Kinematics Analysis of Mechanisms Based on Virtual Assembly

Currently, virtual assembly technology has attracted increasing attention due to considerations of solving assembly problems in virtual environment before actual assembly in manufactory. Previous studies on kinematic analysis of mechanism only aim at analyzing motion law of single mechanism, but can not simulate the multi-mechanisms motion process at the same time, let alone simulating the automatic assembly process of products in a whole assembly workshop. In order to simulate the assembly process of products in an assembly workshop and provide effective data for analyzing mechanical performance after finishing assembly simulation in virtual environment, this study investigates the kinematics analysis of mechanisms based on virtual assembly. Firstly, in view of the same function of the kinematic pairs and the assembly constraints on restricting the motion of components （subassembly or part）, the method of identifying kinematic pairs automatically based on assembly constraints is presented. The information of kinematic pairs can be obtained through calculating the constraint degree of the assembly constraints. Secondly, the incidence matrix eliminating element method is proposed in order to search the information and establish the models of mechanisms automatically after finishing assembly simulation in virtual environment. Both methods have important significance for reducing the workload of pretreatment and promoting the level of automation of kinematics analysis. Finally, the method of kinematics analysis of mechanisms is presented. Based on Descartes coordinates, three types of kinematics equations are formed. The parameters, like displacement, velocity, and acceleration, can be obtained by solving these equations. All these data are important to analyze mechanical performance. All the methods are implemented and validated in the prototype system virtual assembly process planning（VAPP）. The mechanism models are established and simulated in the VAPP system, and the result curves are shown accurately. The proposed kinematics analysis of mechanisms based on virtual assembly provides an effective method for simulating product assembly process automatically and analyzing mechanical performance after finishing assembly simulation.

Integrated Virtual Assembly Process Planning System

Assembly process planning（APP） for complicated products is a time-consuming and difficult work with conventional method. Virtual assembly process planning（VAPP） provides engineers a new and efficiency way. Previous studies in VAPP are almost isolated and dispersive, and have not established a whole understanding and discussed key realization techniques of VAPP from a systemic and integrated view. The integrated virtual assembly process planning（IVAPP） system is a new virtual reality based engineering application, which offers engineers an efficient, intuitive, immersive and integrated method for assembly process planning in a virtual environment. Based on analysis the information integration requirement of VAPP, the architecture of IVAPP is proposed. Through the integrated structure, IVAPP system can realize information integration and workflow controlling. In order to mode/the assembly process in IVAPP, a hierarchical assembly task list（HATL） is presented, in which different assembly tasks for assembling different components are organized into a hierarchical list. A process-oriented automatic geometrical constraint recognition algorithm（AGCR） is proposed, so that geometrical constraints between components can be automatically recognized during the process of interactive assembling. At the same time, a progressive hierarchical reasoning（PHR） model is discussed. AGCR and PHR will greatly reduce the interactive workload. A discrete control node model（DCNM） for cable harness assembly planning in IVAPP is detailed. DCNM converts a cable harness into continuous flexed line segments connected by a series of section center points, and designs can realize cable harness planning through controlling those control nodes. Mechanical assemblies （such as transmission case and engine of automobile） are used to illustrate the feasibility of the proposed method and algorithms. The application of IVAPP system reveals advantages over the traditional assembly process planning method in shortening the time-consumed in assembly planning and in minimizing the handling difficulty, excessive reorientation and dissimilarity of assembly operations.

Contact State Estimation Based on Surface-matching in Virtual Assembly

Contact problems are one of the most challenging fields in virtual assembly. Information of contact states could be utilized to realize compliant motion of work pieces, to analyze the contact stress, to assist positioning parts and so on. Some methods have already been proposed to estimate contact states between objects and in most of these methods contact states between objects are simplified in order to realize real-time visual reality animation. While in virtual assembly contact states between parts are required to analyze contact stress, deformation and quality. Besides the contact state estimation method for virtual assembly should be able to handle a number of complex parts in real time. There are rarely known methods which could meet this requirement till now. In this study a contact state estimation algorithm based on surface-matching for virtual assembly is proposed. Contacts between parts are categorized into six basic types according to contact region of surfaces. Based on continuous collision detection of polyhedral models a novel contact state identification algorithm which is based on surface matching is proposed. Then contact evolution algorithm, which utilizes the extern force and contact information, is implemented to handle evolution of contact state. Finally a prototype system is developed to verify the above technologies. Experiment results reveal that contact state between parts could be estimated correctly in real time virtual assembly. The proposed contact state estimation algorithm provides a complete solution to obtain the contact state between parts in virtual assembly. Information of contact state between parts could be utilized to realize contact dynamic, contact stress analysis, assembly quality analysis, and so on.

Universal Mechanism Modeling Method in Virtual Assembly Environment

Motion simulation and performance analysis of mechanism are important methods for analyzing assembly quality after finishing assembly simulation in virtual assembly environment. However, most simulation systems have no function of mechanism motion simulation due to the randomicity of mechanism and lack of universal mechanism modeling method. In order to realize the simulation of any mechanism after finishing assembly simulation in a virtual environment, a new universal mechanism modeling method is presented. Two main models are contained in the mechanism model： information model and mathematical model. Firstly, the information model of mechanism is proposed to describe the data structure of mechanism which contains bottom geometry data, information of constraint, link, kinematic pair and physical data. Because the object of mechanism simulation is the assembly, which is assembled during the process of assembly simulation, the information of mechanism can be obtained automatically through mechanism automatic search method. Secondly, mathematical model of mechanism is presented. The mathematical model uses mathematical method to express the mechanism. In order to realize the automatic expression of any random mechanism, basic constraint library is presented, consequently random mechanism can be described based on the basic constraint library. Finally, two examples are introduced to validate the method in the prototype system named VAPP（Virtual Assembly Process Planning）. The validation result shows that the mechanism modeling provides a universal modeling method for mechanism motion simulation in virtual assembly environment. This research has important effect on the development both of mechanism motion simulation and virtual assembly.

Realization Techniques of Virtual Assembly Process Planning System

The key realization techniques of virtual assembly process planning （VAPP） system are analyzed, including virtual assembly model, real-time collision detection, automatic constraint recognition algorithm, cable harness assembly process planning and visual assembly process plan at the workshop. A virtual assembly model based on hierarchical assembly task list （HATL） is put forward, in which assembly tasks are defined to express component assembling operations and are sequentially and hierarchically organized according to different subassemblies, which can perfectly model the construction process of product, And a multi-layer automatic geometry constraint recognition algorithm of how to identify assmbly constraint relations in the virtual environment is proposed, then a four-layer collision detection algorithm is discussed. A VAPP system is built and some simple mechanical assemblies are used to illustrate the feasibility of the proposed method and algorithms.

Virtual assembly framework for performance analysis of large optics

Background A longstanding technological challenge exists regarding the precise assembly design and performance optimization of large optics in high power laser facilities,comprising a combination of many complex problems involving mechanical,material,and laser beam physics.Method In this study,an augmented virtual assembly framework based on a multiphysics analysis and digital simulation is presented for the assembly optimization of large optics.This framework focuses on the fundamental impact of the structural and assembly parameters of a product on its optical performance;three-dimensional simulation technologies improve the accuracy and measurability of the impact.Intelligent iterative computation algorithms have been developed to optimize the assembly plan of large optics,which are significantly affected by a series of constraints including dynamic loads and nonlinear ambient excitations.Results Finally,using a 410-mm-aperture frequency converter as the study case,we present a detailed illustration and discussion to validate the performance of the proposed system in large optics assembly and installation engineering.

Object-Oriented Modeling of Virtual Assembly Process

Virtual assembly is a Virtual Reality (VR) based engineering application which allows engineers to evaluate, analyze, and plan the assembly of mechanical systems. To model the virtual assembly process, new methodology must be applied. Based on the idea that the virtual assembly system is an event driven system, the interactive behavior and information model is proposed to describe the dynamic process of virtual assembly. Definition of the object-oriented model of virtual assembly is put forward.

RESEARCH OF GUIDANCE TECHNOLOGY FOR ASSEMBLY MODELING IN VIRTUAL ENVIRONMENT

Technology of movement and knowledge guidance in virtual assembly is presented The designer can move the mechanical part precisely under the movement guidance The movement guidance is implemented based on constraint recognition and assembly degree of freedom analysis A multi hierarchy knowledge base is built to represent the assembly knowledge and information The virtual assembly system judges the requirement of the designer based on the context of design task and searches for the useful knowledge and information, which can be provided to the designer in a natural way

Mixed Reality-based Interactive Technology for Aircraft Cabin Assembly

Due to the narrowness of space and the complexity of structure, the assembly of aircraft cabin has become one of the major bottlenecks in the whole manufacturing process. To solve the problem, at the beginning of aircraft design, the different stages of the lifecycle of aircraft must be thought about, which include the trial manufacture, assembly, maintenance, recycling and destruction of the product. Recently, thanks to the development of the virtual reality and augmented reality, some low-cost and fast solutions are found for the product assembly. This paper presents a mixed reality-based interactive technology for the aircraft cabin assembly, which can enhance the efficiency of the assemblage in a virtual environment in terms of vision, information and operation. In the mixed reality-based assembly environment, the physical scene can be obtained by a camera and then generated by a computer. The virtual parts, the features of visual assembly, the navigation information, the physical parts and the physical assembly environment will be mixed and presented in the same assembly scene. The mixed or the augmented information will provide some assembling information as a detailed assembly instruction in the mixed reality-based assembly environment. Constraint proxy and its match rules help to reconstruct and visualize the restriction relationship among different parts, and to avoid the complex calculation of constraint＇s match. Finally, a desktop prototype system of virtual assembly has been built to assist the assembly verification and training with the virtual hand.

Force Feedback Coupling with Dynamics for Physical Simulation of Product Assembly and Operation Performance

Most existing force feedback methods are still difficult to meet the requirements of real-time force calculation in virtual assembly and operation with complex objects. In addition, there is often an assumption that the controlled objects are completely flee and the target object is only completely fixed or flee, thus, the dynamics of the kinematic chain where the controlled objects are located are neglected during the physical simulation of the product manipulation with force feedback interaction. This paper proposes a physical simulation method of product assembly and operation manipulation based on statistically learned contact force prediction model and the coupling of force feedback and dynamics. In the proposed method, based on hidden Markov model （HMM） and local weighting learning （LWL）, contact force prediction model is constructed, which can estimate the contact force in real time during interaction. Based on computational load balance model, the computing resources are dynamically assigned and the dynamics integral step is optimized. In addition, smoothing process is performed to the force feedback on the synchronization points. Consequently, we can solve the coupling and synchronization problems of high-frequency feedback force servo. low-frequency dynamics solver servo and scene rendering servo, and realize highly stable and accurate force feedback in the physical simulation of product assembly and operation manipulation. This research proposes a physical simulation method of product assembly and operation manipulation.

RESEARCH OF MOVEMENT NAVIGATION BASED ON ASSEMBLY CONSTRAINT RECOGNITION

The requirements and features of virtual assembly movement navigator areanalyzed to help operators flexibly manipulate virtual objects, precisely locate or assemble virtualparts in virtual environment. With the degree-of-freedom analysis, the assembly constrainthierarchical model is constructed and the system's constraints are built dynamically. Thus, allobjects in virtual environment can be located reasonally by the navigator. Moreover, the assemblyconstraint recognition in the process of assembly and movement correction is also discussed.

Design and Dynamic Analysis of the Recirculating Planetary Roller Screw Mechanism

The recirculating planetary roller screw mechanism(RPRSM)is a transmission mechanism that engages the screw and nut threaded by multiple grooved rollers.In this paper,frstly,the design method of RPRSM nut threadless area is proposed,and the equations related to the structural parameters of nut threadless area are derived.On this basis,the cross-section design method of roller,screw and nut is constructed according to the actual situation of engagements between the screw/nut and the roller.By adjusting the gap between the two beveled edges and that between the arc and the beveled edge,the accuracy of the thread engagements between the screw/nut and the roller can be improved.Secondly,to ensure the engagements of the screw/nut and the roller,the distance equation from the center surface of the diferent rollers to the end surface of cam ring is given.Thirdly,combined with the working principle and structural composition of RPRSM,the component model is established according to its relevant structural parameters,and the virtual assembly is completed.Finally,the 3D model is imported into the ADAMS simulation software for multi-rigid body dynamics.The dynamic characteristic is analyzed,and the simulated values are compared with the theoretical values.The results show that the contact forces between the screw/nut and the roller are sinusoidal,mainly due to the existence of a small gap between the roller and the carrier.The maximum collision forces between the roller and cam ring are independent from load magnitude.Normally,the collision force between the roller and the carrier increases as the load increases.When RPRSM is in the transmission process,the roller angular speed in nut threadless area begins to appear abruptly,and the position of the maximum change is at the contact between the roller and the convex platform of cam ring.The design of the nut threadless area and the proposed virtual assembly method can provide a theoretical guidance for RPRSM research,as well as a reference for overall performance optimization.

Intelligent Industrial Auxiliary System Based on AR Technology

The traditional industrial assembly method is inefficient,and it is difficult to meet the needs of rapid production in modern society.Although many virtual assembly systems based on augmented reality technology have appeared in recent years,most of these assembly systems are noninteractive,nonintelligent,and inefficient.In response to this problem,we combined AR technology and AI technology to design and implement a strong interactive,high-intelligence virtual assembly guidance system in four levels.Finally,we took a UAV assembly as an example to show our design results.Operators can use this system to quickly master the assembly process.Finally,according to some problems encountered in the process of system implementation,the improvement direction of the virtual assembly system is proposed,and the future development of the AR auxiliary industry is proposed.This article describes the functions and implementation process of the four levels of the AR assembly system in detail,which can help readers quickly understand the connection between AR technology and AI technology and understand the principle of the virtual assembly guidance system.