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

该学院早期职业发展（CAREER）计划资助支持建模的综合研究和教育项目;分析和控制复杂多级装配过程（MAP）中的尺寸变化，如汽车，航空航天，家电和电子行业。 我们的目标是开发一个通用的MAP模型的能力，代表关键的产品和过程控制特性/功能（KPC/KCC）与不同的分辨率/“信息粒度”，可以在设计，推出和全面生产阶段的一个新的制造系统。 该模型将基于一个通用的计算机辅助设计和制造（CAD/CAM）系统，该系统集成了统计分析，以预测早期设计阶段的制造过程性能。 拟议计划面临的一个挑战是，所需资料多种多样，而且科索沃CC公司和科索沃保护团之间缺乏实际和几何关系。 该研究将集中于开发：（1）集成统计和CAD/CAM信息的变化传播模型;（2）KPC/KCC在产品开发过程中变化时的多分辨率/粒度;（3）多级装配过程模拟的计算效率;以及（4）与新的面向过程的建模，设计和控制有关的一般问题。 教育工作的目的是：（1）将统计分析整合到CAD/CAM课程中;（2）探索新MAP系统开发和实现中的挑战;（3）提供使用3D仿真工具开发和分析MAP系统的机会。它还包括创建特定等级的更广泛的影响：如果成功，这个项目将导致一个新的方法，可以：（1）从根本上将CAD/CAM模型与统计分析相结合，以预测设计期间的制造过程尺寸变化，因为它涉及顺应性部件，从而通过快速故障根本原因检测来持续改进产品质量，同时减少整个新MAP开发时间。(2)促进MAP系统的基于数学的设计和制造：产品和过程变量的集成将经典的“零件可重复性”概念扩展为在新MAP开发的早期设计阶段考虑的“过程可重复性”。这对于选择供应商、设定基准或外包至关重要。(3)培训工业工程师统计方法及其在CAD/CAM系统中的应用，从而为开发新一代CAD/CAM系统做好准备，以实现MAP的虚拟实现。

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.