小支座 偏心支座机械加工工艺规程和镗φ25H7孔夹具设计(全套含CAD图纸)
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上传时间:2018-01-04
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GSELIGERETALEDS,ADVANCESINSUSTAINABLEMANUFACTURINGPROCEEDINGSOFTHE8THGLOBALCONFERENCE149ONSUSTAINABLEMANUFACTURING,DOI101007/9783642201837_22,SPRINGERVERLAGBERLINHEIDELBERG2011METHODOLOGYFORHIGHACCURACYINSTALLATIONOFSUSTAINABLEJIGSANDFIXTURESJJAMSHIDI,PGMAROPOULOSDEPARTMENTOFMECHANICALENGINEERING,UNIVERSITYOFBATH,UKABSTRACTTHEABILITYTOACCURATELYMEASURETHECOMPONENTSOFJIGSANDFIXTURESDURINGTHEIRINSTALLATIONDETERMINESTHESTATEOFTHEIRPRECISION,ESPECIALLYFORLARGESIZEPRODUCTSANDAPPLICATIONSTHISMATTERISCRUCIALINMASSCUSTOMISATIONWHERESMALLBATCHESOFPRODUCTSANDCOMPONENTSWITHHIGHVARIETYINDESIGNAREMANUFACTUREDPRODUCTQUALITYSHOULDBEINHARMONYWITHRAPIDCHANGEOVERPHILOSOPHYASCOMPROMISINGQUALITYFORSPEEDISNOTFORGIVABLEFORSENSITIVECOMPONENTSANDASSEMBLIESSUCHASTHOSESEENINTHEAEROSPACEINDUSTRYITISNECESSARYFORTHEINSTALLATIONOFTHEJIGSANDFIXTURESTOBEHIGHLYACCURATEINORDERTOMINIMISETHEUSEOFTOLERANCEBUDGETDUETOVARIATIONSINJIGSANDFIXTUREPOSITIONINGMAJOROVERHEADCOSTSFORJIGSANDFIXTURESPARTICULARLYINTHEAEROSPACEINDUSTRYLEDTOTHEDEVELOPMENTOFTHECONCEPTOFFLEXIBLEANDRECONFIGURABLEJIGSANDFIXTURESREUSABILITYOFRECONFIGURABLEJIGSANDFIXTURESMAKESTHEMATTRACTIVEFORSUSTAINABLESOLUTIONSASTHEIRCOMPONENTSCANBEREUSEDFORSEVERALVARIANTOFAPRODUCTORASSEMBLYTHEMAINDRAWBACKSOFTHISTYPEOFJIGSANDFIXTURESHAVEBEENTHEIRPOORACCURACYANDRELIABILITYINTHISPAPERACCURATEPOSITIONINGOFTHEKEYCOMPONENTSOFSUSTAINABLEJIGSANDFIXTURESISINVESTIGATEDTHEFACTORSAFFECTINGTHEPERFORMANCEOFTHEJIGSANDFIXTURESAREREVIEWEDFROMTHEINSTALLATIONSTAGETHEPAPERINTRODUCESAMETHODOLOGYFORMINIMISINGUNCERTAINTIESINPOSITIONINGOFTHEHOLDSANDCLAMPSFORFLEXIBLEJIGSANDFIXTURESKEYWORDSSUSTAINABLEJIG,JIGINSTALLATION,CALIBRATIONUNCERTAINTY,JIGMONITORING,METROLOGY,REUSABLEJIG1INTRODUCTIONFACTORSSUCHASQUALITYANDRELIABILITYHAVELONGCONVERTEDTOIMPLICITCHARACTERISTICSOFTHENEWPRODUCTSRECENTMARKETTRENDSHAVEFORCEDMANUFACTURINGINDUSTRIESTOMOVETOWARDSMASSCUSTOMISATIONINTHEIRPRODUCTSANDSERVICERANGEINCREASEDVARIATIONINTHEDESIGNOFNEWPRODUCTSISFOLLOWEDBYASECONDWAVEOFVARIATIONWITHHIGHERAMPLITUDEATSUBASSEMBLIESANDCOMPONENTLEVELSTATEOFTHEARTMANUFACTURINGSYSTEMSANDTECHNOLOGIESHAVEPROVIDEDMOREFLEXIBILITY,ENABLINGDESIGNERSTOTHINKMOREFREELYFORINSTANCENEWLARGEVOLUMEMEASUREMENTSYSTEMS,DEVELOPEDINTHEPASTFEWYEARS,ARECAPABLEOFMEASURINGSEVERALDECAMETREDISTANCESSUCHTECHNOLOGIESFACILITATETHEVERIFICATIONOFLARGESIZECOMPONENTSTHATUSEDTOBEMANUFACTUREDFROMSEVERALASSEMBLEDCOMPONENTSTHEMANUFACTURINGOFLARGESIZEPRODUCTSREQUIRESSPECIALISTJIGSANDFIXTURESINORDERFORTHEIRCOMPONENTSTOBEHELDINTHEDESIREDORIENTATIONDURINGBUILDANDASSEMBLYTHISREQUIRESMAJOROVERHEADCOSTTHATCANONLYBEJUSTIFIEDBYMASSPRODUCTIONINSOMECASESOROTHERWISETHECOSTOFFINISHEDPRODUCTSCANBEVERYHIGHTHISISSUECONTRADICTSWITHTHEMARKETTRENDSWHERECUSTOMERSARECONSTANTLYLOOKINGFORHIGHERVALUEFORTHEIRMONEYINATYPICALPRODUCTTHEVARIATIONINTHEPRODUCTCREATESAMORESUSTAINABLEBUSINESSASITCANFULFILTHENEEDSOFARELATIVELYLARGERMARKETFLEXIBLEANDRECONFIGURABLEJIGSANDFIXTURETHATCANBEFORMEDINDIFFERENTSHAPESTOSUPPORTDIFFERENTVARIATIONOFPRODUCTSISAKEYSOLUTIONFORTHEABOVECHALLENGESTHECONCEPTOFFLEXIBLEJIGEXISTEDFORSEVERALYEARSINTHERESEARCHDOMAIN1HOWEVER,THEYARENOTFULLYUTILISEDTOAGREATEXTENTINREALPRODUCTIONFACILITIESESPECIALLYFORLARGESIZEPRODUCTMANUFACTURERS,SUCHASAEROSPACETHISISDUETOTHECHALLENGESRELATEDTOTHEIRINITIALINSTALLATION,POORCALIBRATION,ANDREPEATABILITYTHATOFTENEXCEEDTHETOLERANCEREQUIREMENTTHEMANUFACTURINGOFTHESEJIGSANDFIXTURESFROMHIGHQUALITYKEYCOMPONENTSASWELLASTHEIRINTEGRATIONWITHLARGEVOLUMEMETROLOGYSYSTEMSCANREDUCETHEABOVELIMITATIONSTHISPAPERCOVERSMETROLOGYISSUESRELATEDTOTHEINSTALLATIONANDCALIBRATIONOFFLEXIBLEJIGSANDFIXTURESASWELLASTHEIRMONITORINGDURINGSERVICE2RELATEDWORK21MANUFACTURINGANDASSEMBLYOFLARGESCALEPARTSTYPICALLYPRIORTOPRECISIONMANUFACTURINGOFMECHANICALPARTSITISESSENTIALTOMOVETHERAWMATERIALTOTHEMACHINEBENCH,PROCEEDWITHROUGHCUTTINGTHENFINEALIGNMENTANDCLAMPINGATTHISSTAGETHEPARTISREADYFORMACHININGOFITSHIGHPRECISIONKEYFEATURESHOWEVER,THISISNOTALWAYSPOSSIBLEFORLARGESIZEAND/ORHEAVYCOMPONENTSLARGESCALEPRODUCTSREFERTOTHOSEWITHCOMPONENTSTHATARENOTECONOMICALLYPOSSIBLETOHANDLEORMOVEAROUNDINTHEFACTORYFORFABRICATIONANDASSEMBLYPURPOSES2THEMANUFACTURINGANDASSEMBLYPROCESSESOFTHESEPARTSENCOMPASSMOVEMENTOFTHEMACHINESANDSYSTEMSTOTHEDESIREDLOCATIONANDORIENTATIONWITHRESPECTTOTHESEPARTSSUCHPARTSARENORMALLYHELDINTHEIRPOSITIONSUSINGLARGESIZEJIGSANDFIXTURESIFTHESEPARTSAREPRODUCEDINSMALLBATCHSIZESTHATISTHECASEFORAEROSPACEINDUSTRIES,HIGHOVERHEADCOSTPERPRODUCTWILLOCCURTHEREHAVEBEENMANYATTEMPTSTODESIGNANDMANUFACTUREJIGSANDFIXTURESSOTHATTHEYCANHOLDANUMBEROFVARIANTSOFCOMPONENTS3,4HOWEVER,THISAPPROACHISNOTFEASIBLEFORPARTSWITHSENSITIVEORKEYFEATURESDUETOTHEIRHIGHACCURACYREQUIREMENTSJJAMSHIDI,PGMAROPOULOS150ADJUSTABLE,RECONFIGURABLEJIGSANDFIXTURESPRODUCELOWERREPEATABILITYOVERTIMECOMPAREDTOFIXEDONESFIXEDJIGSHAVEPERMANENTTOPOLOGYACHIEVEDTHROUGHTHEIRPERMANENTJOINTSTHATAREWELDEDORRIVETEDMECHANICALFAILUREOFTHESEJIGSANDFIXTURESFOREXAMPLEDUETOFATIGUEANDPLASTICDEFORMATIONISAMAINCAUSEOFTERMINATINGTHEIRSERVICEANDSENDINGTHEMFORRECYCLINGWITHSMALLBATCHMANUFACTURINGREQUIREMENTSITISNOWCOMMONTORETIREACONFORMINGJIGASTHEIRSERVICELIFEDEPENDSONTHELIFEOFPRODUCTSINOTHERWORDSSOONAFTERTHECEASEOFMANUFACTURINGAPARTSVARIANT,THEASSOCIATEDJIGSANDFIXTURESBECOMEREDUNDANTEVENIFTHEJIGSARESTILLINWORKINGORDER,THEYHAVETOBESCRAPPEDANDSENTFORRECYCLINGTHISMETHODBRINGSTHEBURDENOFHIGHENERGYCONSUMPTIONFORRECYCLINGEVENFORTHEFIXEDJIGSANDFIXTURESTHEDRIFTINTHELARGESIZEPARTSANDJIGCANAFFECTTHEACCURACYOFALARGESIZEASSEMBLY5SEVERALMETHODSFORANALYSINGJIGRIGIDITYHAVEBEENDEVELOPED6TOEVALUATETHEIMPACTOFVIBRATIONONLARGESIZEJIGSINANYCASEAMORESUSTAINABLEMANUFACTURINGCANONLYBEACHIEVEDBYALTERNATIVESOLUTIONSFIGURE1TYPICALCOMPONENTSOFLARGESCALEJIGIMAGECOURTESYOFELECTROIMPACTHTTP/WWWELECTROIMPACTCOM/G150TFIX/GALLERYASPEXTENSIVELEADTIMETOMANUFACTUREISANOTHERMAJORDRAWBACKFORFIXEDJIGSANDFIXTURESTHESEJIGSSHOULDBEORDEREDWELLINADVANCEOFANYMANUFACTURINGPROCESSESTHISCANCREATEADDITIONALCOMPLEXITYINPRODUCTIONPLANNINGANDPRODUCTTIMETOMARKETREGARDLESSOFTHEIRTYPE,LARGESCALEJIGSHAVEANUMBEROFCOMMONELEMENTSINCLUDINGONEMAINFRAME,ONEORANUMBEROFINNERFRAMES,POTENTIALLYONEORANUMBEROFMOVINGMECHANISMS,ANDSMALLERCOMPONENTSSUCHASCLAMPS,BUSHINGS,PICKUPSANDADJUSTABLESCREWSFIGURE122FLEXIBLEJIGSANDFIXTURESTHECONCEPTOFFLEXIBLEJIGSANDFIXTURESISDEVELOPEDFORINCREASEDSUSTAINABILITY,RAPIDCHANGEOVERASWELLASLOWCOSTITISNOWPOSSIBLETOUSEOFFTHESHELFMODULESANDCLAMPSFORJIGSANDFIXTURESDESIGNANDASSEMBLYDEPENDINGONTHEREQUIREMENTONLYAHANDFULOFSPECIALISEDCOMPONENTSFORTHEJIGSANDFIXTURESMIGHTBENEEDEDTOBECUSTOMDESIGNEDANDMANUFACTUREDINTHISCONCEPTTHEMAJORITYOFBULKCOMPONENTS,JOINTSATTHEATTACHMENTSAREUSEDINFORASPECIFICAPPLICATIONONCETHEPRODUCTDESIGNVARIANTISFULLYMANUFACTUREDITISTHENPOSSIBLETODISASSEMBLETHEABOVECOMPONENTSANDREASSEMBLETHEMINANEWTOPOLOGYTOSUITETHENEXTDESIGNVARIANTTHISCYCLECANBEREPEATEDOVERALARGENUMBEROFTIMESRESULTINGINREDUCEDOVERHEADCOSTFORJIGSANDFIXTURESNEEDLESSTOMENTIONTHEOTHERFACTORSSUCHASDISASSEMBLYTIME,RESETTINGTIME,OPERATORSTIMESHOULDBECONSIDEREDFOREVALUATINGTHEREALCOSTBENEFITOFUSINGTHISTYPEOFJIGSANDFIXTURESTHISAPPROACHBESTREDUCESTHECOSTOFJIGSANDFIXTURESFORTHEASSEMBLYANDCOMPONENTRANGESTHATAREFAIRLYCLOSEINDESIGNDEPENDINGONTHELEVELOFVARIATIONSINTHECOMPONENTSANDTHETYPEOFWORKREQUIREDONEACHADIFFERENTPERCENTAGEOFTHEFLEXIBLEJIGSNEEDTOBEREARRANGEDTHISMATTERISCRUCIALTOBECONSIDEREDATDESIGNSTAGEINORDERTOINCREASETHEBENEFITOFUSINGTHISTYPEOFJIGSANDFIXTURESFOREXAMPLE,WHENPOSSIBLE,THELOCATIONAND3DPOSITIONINGOFPICKUPSANDCLAMPSONDIFFERENTVARIANTSOFTHECOMPONENTOREVENTOTALLYDIFFERENTPARTSSHOULDBEINCLOSEPROXIMITYTOINCREASECOMPATIBILITYANDINTERCHANGEABILITYOFSUBSYSTEMSOFJIGSANDFIXTURESHAVINGACOLLECTIONOFTHEKEYCOMPONENTSOFTHEJIGSCANGUARANTEETHEAVAILABILITYOFTHEDESIREDJIGSINASHORTTIMEINADDITIONTOTHISTHESTORAGEOFTHEJIGSREQUIREDLESSSPACEASITISPOSSIBLETODISMANTLEALLTHEMODULESTHATARETYPICALLYINTHEFORMOFSCAFFOLDINGANDPLACETHEMNEXTTOEACHOTHERFLEXIBLEJIGSARECURRENTLYUTILISEDINSOMEOFTHEAUTOMOTIVECOMPANIESFIGURE2ASTHEIRACCURACYLEVELISSUFFICIENTFORTHISSECTORDESPITETHEABOVEBENEFITSTHEREARECLAMPMAINFRAMEINNERFRAMECOMPONENTADJUSTABLEHOLDSMOVINGMECHANISMSMETHODOLOGYFORHIGHACCURACYINSTALLATIONOFSUSTAINABLEJIGSANDFIXTURES151NOTMANYFLEXIBLEJIGSINOPERATIONINLARGESIZEMANUFACTURINGFACILITIESSUCHASAEROSPACEFACTORIESACCURACYANDUNCERTAINTYOFPOSITIONINGPINS,REPEATABILITYOFTHECLAMPSANDDRIFTOFTHEJIGSTRUCTUREAREALLCONTRIBUTINGTOTHEFACTTHATTHESEJIGSCANNOTMEETTHETOLERANCEREQUIREMENTSOFTHEPOWERGENERATIONANDAEROSPACEINDUSTRIESTHESEJIGSHAVEHIGHPOTENTIALSFORUTILISATIONINTHEABOVEINDUSTRIESONCETHEIRACCURACYPROBLEMSARERESOLVEDFIGURE2FIXTUREWITHRECONFIGURABLECOMPONENTSFORAUTOMOTIVEINDUSTRYIMAGECOURTESYOFWITTEHTTP/WWWHORSTWITTEDE/EN/THEREHASBEENANUMBEROFNEWDEVELOPMENTSINLARGEVOLUMEMETROLOGYSYSTEMSANDTECHNOLOGIESMODERNLASERBASEDMETROLOGYSYSTEMSANDTECHNOLOGIESARENOWCAPABLEOFMEASURINGLARGESIZEPRODUCTSUPTOSEVERALDECAMETRESWITHACCEPTABLEACCURACYTHESESYSTEMSCANBEUSEDTOACCURATELYPOSITIONMOUNTINGSOFTHEKEYCOMPONENTSOFTHEJIGDURINGITSINSTALLATIONANDINITIALSETUPTHEINSTALLATIONOFJIGSANDFIXTURESTYPICALLYSTARTSFORMITSBASEORMAINFRAMETHENLARGECOMPONENTSANDGRADUALLYTOTHESMALLERCOMPONENTSSUCHASPICKUPSANDCLAMPSMETROLOGYSYSTEMSCANBEUSEDFORTHEINSTALLATIONOFFLEXIBLEJIGMAINFRAMEANDITSINNERFRAMESTOGUARANTEETHECORRECTPOSITIONINGOFEACHANDEVERYCOMPONENTTABLE1SHOWSAFEWOFTHESELARGESCALEMEASUREMENTSYSTEMSFORTECHNOLOGICALREVIEWOFTHESESYSTEMSSEE7LASERTRACKERSYSTEMSCAPABLEOFMEASURINGREFERENCEPOINTS,AREAMONGTHEMOSTSUITABLEMEASUREMENTSYSTEMSFORTHISPURPOSETHEINSTRUMENTTRACKSASPHERICALLYMOUNTEDRETROREFLECTORSMRTARGETTHEPOSITIONOFWHICHCANBEREGISTEREDINTHREEDIMENSIONALSPACESMRCANBECONTACTEDDIRECTLYWITHTHETARGETOBJECTTOPROVIDEGEOMETRICALPOSITIONALINFORMATIONORCANBEUSEDWITHINAMECHANICALLYREPEATABLESMRNESTKNOWNASLASERTRACKERTARGETORINSHORTTARGETFROMTHISPOINTONLASERTRACKERSLIKEANYOTHERMEASUREMENTINSTRUMENTHAVEALEVELOFUNCERTAINTYTHATNEEDTOBEACCOUNTEDFORDURINGTHEJIGINSTALLATIONPROCESSALSOTHELINEOFSIGHTISSUESBETWEENTHELASERTRACKERANDITSTARGETPOINTSHOULDBECONSIDEREDANDIFNECESSARYMULTIPLETRACKERPOSITIONSSHOULDBEUSEDINREALMEASUREMENTACTIVITYTHERESULTMUSTBEACCOMPANIEDWITHASTATEMENTOFUNCERTAINTYSUCHSTATEMENTCHARACTERISESTHEDISPERSIONOFTHEVALUESTHATAREREASONABLYATTRIBUTEDTOTHEMEASURAND8THISISSUEISTHESAMEFORTHEINSTALLATIONANDLATERVERIFICATIONOFANYJIGORFIXTURETHISKNOWLEDGECLARIFIESTHEJIGCAPABILITYOFAGIVENPOSITIONINGANDASSEMBLYTASKINOTHERWORDITINDICATESIFAJIGCANMEETTHETOLERANCEREQUIREMENTSFORITSRELATEDPROCESSES23COMPARISONOFJIGPHILOSOPHIESTHEREAREALARGENUMBEROFDIFFERENTSHAPEANDDESIGNJIGSANDFIXTURESINDIFFERENTCOMPANIESFORVARIOUSMANUFACTURINGANDASSEMBLYAPPLICATIONSSOMEOFTHESEJIGSANDFIXTURESAREREADILYAVAILABLEINSTANDARDFORMS,WHILESOMEAREDESIGNEDANDMANUFACTUREDSPECIFICTOPARTICULARPARTSANDTASKSTHELATTERCANBEVERYEXPENSIVEBASEDONTHECOMPLEXITYANDSCALEOFTHEPRODUCTS9REGARDLESSOFCOSTANDPURPOSEAMANUFACTURINGORASSEMBLYPROCESSCANBEPERFORMEDUSINGWITHNOJIG,WITHFIXEDFRAMEJIGS,ORWITHRECONFIGURABLEORFLEXIBLEJIGSTABLE2PROVIDESACOMPARISONOFTHESEMETHODSWITHTHEIRTYPICALAPPLICATIONSFIXEDFRAMEJIGSARETYPICALLYFORHEAVYDUTYAPPLICATIONSTHEYAREMORESUITABLEFORAPPLICATIONSWITHALARGENUMBEROFPRODUCTSTHATCANRELAXTHEOVERHEADCOSTOFTHEJIGTHEREARESEVERALADVANTAGESINTHEAPPLICATIONOFFLEXIBLEJIGSANDFIXTURESFORTHEMANUFACTURINGANDASSEMBLYOFLARGEANDCOMPLEXPRODUCTSINPARTICULARFORRESEARCHANDDEVELOPMENTWORK,ASWELLASFORCASESWHERELOWVOLUMEPRODUCTSAREMANUFACTUREDFLEXIBLEJIGANDFIXTURECANBEVERYBENEFICIALINADDITIONTOTIMEANDMONEYSAVINGBENEFITSTHEPOSSIBILITYOFHAVINGAFLEXIBLEJIGGIVESMOREFREEDOMTOTHEDESIGN,MANUFACTURINGANDASSEMBLYPROCESSESDUETOTHELOWDIRECTANDRECURRENTCOSTOFCHANGINGTHEOVERALLTOPOLOGYOFTHEJIGRECONFIGURABILITYANDREUSABILITYOFFLEXIBLEJIGISAMAINCLAMPMAINFRAMEINNERFRAMECOMPONENTJJAMSHIDI,PGMAROPOULOS152ADVANTAGEFORTHISTYPEOFJIGCOMPAREDTOCONVENTIONALJIGSTHISISPARTICULARLYIMPORTANTASITISINLINEWITHTHEINDUSTRYDIRECTIONINTERMSOFGREENMANUFACTURINGBYRECYCLINGCOMPONENTSFROMAUSEDSYSTEM,REDUCINGPROJECTCOSTSWITHREGARDSTOEXPENSESFORTOOLINGOFASSOCIATEDITEMSTABLE1EXAMPLESOFLARGEVOLUME/PORTABLEMEASUREMENTINSTRUMENTSFORJIGVERIFICATIONMEASUREMENTTYPEINSTRUMENTAUXILIARYCOMPONENTSCONTACTNONCONTACTIMAGESMRPROBE9LASERTRACKERTPROBE9LASERRADARSPHERICALTARGETS9TARGETS9PHOTOGRAMMETRYLIGHTPROJECTION9LASERBASEDSCANNINGHEAD9ARTICULATEDARMCMMCONTACTPROBE93FLEXIBLEJIGINSTALLATIONTHEISSUESANDCONCERNSTHATNEEDTOBECONSIDEREDINTHEJIGINSTALLATIONPROCEDUREAREDESCRIBEDINTHISSECTIONTHEINSTALLATIONOFTHEJIGCOMPONENTSINTHERIGHTPOSITIONCANBEACHALLENGINGESPECIALLYWHENTHEPOSITIONINGTOLERANCESARETIGHTSFLEXIBLEJIGSSHOULDALSOBEMONITOREDINORDERTOEXPLOITANDCOMPARETHEIRRIGIDITYWITHTHATOFTHECONVENTIONALONESSTAGEBYSTAGEMEASUREMENTINSTRUCTIONFORTHEJIGINSTALLATIONBASEDONTHERESULTSOFANINITIALJIGSETUPINTHESIMULATIONSOFTWAREENVIRONMENTANDPRACTICALEXPERIMENTOFALARGESIZEJIGWITHDIMENSIONSOF5MX4MX3MISGIVENINAGENERICDESCRIPTIONTHISISREGARDLESSOFWHETHERTHEJIGISINFIRSTTIMEINSTALLATIONORITISACHANGEOFANEXISTINGJIGTOPOLOGYINTOANEWSHAPE,FORHOLDINGADIFFERENTCOMPONENTDEPENDINGONTHECOMPLEXITYATYPICALLARGESIZEJIGHASBETWEENTHREETOFIVELEVELSOFFRAMESAPARTFROMTHEBASELEVELWITHNORMALLYONEMAINFRAME,ATEACHLEVELTHERECANBEONEORSEVERALFRAMESTHESEFRAMESAREINTERRELATEDWITHREFERENCETOTHEJIGDATUMINORDERTOFACILITATETHEPOSITIONINGANDFUNCTIONALITYREQUIREDINANAUTOMATED,FIXEDPLATFORM,ROBOTICSYSTEMSCARRYOUTSEVERALTASKSSUCHASPARTPOSITIONING,MACHININGANDASSEMBLYTHEROBOTWORKINGDATUMTHEREFOREISLINKEDWITHTHEWORKINGFRAMEOFTHEJIGCAREFULCONSIDERATIONOFJIGDATUMINGSTRATEGYANDITSSUBSEQUENTINSTALLATIONCANSECUREACHIEVINGTHEDESIREDTOLERANCE31MEASUREMENTASSISTEDFLEXIBLEJIGINSTALLATIONTHEREARESEVERALSTAGESFORTHEINSTALLATIONOFFLEXIBLEJIGSTHATCANBECARRIEDOUTINFIRSTSIMULATIONANDTHENREALWORLDTHEUSEOFSIMULATIONEXERCISECANREDUCETHENUMBEROFPOTENTIALERRORSANDREWORKDURINGTHISPROCESSTHEPROCESSOFMEASUREMENTASSISTEDINSTALLATIONISSIMILARTOTRACKINGOBJECTSTOPOSITIONTHATISCOMMONFORLARGESIZEASSEMBLIESINTHISAPPROACHTHECOMPONENTSOFTHEJIGAREROUGHLYPOSITIONED,WITHIN1MMTOLERANCEFROMTHETARGETPOSITION,ATFIRSTTHENWHENALLOFTHEJIGCOMPONENTSAREATTACHEDINTOTHEIRDESIGNATEDPOSITIONS,WITHIN01MMTO015MMTOLERANCE,THEYARETIGHTENEDUSINGTHEAPPROPRIATETORQUETHETYPICALSTAGESOFMETROLOGYASSISTEDFLEXIBLEJIGINSTALLATIONAREGIVENBELOW1SETTINGINITIALREFERENCEFRAMESINTHEFACTORY2MEASUREMENTOFINITIALREFERENCEFRAME3INSTALLATIONOFBASEORMAINFRAMEINITSPOSITION4INSTALLATIONOFINNERFRAMESOFFLINE5INSTALLATIONOFHOLDINGANDPOSITIONINGBRACKETS6INSTALLATIONOFCLAMPS,BUSHINGSANDPICKUPSINTHEIRROUGHPOSITIONONINNERFRAMESANDMAINFRAME7INSTALLATIONOFINNERFRAMEONTHEBASEFRAME8FINEADJUSTMENTANDFASTENINGOFKEYLOCATINGCOMPONENTS9VERIFICATIONOFREFERENCEFRAMESANDCLAMPS10INSERVICEMONITORINGOFKEYPOSITIONSONTHEJIGTHESESTAGESARERELATEDTOTHECOMPLETEINSTALLATIONOFTHEJIGFROMTHESCRATCHNEEDLESSTOMENTIONTHATINCASEOFSLIGHTMETHODOLOGYFORHIGHACCURACYINSTALLATIONOFSUSTAINABLEJIGSANDFIXTURES153CHANGEINDESIGNVARIATIONSOMEOFTHEFOLLOWINGOPERATIONSWILLBEOMITTEDTABLE2ABRIEFCOMPARISONBETWEENDIFFERENTJIGPHILOSOPHIESTYPICALCHARACTERISTICFIXEDFRAMEFLEXIBLEJIGJIGLESSAPPLICATIONLARGEVOLUMEPRODUCTIONLOWVOLUMEPRODUCTIONPROTOTYPINGUNIQUENESSREPEATABLERECONFIGURABLECOSTEFFECTIVENESSDURABILITYVERYHIGHHIGHLOWPROSRIGIDITYVERYHIGHUNCERTAINTYRIGIDITYLOWWEIGHTHEAVYMEDIUMLOWPORTABILITYNONPORTABLEDIFFICULTCOMPONENTPOSITIONINGINEACHSETUPDIFFICULTTOPROGRAMCOSTVERYHIGHMEDIUMLOWCONSMANUFACTURINGTIMELONGMEDIUMSHORT32ALGORITHMFORFLEXIBLEJIGINSTALLATIONTHEINSTALLATIONPROCESSESFORFLEXIBLEJIGSTAKETHEFOLLOWINGMAINSTAGES1THEINSTALLATIONOFMAINFRAMEOFTHEJIG2THEASSEMBLYOFMOVINGUNITSANDSUBSYSTEMS3THEINSTALLATIONOFTHEJIGINNERFRAMESONTHEJIGASSEMBLY4THEASSEMBLYOFPICKUPSANDCLAMPSONTHEJIGTHEMAINFRAMEISTHEBACKBONEOFTHEJIGTHATISTYPICALLYFIXEDFORALARGENUMBEROFJIGTOPOLOGYANDDESIGNVARIATIONSTHEREFOREITDOESNOTCHANGEINSHAPEASREGULARLYASTHEINNERFRAMEORTHESMALLERELEMENTSOFTHEJIGSUCHASBUSHINGS,PICKUPSANDCLAMPSCAREFULCONSIDERATIONOFTHEMANUFACTURINGPROCESSCANREDUCETHENECESSITYOFREARRANGINGLARGERELEMENTSOFTHEJIGCOMPONENTSRESULTINGINFURTHERTIMEANDMONEYSAVINGFIGURE3INTHREESEPARATEGROUPSOFACTIVITIESSHOWSTHEPROCESSESOFFLEXIBLEJIGINSTALLATIONINTHISPROCESSITISASSUMEDTHATTHESTANDARDPARTSOFTHEJIGARESELECTEDFROMTHEAVAILABLE,OFFTHESHELFSECTIONSANDCOMPONENTSTHENINADVANCEOFTHEPHYSICALINSTALLATIONANUMBEROFTESTSANDTRIALSARECARRIEDOUTTOPLANTHEJIGINSTALLATIONINSUCHAWAYTHATTHEUNCERTAINTYOFMEASUREMENTISREDUCEDONCETHEACCEPTABLELEVELOFUNCERTAINTYISACHIEVEDTHEPHYSICALINSTALLATIONCANTAKEPLACEFIGURE3MEASUREMENTASSISTEDINSTALLATIONPROCEDUREFORFLEXIBLEJIGJJAMSHIDI,PGMAROPOULOS154INJIGINSTALLATIONPROCESSITMIGHTBEREQUIREDTOUSEMULTIPLEMEASUREMENTSYSTEMORAMEASUREMENTSYSTEMFROMSEVERALLOCATIONSTOCOVERTHECOMPLETESETOFKEYPOINTSFORJIGINSTALLATIONTHISSHOULDINCLUDETHEAUXILIARYTARGETREFERENCEPOINTSTHATAREPLACEDONTHEFACTORYFLOORANDWALLFORSTABILITYANDDRIFTCHECKDURINGTHEJIGSERVICEDURINGTHELOCALISATIONOFTHEKEYPOINTSONTHEJIGTHEUNCERTAINTYOFTHEMEASUREMENTINSTRUMENTSHOULDBETAKENINTOACCOUNTASARULEOFTHUMBTHEACCURACYOFTHEJIGPOSITIONINGFOREACHKEYLOCATIONSHOULDBEINANORDER10TIMESBETTERTHANTHEREQUIREDTOLERANCEINOTHERWORDIFTHETOLERANCEONTHECOMPONENTISSPECIFIEDAS01MMTHEACCURACYOFTHEJIGPOSITIONINGSHOULDBEATLEAST001MMTHEBESTPRACTICEAPPROACHESFORTHEFLEXIBLEJIGINSTALLATIONAREGIVENBELOW1APLANNEDPOSITIONFORTHEINITIALREFERENCEPOINTSONTHEFACTORYWALLANDFLOORISPREFERREDINORDERTOMINIMISEUNCERTAINTYOFTHEMEASUREMENT2THEINSTRUMENTPOSITIONSHOULDBEVERIFIEDONREGULARBASESUSINGTHEINITIALREFERENCEPOINTS3ONEACHLARGESECTIONOFTHEJIGSEVERALSMRNESTSCANBEATTACHEDFORBETTERTRACKINGANDREPEATABILITY4WHERETHELARGECOMPONENTSOFTHEJIGHAVEBENDORTWISTTHELEVELMEASUREMENTSHOULDBEFOCUSSEDONTHECENTRALSECTIONOFTHEBEAMSTOREDUCEANGULARPOSITIONINGERROR5THEREFERENCEPOINTSONTHEINNERFRAMESSHOULDBESELECTEDASDISTANTASPOSSIBLEFORCREATINGFRAMECOORDINATESYSTEMSTHISCANRESULTINSMALLERUNCERTAINTYWHENINTHEINNERFRAMECOORDINATESYSTEM4UNCERTAINTYUNCERTAINTYIFDEFINEDBYGUM8ASTHERESULTOFTHEEVALUATIONAIMEDATCHARACTERISINGTHERANGEWITHINWHICHTHETRUEVALUEOFAMEASUREDOBJECTISESTIMATEDTOLIE,GENERALLYWITHAGIVENCONFIDENCETHEUNCERTAINTYHEREISREVIEWEDFROMTWOASPECTS,THEFIRSTISRELATEDTOTHEMEASUREMENTPROCESSANDTHESECONDISRELATEDTOTHEUNCERTAINTYOFJIGPOSITIONINGMEASUREMENTUNCERTAINTYHASANUMBEROFCONTRIBUTINGFACTORSSUCHAS
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