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Assembly Simulation Through a Digital Mock-Up Application

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Assembly Simulation Through a Digital Mock-Up Application ASSEMBLY SIMULATION THROUGH A DIGITAL MOCK-UP APPLICATION Giampaolo Pascali, Angelo Corallo, Mariangela Lazoi and Alessandro Margherita EuroMediterranean Incubator, University of Salento, Via Monteroni s.n., Lecce, Italy Keywords: Design for assembly, Digital mock-up, Naval sector. Abstract: “Design for X” includes a set of techniques to realize the best product yet during the design avoiding re- works and loose of time and money. Among these, the design for assembly covers an important role and aims to design a product “thinking” to the physical assembling moment. Digital Mock-Up (DMU) is a process to enhance assembly feasibility and efficiency through specific design analysis and allow re- producing a product virtual assembling. Based on an action research based on a collaboration among company and university researchers, the paper aims to describe the development of a DMU application in a naval Italian aerospace company to improve a ship fuel system assembling. Technical features of the application are described. 1 INTRODUCTION company processes, the activities for assembling individual parts to obtain the final product are Different authors face the topics of the new product crucial as they use over 50% of total production development phases (Clark, Wheelright, 1995; time, with costs varying from 20% to 40% for a Crawford, Di Benedetto, 2003; Ulrich, Eppinger, single unit. The use of DFA can improve 2007; Ribbens, 2000; Rosenau et al., 1996), significantly such performance and several methods everyone specify such phase that goes from the have been developed at this purpose (Miyakawa and conceptualization until the production trough the Ohashi, 1986; Boothroyd and Dewhurst, 1986; engineering. Ulrich and Eppinger (2007) suggest Holbrook and Sackett, 1988). The research on DFA five phases: 0. Planning, 1. Concept Development, is based on the premise that the lowest assembly cost 2. System Level Design, 3. Detail Design, 4. Test, 5. can be achieved by designing a product in such a Production. Specially, the Design Phase defines the way that it can be economically assembled by the new product and prepares the work on which the most appropriate assembly system. (Boothroyd and manufacturing units will impact (Ulrich and Dewhurst, 1986). Eppinger, 2007). The main objective in the product Digital Mock-up is used to support design for design is to create a product architecture directly assembly providing assembly simulations that can linked with his functionalities. The creativity in the be used to address changes in product design and first phase of conceptualization has to be translated support the physical assembly phase. in a set of wished functions and blended in the The naval industry is an interesting context of product architecture through the design in order to research. Particular dynamics and routine are facilitate and optimize the manufacturing and the peculiarities of this sector and cannot be found in following maintenance operations providing an other industry. The products are very complex and optimized product. (Ribbens, 2000). require high-technological knowledge and skills. In the ‘design for x’ family, design for assembly Design for Assembly and Digital Mock-Up (DFA) is a particularly relevant process/approach by application can support the development of naval which product assembly issues (mostly number of system improving the company performance. parts, their insertion and orientation) are addressed Based on an action research carried by in the early design phase, with the goal to reduce Università del Salento and Avio S.p.A., the overall assembly cost, time and complexity. Among commercial application Teamcenter Visualization Mock Up (VISMOCKUP) has been integrated in the 492 Pascali G., Corallo A., Lazoi M. and Margherita A.. ASSEMBLY SIMULATION THROUGH A DIGITAL MOCK-UP APPLICATION. DOI: 10.5220/0003650304920497 In Proceedings of the 8th International Conference on Informatics in Control, Automation and Robotics (MSIE-2011), pages 492-497 ISBN: 978-989-8425-75-1 Copyright c 2011 SCITEPRESS (Science and Technology Publications, Lda.) ASSEMBLY SIMULATION THROUGH A DIGITAL MOCK-UP APPLICATION company CAD system (NX). The paper aims to the aim to fulfil goals of time and cost reduction, and answer the question “How is characterized a Digital quality improvement (Döllner, Kellner and Tegel, Mock-Up application in a naval company?”. The 2000). paper shows criticalities and benefits from the Shipbuilding is another interesting field for integration of Digital Mock-Up and CAD applying virtual assembly features as it requires a environment in a unique Product Lifecycle sophisticated product information model to achieve Management System. the seamless flow of product information. A DMU In the next section of the paper the Digital Mock- system that builds a prototype in a computer has Up process is described, further insights from the been proposed for consistent quality control. The research design are highlighted and the method used system can simulate models and assemblies on-the- and application context are described. Another fly as well as project real-world manufacturability section is dedicated to the mock-up application without the expense and time required to make a description and finally, conclusions are provided physical mock-up (Won Don, Jong-Ho and Ju Yong, underling the technological limits of the developed 2007). solution. 3 RESEARCH DESIGN 2 DIGITAL MOCK-UP 3.1 Research Method In the last years, there has been a great development of digital technologies to verify product lifecycle The study is carried out through an action research processes and reduce the need (and thus the costs) based on an inductive approach in which problems for physical prototypes. Information technologies and solutions have been deducted from observation can contribute not only to efficiency improvements of the organizational practices (Bryman, Bell, 2007; but also to improved hypothesis creation capabilities Thomas, 2006; O’Brien, 2001) and working together in engineers and organizations through technical to develop the final application. Working with Avio features such as full visualization, digital pre- in several research projects, the researchers of assembly and simulation (Baba and Nobeoka, 1998). Università del Salento are very confident with the In particular, digital mock-up (DMU) allows company problems and ICT used. The DMU project designers to investigate the assembly feasibility of a has been launched from Avio to improve its product and the constraints imposed by products design through the integration of manufacturing processes. DMU allows the user to VISMOCKUP and the NX CAD system in a way to represent the structure of a product and the accurate work in the direction of a product lifecycle position of its geometry, and enables a management system for the company. To develop multidisciplinary presentation of assembly processes the DMU system, three phases have been and analysis (design ‘in context’) such as insertion, accomplished. In the first phase, an analysis has view and collision. been done to evaluate how realizes the integration Through DMU, it is possible to obtain a virtual and its potentialities. A second phase has been of representation of a product and simulate the shape development and the two software tools have been and spatial positioning of its components or integrated in order to guarantee the best performance subsystems, as well as of the necessary production for the company. In a last phase, the DMU/CAD tools. By providing the basic representation of a integration has been tested. This phase has been product, DMU permits to share the core product data concluded with a positive results and the application that the different company areas and disciplines use is widely used inside the company. This action to collaborate. research is carried out by a team of engineers of DMU has been extensively applied in different Avio S.p.A and researchers of University of Salento industries such as automotive (Rooks, 1998) and and the results are presented in the paper in the form aerospace. Ford Motor Company is today strongly of case study (Yin, 1994) to address the research involved in the adoption of virtual manufacturing question: “How is characterized a Digital Mock-Up tools and processes designed to catch possible application in a naval company?”. It is a single case manufacture concerns by simulating automotive study that wants to express the experiences matured performance. An optimized product development from the collaboration beetwenn Avio and process based on the use of DMU and rapid Università del Salento in the context of DMU prototyping has been defined in the automotive with highlighting the importance and high relevance of 493 ICINCO 2011 - 8th International Conference on Informatics in Control, Automation and Robotics this kind of system for the naval company. To distance is expressed in the same unit of measure as answer to the research question has been developed the part. For the two LOD defined we have set a a software solution and the related findings have chordal value of 0.2 and 0.5 millimetres. described highlighting technological aspects and Furthermore the second LOD defined has forty managerial implications. percent less or fewer polygons respect the first (because its Simplify option has been set to 0.4). 3.2 Company Context Finally we have used a lossless compression for the first LOD and a lossy compression in the second AVIO is a world leader in the design, production
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