CAREER: Stream-of-Variation Modeling and Analysis for Multi-Station Manufacturing Processes Modeling Infrastructure for Virtual Assembly

这项教师早期职业发展（Career）计划资助了一个关于建模的综合研究和教育项目；汽车、航空航天、电器和电子等行业中具有柔性零件的复杂多阶段装配过程（MAP）中尺寸变化的分析和控制。目标是开发一个通用的MAP模型，该模型具有以不同的分辨率/“信息粒度”表示关键产品和过程控制特征/特征（KPC/KCC）的能力，可以在新制造系统的设计、启动和完整生产阶段使用。该模型将基于通用的计算机辅助设计和制造（CAD/CAM）系统，并集成统计分析，以预测早期设计阶段的制造过程性能。所提出的计划面临的挑战是所需信息的多样性以及KCC和KPC之间缺乏物理和几何关系。今后的研究重点是：(1)结合统计信息和CAD/CAM信息的变异传播模型；(2)产品开发过程中KPC/KCC的多分辨率/粒度变化；(3)多阶段装配过程仿真的计算效率；(4)与新的面向过程的建模、设计和控制有关的一般问题。教育工作是：(1)将统计分析纳入CAD/CAM课程；(2)探索新型MAP系统开发与实现中的挑战；(3)提供利用三维仿真工具开发和分析MAP系统的机会。它还包括创建特定年级（研究生、本科生和K-12）的项目。更广泛的影响：如果成功，该项目将带来一种新的方法，它可以：(1)从根本上集成CAD/CAM模型和统计分析，以预测设计过程中与合规部件相关的制造过程尺寸变化，从而不断提高产品质量，同时通过快速故障根本原因检测减少整体新MAP开发时间。(2)促进基于数学的MAP系统的设计和制造：产品和过程变量的集成将经典的“部件互换性”概念扩展为在新MAP开发的早期设计阶段考虑的“过程互换性”。这在供应商选择、基准测试或外包方面至关重要。(3)对工业工程师进行统计方法及其在CAD/CAM系统中的应用方面的培训，从而为开发新一代CAD/CAM系统以实现MAP的虚拟实现做好准备。

This Faculty Early Career Development (CAREER) Program grant supports an integrated research and education project on modeling; analysis and control of dimensional variation in complex multistage assembly processes (MAP) with compliant parts such as in automotive, aerospace, appliance and electronics industries. The goal is to develop a generic MAP model with capabilities to represent key product and process control characteristics/features (KPC/KCC) with varying resolution/"information granularity" that can be utilized during design, launch and full production phases of a new manufacturing system. The model will be based on a generic Computer-Aided Design and Manufacturing (CAD/CAM) system integrated with statistical analysis to predict manufacturing process performance in early design phase. A challenge facing the proposed plan is the diversity of required information and lack of physical and geometrical relations between KCC and KPC. The research will focus on developing: (1) variation propagation models integrating statistical and CAD/CAM information; (2) multi-resolution/granularity of KPC/KCC as they change during product development; (3) computational efficiency for simulation of multistage assembly processes; and (4) generic issues pertaining to new process-oriented modeling, design and control. The education efforts are to: (1) integrate statistical analysis into CAD/CAM courses; (2) explore challenges in the development and realization of new MAP systems; and (3) provide opportunities in developing and analyzing MAP systems using 3D simulation tools. It also includes creating grade-specific (graduate, undergraduate and K-12) projects.Broader Impact: If successful, this project will lead to a new methodology that can: (1) Fundamentally integrate CAD/CAM models with statistical analysis to predict manufacturing process dimensional variability during design as it relates to compliant parts, thus continuously improving product quality while reducing overall new MAP development time through rapid fault root cause detection. (2) Facilitate math-based design and manufacturing of the MAP systems: The integration of product and process variables expands the classical "part interchangeability" concept into "process interchangeability" considered during early design phase of a new MAP development. This is critical in relation to suppliers selection, benchmarking or outsourcing. (3) Train Industrial Engineers in statistical methods and their application in CAD/CAM systems thus preparing them towards developing a new generation of CAD/CAM system for virtual realization of MAP.