constraint design is equivalent to 3-2-1 assembly In effect, in a kinematic assembly, the parts act as fixtures for each other You just put them together
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Three-leg stool rests firmly and is fully constrained Four-leg stool gives the security of an extra leg and wider footprint but will not rest firmly unless the legs are elastic enough to deform until all four are in contact, or there are screw adjustments Other examples
shrink fit of wheel on shaft preloaded angular contact ball bearing pairs pre-stressed concrete and case-hardened armor plate planetary gear trains
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Boeing:
Ensure that there is open space at max material condition Fill the gap with shims, reducing gap to XXX Report remaining gap to Engineering Lately: use better process control to predict gaps and prepare standard shims in as many cases as possible
Airbus:
Make parts from 3D CAD/NC Join them directly Look, Dr Whitney, no shims!
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Preload increases contact stress, creating a stiff bearing system (see next page)
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Fixed housing
Preload nut
Rotating shaft
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A B C
World Model
B C
Use consistency check to find joining errors Cant detect most over- or under-constraints
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Increase the diameter of one hole Increase the diameter of both holes Use one hole and one slot Match drill one hole pair and use a slot
Accept a little locked-in stress We will use these ideas later when we use features to transfer dimensional constraint and location from part to part using the Datum Flow Chain
over-constraint = ambiguity about dimensional transfer
requires a stress analysis to decide where the parts are
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It takes skill to put the parts together and get them just right The assembly task is operator-dependent
Fasteners have to be tightened in a particular sequence It is hard to get welded parts out of the fixture
Some parts will assemble easily but other identical ones will not You can never get everything to line up the way you want it to Results are inconsistent
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Locating gets it there Stabilizing keeps it there This area is a common cause of confusion
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Whiteheads Definitions
Enough Joints
Effected by small force
Pure kinematic design
3 legged stool with pointtipped legs
Semi-kinematic design with redundant constraint in the small contact area of each locator
3 legged stool with nonzero contact area at each leg tip
Semi-kinematic design
3 legged stool with nonzero contact area and each leg bolted down tight
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Over-constraint
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Taxonomy of Assemblies
Underconstrained
Properly Constrained
Over-constrained
Mechanisms
zero-stress
(or almost
zero stress)
assemblies that deliver Interference KCs by and stress achieving location (using transform T)
Line fit
Clearance
AKA redundant
=Noise
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Duplicated arrangements
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Allowed motion of the black part is shown, when the red part is stationary
Images removed for copyright reasons.
Source:
Table 4-3 in [Whitney 2004] Whitney, D. E. Mechanical Assemblies: Their Design, Manufacture,
and Role in Product Development. New York, NY: Oxford University Press, 2004. ISBN: 0195157826.
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y z
x y
y z
Pin in Slot
P xc
Px
Two Plates
Nxc
Py
l
y z
ymax
ymin y
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The constraint testing methods described next must be applied with caution, depending on which option is used
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Elementary surfaces (TTRS) - one-sided Have location, no size Intersect these to make new features. They will contain overconstraint if 2-sided. They will have location and size if 2-sided Make new features from scratch. They will not contain over-constraint even if 2-sided. They will have location and size if 2-sided Intersect these to make compound features - will contain overconstraint if 2-sided or if mistakes are made
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M = 3(n g 1) + fi n = number of links g = number of joints M = 0 . proper constraint M < 0 . over - constraint M > 0 . under - constraint
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Our Approach
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The contact permits some dof to move with respect to each other and prevents motion of other dof. Different kinds of surface pairs permit and prevent motion of different dof
Z Y X
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Z Y
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Reciprocal of Screw
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In general, force and velocity (or any pair of variables whose product = power) are related by an impedance (v=iR, for example) When parts are rigid and friction is zero, all impedances are zero or infinite.
Any velocity! No force! Any force!
No velocity!
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M 0 0 1 0 0]
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T= recip (W) = [0 0 0 0 1 0]
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W = (recip (T)) = [0 0 0 -1 0 0 0 0 0 -1 0 0 0 0 0 1 0 0 0 0 0 0 1 0 0
} }
Twist Representation of Plate and Slotted Pin Joint Shows What Motions are Allowed
2 x 1 part ctr coords z y
y x y
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z
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{ {
. v
[0 0 0 0 1 0]
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z
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{ {
. v
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=1 0 0 0 0 -2 = X force at pin 0 0 1 0 0 0 = Z force 0 0 0 1 0 0 = X Moment 0 0 0 0 1 0 = Y Moment The wrench has four rows because the feature can resist four different forces
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If any motion exists in TR, then every joint this part has allows this motion
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function R = recip(T) % Takes the reciprocal of a screw matrix p = (null(T))'; [i,j]=size(p); if i>0 R = flip(p); R=rref(R); else disp('empty matrix') R=zeros(0); end % rref finds row-reduced echelon form % takes transpose function W = flip(WU) % FLIPs columns of WU % col 1 becomes 4, 2 becomes 5, and 3 becomes 6 % col 4 becomes 1, 5 becomes 2, and 6 becomes 3 [i,j] = size(WU); if j == 6 for l=1:i for k=1:3 W(l,k) = WU(l,k+3); W(l,k+3) = WU(l,k); end end W; else end
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T2=[0 0 0 1 0 0]
T1=[0 0 0 0 1 0] X
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T12=?
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T2=[0 0 0 1 0 0] T2 = 0 0 0 1 0 0
W2=recip(T2) W2 = 0 0 0 0 0 1 0 0 0 0 0 1 0 0 0 0 0 1 0 0 0 0 0 1 0 0 0 0 0 1
So it cant move
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If a wrench appears in WR then every joint can exert that wrench, which means over-constraint But if WR is empty, it does not mean that there is no over-constraint! You have to check all pairs, triplets, etc.
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} }
. (Wi)=WU .
TR
WR
reciprocal . = union
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The assembly
2 4 x x X f1 Y y y y x f2 2 y x f3 Z z z z z
Z
x y y
X Y
f1=6
f2=16
f3=Library Feature 9
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T1=[0 0 1 2 -2 0;0 0 0 0 0 1] T1 = 0 0 1 2 -2 0 0 0 0 0 0 1 T2=[0 0 1 6 -2 0;0 0 0 1 0 0;0 0 0 0 0 1;0 1 0 0 0 2] T2 = 0 0 1 6 -2 0 0 0 0 1 0 0 0 0 0 0 0 1 0 1 0 0 0 2 T3=[0 0 0 1 0 0;0 0 0 0 1 0;0 0 1 0 0 0] T3 = 0 0 0 1 0 0 0 0 0 0 1 0 0 0 1 0 0 0 W1=recip(T1) W1 = 1.0000 0 0 1.0000 0 0 0 0 W2=recip(T2) W2 = 0 1.0000 0 0 W3=recip(T3) W3 = 0 0 1 0 0 0 0 1 0 0 0 0
0 0 -2.0000 0 0 2.0000 0 1.0000 0 0 0 0 1.0000 -0.0000 0.0000 0 -0.0000 2.0000 0 1.0000 0 0 0 0 1 0 0 0 9/21/2004
0 0
WU=[W1;W2;W3] WU = 1.0000 0 0 0 0 -2.0000 0 1.0000 0 0 0 2.0000 0 0 0 1.0000 0 0 0 0 0 0 1.0000 -0.0000 0 1.0000 0.0000 0 -0.0000 2.0000 0 0 0 1.0000 0 0 0 0 1.0000 0 0 0 0 0 0 1.0000 0 0 0 0 0 0 1.0000 0 TU=recip(WU) TU = 0 0 1.0000 2.0000 -2.0000 0.0000
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Intersect all twists: TU123=[T1;T2;T3] TU123 = 0 0 1 2 -2 0 0 0 0 0 0 1 0 0 1 6 -2 0 0 0 0 1 0 0 0 0 0 0 0 1 0 1 0 0 0 2 0 0 0 1 0 0 0 0 0 0 1 0 0 0 1 0 0 0 WU123=recip(TU123) WU123 = 0 0 0 1 0 0 Intersect all pairs of twists:
TU12=[T1;T2]
TU12 =
0 0 1 2 -2 0 0 0 0 0 0 1 0 0 1 6 -2 0 0 0 0 1 0 0 0 0 0 0 0 1 0 1 0 0 0 2 WU12=recip(TU12) y z WU12 = 0 1.0000 -0.0000 0 0.0000 2.0000 0 0 0 1.0000 0 0
F &M Mx
Mx
2 4 x X f1 Y y y y x f2 2
0 0 1 2 0 0 0 0
Mx Mx My
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1 2 WU12 = 0 1 0 0 0 2
Y Mx X
3
WU12 =
0 0
Z
0 1 0 0
My
WU23 =
0 0 0
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Y
1 0
Z
0
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Second Example
2 4
Analysis results:
x f2 y 2
x X f1
Y y
f3
Z z z
0 0 1 0 0
0 0 0 1 0
0 1 0 0 1
1 0
T2 = 0 0 0 1
0 0 0 0
1 0 0 0
6 0 0 0
-2 0 1 0 0 1 0 -6
TU = []
empty matrix
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x y 1 X Y 1 2 y z Z z y x y
Use library features 18 and 19 instead of 6 and 16. These X-Y locators do not fight with each other over orienting the top plate and do not fight with the bottom plate over orienting the top plate
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. (Wi)=WU .
TR
. =
recip
*No direction of motion can be provided by all these features #One or more directions of motion can be provided by all these features
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recip
*No force or moment can be resisted by all these features #One or more forces or moments can be resisted by all these features
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Our solution is based on Screw Theory and a method due to Konkar for intersecting twists It is based on tracing paths through the mechanism from a link of interest to a fixed link Separate motion and constraint analyses are done
Our method works for a class of mechanisms It can be applied to a succession of subassemblies in an assembly sequence A complete solution method exists - see the CD
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END NODE
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L1
1 R2 L1
L3
R3
R2
R2
R3
L3 2 L4
L2
L4
L2
R1
R4
R4
L5 R1 2 R4
The required unions and intersections can be written as a Boolean expression and fed right into Matlab
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All the dof of joints connected to the link of interest must be independent of each other
Same as saying there cannot be any cross-links between paths near link of interest
L1 This mechanism is both overand under-constrained. Our method does not work on it. The Kutzbach criterion also gives the wrong answer.
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Fixed
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3 1 2 4 (1 2) 3
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Slocum A. H.,Precision Machine Design, New York: Prentice-Hall, 1991. Smith, S. T., and D. G. Chetwynd, Foundations of Ultraprecision Mechanism Design, Philadelphia: Gordon and Breach, 1992 Whitehead, T. N., The Design and Use of Instruments and Accurate Mechanism, New York: Dover Press, 1954.
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Publications
Whitney, D. E., Gilbert, O., and Jastrzebski, M., "Representation of Geometric Variations Using Matrix Transforms for Statistical Tolerance Analysis in Assemblies, Research in Engineering Design, (1994) 6: pp 191-210 Mantripragada,R., Cunningham, T. W., and Whitney, D E, Assemblyoriented Design: A New Approach to Designing Assemblies, Proceeding, IFIP WG5.2 Workshop on Geometric Modeling in CAD, May 19 - 23, 1996. Mantripragada, R. and Whitney, D. E., The Datum Flow Chain, Research in Engineering Design, v 10, 1998, pp 150-165. Mantripragada, R. and Whitney, D. E., Modeling and Controlling Variation Propagation in Mechanical Assemblies using State Transition Models, IEEE Trans on Robotics and Automation, 1, no 1, Feb, 99, pp 124-140. Adams, J D and Whitney D E, Application of Screw Theory to Constraint Analysis of Assemblies of Rigid Parts, 1999 IEEE ISATP Whitney, D E, Mantripragada, R., Adams J D, and Cunningham, T W, Use of Screw Theory to Detect Multiple Conflicting Key Characteristics in Complex Mechanical Products, 1999 ASME DFM Conf
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