Professional Documents
Culture Documents
Z.B. Wang
Mechanical Engineering Department, National University of Singapore, Singapore, and
1. Introduction
Product design and assembly planning are critical to the
product development (PD) process. Generally, design of
components is generated before deciding their assembly and
sequence. The assembly is evaluated and modifications are
made when required. Design for assembly (DFA) (Boothroyd
et al., 2001) aims to design products prioritising assembly by
reducing the components and designing easy-to-assemble
components based on DFA rules. Ergonomics in assembly
design studies the layout of the workspace, the sequence, the
tools and components handling and the effects on human.
DFA tools allocate time to the human actions required for
assembly but there is no consideration of their effects.
Virtual reality (VR) assembly tools create an immersive VR
environment with 3D representations of a product, the
human operator and the work environment. Advanced 3D
human-computer interaction (HCI) interfaces are used to
simulate the manual assembly process. Haptic devices
The current issue and full text archive of this journal is available at
www.emeraldinsight.com/0144-5154.htm
Assembly Automation
33/4 (2013) 345 359
q Emerald Group Publishing Limited [ISSN 0144-5154]
[DOI 10.1108/AA-10-2012-058]
345
Assembly Automation
Assembly Automation
LCD Monitor
HMD View
Monitor View
Web Camera
(Firefly2)
Real Object
Head Mounted Device
(Wrap920)
Virtual models
can use his bare hands to create, grab and manipulate 3D models
in the design environment to assemble the virtual components.
The system consists of five modules, namely, the AR tracking
module (ARTM), the BHI module (BHIM), the data exchange
module (DEM), the CAD module (CADM), and the
visualization module (VM) (Figure 3). ARTM performs
tracking and registration. BHIM detects and tracks the hands
and fingers of the user and calculates their 3D poses for
Markers
AR WCS origin marker
object markers
Virtual models
- Detection
- Recognition
- Pose Estimation
- Hand Strain
Detection
Direct
Manipulation
Real objects
Data Exchange
Module
Collision Detection Library
Stereo camera
Web camera
Tracking Module
Gestures
Design Parameters
- Dimensions
- Positions
- Orientations
Part Creation
Addition and Position
Combination of Parts
Design
Generation
Detailed design
Assembly constraints
- Mating constraints
- Geometric
constraints
Assembly creation
Mates definition
Solid Works API
Visualization Module
3D Rendering
Display Tools
OpenGL
OpenCSG
Desktop Monitor
Head Mounted Device
347
Assembly
Evaluation
Assembly Automation
YOA
YOM
XOA
XOM ZOA
ZOM
ZH
YCF
ZCB
XVA
YCB
YA
YVA
YH
XH
ZA
XA
Hiro
Real Object with Object
Marker
ARWCS Origin Marker
348
Assembly Automation
Base Model
Model 1
Design Parameters
1
Design parameters
Assembly Model
Mating Constraints
Assembly
constraints
Base Model-Model 1
Assembly
Evaluation
Sequence 1
Assembly
constraints 1
Base Model-Model 2
Time taken
Model 2
Base Model-Model 3
Orientation
Changes
Design Parameters
2
Assembly
constraints 2
Base Model
Model 3
Model 1
Design Parameters
3
Model 2
Assembly
constraints 3
Model 3
Errors
Hand Strain Index
Sequence 2
Assembly Automation
using two unit vectors, namely, V^ th!if between the thumb and
the index finger and V^ hc!mp between the midpoint of the first
vector and the centre of the hand. The x-axis is V^ th!if , the
z-axis is the cross product of V^ th!if and V^ hc!mp , and the y-axis
is the cross product of the z- and x-axes (Figure 4(a)). At the
first contact between the hand and a virtual model,
the coordinate system, CSfc, is recorded and the displacement
of the hand from the centroid of the virtual model is
recorded as T PMP!VMC . The hand rotation RCS fc !CS new is the
rotation from CSfc to the new coordinate system CSnew at
the new hand position and it is calculated using equation (1).
The resultant transformation matrix of the virtual model,
TM vmt1 , is expressed in equation (2), where
^ fc ; Y^ fc ; Z^ fc ; X
^ new ; Y^ new and Z^ new are the unit vectors of the
X
x-y-z axes of CSfc and CSnew, respectively:
0^
Xnew x
B
BX
RCSfc !CSnew B ^ new y
@
^ new z
X
1 0^
Xfc x
Y^ new x Z^ new x
C B
B^
Yfc x
Y^ new y Z^ new y C
CB
A B
@
Y^ new y Z^ new z
Z^ fc x
^ fc y X
^ fc z
X
C
C
Y^ fc y Y^ fc z C
C
A
^
^
Zfc y Zfc z
1
350
Assembly Automation
Flexural
Extension
Radial
Ulnar
Pronation
Supination
Discomfort range
958
858
458
708
1308
1458
. 45% of ROM
. 45% of ROM
. 45% of ROM
. 45% of ROM
. 45% of ROM
. 45% of ROM
.438
.388
.208
.328
.598
.658
Xnp
Assembly Automation
^ np to
are calculated from the rotations about Z^ new of CSnew from X
^ new , about X
^ new of CSnew from Z^ np to Z^ new and about Y^ new of
X
^ np to X
^ new , respectively. The rotation from CSnp to
CSnew from X
^ np to
CSnew, RCSnp !CSnew , is a combination of the rotation from N
^ new with u, as
^ new , RN !N , and the rotation RN2 u about N
N
np
new
indicated in equation (3), where N represents the
corresponding axis to find u. RCSnp !CSnew is derived using
equation (1) and is derived from RN2 u:
%S i
^ np V^ np
^ V^ new
X
X
hc!mp
hc!mp
np
4i
^ Z^ new 0
X
np
^ V^ new
X
Z^ new 1
hc!mp
np
4ii
4iii
5. Design generation
Using BHI to create 3D virtual models allows a user to think
and experiment with his hands. Components can be created
Hand/wrist posture
%Si
1
2
3
4
5
0-9
10-19
$20
352
Efforts/min
,10 (0.5)
10-29 (1.0)
30-49 (1.5)
50-79 (2.0)
$80 (3.0)
, 4 (0.5)
4-8 (1.0)
9-14 (1.5)
15-19 (2.0)
$20 (3.0)
Assembly Automation
Gestures
Tracked features
ARDnA operations
Grab
Move
Hand movements
Finger movements
Rotate
Pinch
Point and
click
6. Assembly evaluation
Assembly Automation
First
Block?
No
No
In desired
transformation?
Manipulate
existing primitives
Yes
Report error to
user
Select Boolean
operation
Perform modelling
operations in CAD
software
Send modelling
information to
CAD software via
DEM
No
Successful
Operation?
Yes
Design
completed?
Yes
Design Completed
No
Assembly Automation
355
Assembly Automation
7. Case study
A case study on the design and assembly of an electric toy car
was conducted to demonstrate the ARDnA methodology and
system. The design requirements are the car must be of
similar size to an existing toy car, a predefined electric motor
must be used and it must be easy-to-assemble.
The designer starts by creating a block primitive as the body
using an existing toy car as a spatial reference. The front nose
is created using a wedge and the wheel using a cylinder.
As more than one wheel is required, the wheel is duplicated
and placed at different locations. The motor is added using a
real motor. The real motor is tracked in the ARWCS by
affixing marker onto it (Figure 10(c)). The designer
manipulates the motor and adds it to the virtual model of
the car, using both real and virtual objects. Finally, a spoiler
(a wedge) is created and placed on top of the motor.
Figure 10 Design generation of a toy car in ARDnA
(a) Creating a block for the chassis and a wedge for the nose
Motor
(c) Adding the real motor to the toy car
356
Assembly Automation
Nose Design
Spoiler Design
Wheel Design
(b) Detailed design of the individual components
Assembly Automation
(c) Assembly issue when assembling the spoiler (detected wide pinch
hand strain and interference from the rear wheels)
Sequence
Total time taken (s)
No. of orientation changes
No. of errors
HSI
Body-nose-wheel1-wheel2-wheel3-wheel4-motor-spoiler
90
1; at body-wheel3
Body (1808)
0
1.5; at body-spoiler
Wide pinch strain of 14%S of duration 7s
Body-nose-motor-spoiler-wheel1-wheel2-wheel3-wheel4
78
1; at body-wheel3
Body (1808)
0
0
References
Assembly Automation
359