Computer-Aided Design and Manufacturing

1 CAD Systems and Their Interface with CAM.- 1.1 Introduction.- 1.2 Philosophy of the Application of CAD Systems.- 1.3 Software Structure of CAD Systems.- 1.4 Computer Internal Model.- 1.4.1 Different Geometric Models for CAD.- 1.4.2 Importance of Technology-Oriented Model for CAD/CAM.- 1.5 Interfaces of CAD Systems.- 1.5.1 Database Manipulation Language (DML).- 1.5.2 Initial Graphics Exchange Specification (IGES).- 1.5.3 Graphical Kernel System (GKS).- 1.6 Integration of the Manufacture Planning Process.- 1.6.1 Planning Process Based on CAD Models.- 1.6.2 NC-Machine Tool Programming Based on CAD Models.- 1.7 Economic Aspects.- 1.8 Conclusion.- 1.9 References.- 1.10 Additional Literature.- 2 Design for Assembly.- 2.1 Introduction.- 2.2 Design for Assembly Philosophy.- 2.3 Determination of the Most Appropriate Process.- 2.4 Re-design for Manual Assembly.- 2.4.1 Classification and Coding for Handling and Insertion.- 2.4.2 Sequence of Design Analysis.- 2.4.3 Determination of the Sequence of Assembly.- 2.4.4 Compilation of the Worksheet.- 2.4.5 Determination of Assembly Efficiency.- 2.4.6 Elimination of Potentially Redundant Parts.- 2.4.7 Re-design of High-Cost Handling or Insertion Parts.- 2.5 Re-design for Automatic Assembly.- 2.5.1 Classification and Coding for Automatic Handling.- 2.5.2 Classification and Coding for Automatic Insertion.- 2.6 Robots in Manufacturing.- 2.7 Characteristics of Assembly Robots.- 2.8 Requirements for Robotic Assembly.- 2.8.1 Faster Robots.- 2.8.2 Limited Capability, Cheap Robots.- 2.8.3 Versatile, Inexpensive Grippers.- 2.8.4 Identification of Assembly Families.- 2.8.5 Improved Assembly Efficiency.- 2.8.6 Low Cost Feeding.- 2.9 Classification and Coding for Automatic Parts Handling for Flexible Assembly.- 2.10 Classification and Coding for Automatic Insertion for Flexible Assembly.- 2.11 Conclusions.- 3 Technological Planning for Manufacture - Methodology of Process Planning.- 3.1 Methodology of Process Planning.- 3.1.1 Introduction.- 3.1.2 Tasks of Process Planning.- 3.1.3 Generation of the Process Plan.- 3.1.4 Principles of Process Planning.- 3.2 Development of APT and EXAPT.- 3.2.1 APT System.- 3.2.2 EXAPT System.- 3.2.2.1 Programming of N/C Turning Operations.- 3.2.2.2 Programming of Drilling and Milling Operations.- 3.2.2.3 Programming of Punching, Nibbling and Flame-Cutting Operations.- 3.2.2.4 Programming of Wire-Eroding Operations.- 3.2.2.5 Files for Working Data.- 3.3 Techniques of Computer Aided Process Planning.- 3.3.1 Dialog Aided Planning.- 3.3.2 Algorithms.- 3.3.3 Decision Tables.- 3.3.4 Data Files.- 3.4 Graphical Simulation of Manufacturing Processes in Process Planning.- 3.5 Systems for Computer Aided Process Planning Including Quality Control.- 3.5.1 AUTAP System.- 3.5.2 ARPL System.- 3.5.3 CAPEX System.- 3.5.4 CAPP System.- 3.5.5 DISAP System.- 3.5.6 DREKAL System.- 3.5.7 PREPLA System.- 3.5.8 CAPSY System (Inspection Planning).- 3.6 The CAPSY Process Planning System.- 3.7 Planning of Assembly Sequences.- 3.8 N/C Technology.- 3.9 N/C Programming on the Shop Floor Using Graphical Simulation Techniques.- 3.10 Programming of Robots Using Graphical Techniques.- 3.11 Integrated Aspects of Technological Planning.- 3.12 References.- 4 Evolutionary Trends in Generative Process Planning.- 4.1 Introduction.- 4.2 The Principal CAPP Methodologies.- 4.3 Generative Process Planning.- 4.3.1 Extended Part Programming Systems.- 4.3.2 GPP Using Decision Tables and Tree Structures.- 4.3.3 Iterative Algorithms.- 4.3.3.1 Recursive Process Planning.- 4.3.4 The Concept of Unit-Machined Surfaces.- 4.3.4.1 COFORM.- 4.3.4.2 APPAS.- 4.3.4.3 AUTAP and AUTAP-NC.- 4.3.4.4 More Sophisticated GPP Systems.- 4.4 Adequacy of the Existing GPP's in the Wake of New Developments.- 4.4.1 Recent Trends in the Design of CMS Control Systems.- 4.5 Dynamic GPP Using Pattern Recognition Techniques: A New Concept.- 4.5.1 Proposed Representation Schemes.- 4.5.1.1 Object Representation.- 4.5.1.2 Machine Tool Representation.- 4.5.2 Process Planning Steps (Briefly).- 4.5.2.1 Flexible Planning Logic.- 4.5.2.2 Identification of Surface Precedences.- 4.5.2.3 Selection of Machines, Tool Bits and Clamping Positions.- 4.6 References.- 5 Design Methodology of Computer Integrated Manufacturing and Control of Manufacturing Units.- 5.1 Introduction.- 5.2 The Need for a Methodology and a Conceptual Model of a CIM System.- 5.2.1 The Use of a Design Methodology.- 5.2.2 The Complexity of Computer Integrated Manufacturing.- 5.3 Conceptual Model of a CIM System.- 5.3.1 The Notion of the System.- 5.3.2 Conceptual Models.- 5.3.3 ICAM Model and Architecture.- 5.3.4 GRAI Conceptual Model.- 5.4 Methods of Designing Production Control Systems.- 5.4.1 The Structured System Analysis and Design Method (SSAD).- 5.4.2 ICAM Definition Language (IDEF).- 5.4.3 GRAI Method of Process Analysis.- 5.5 Design of Flexible Manufacturing Systems Using Modelling Techniques and Simulation.- 5.5.1 What is a Flexible Manufacturing System?.- 5.5.2 Design of Flexible Manufacturing Systems.- 5.5.3 GRAI Methodology.- 5.6 The Control of the Manufacturing Unit.- 5.6.1 Scheduling.- 5.6.2 Classification of Scheduling Problems.- 5.6.3 Scheduling Method.- 5.7 GRAI's Approach to Manufacturing Control.- 5.7.1 Introduction.- 5.7.2 GRAI's Approach to Modelling.- 6 Computing Aids to Plan and Control Manufacturing.- 6.1 Hierarchical Computer Control Equipment for Manufacturing Systems.- 6.1.1 Introduction.- 6.1.2 Definition of Hierarchical Control Systems.- 6.1.3 Control Tasks at Each Level in the Hierarchy.- 6.1.4 The Communication Network.- 6.1.5 Influence of VLSI Technology on Hierarchical Control Systems.- 6.1.5.1 Minicomputers for Higher Control Levels.- 6.1.5.2 Microcomputers for Operational Control Levels.- 6.1.5.3 VLSI Interface Modules.- 6.1.5.4 Memory.- 6.1.5.5 VLSI Data Peripherals.- 6.1.5.6 Data Peripherals.- 6.1.6 Software and System Development Aids.- 6.2 Hierarchical Control Architecture for Manufacturing Cells.- 6.2.1 Introduction.- 6.2.2 Robot Architecture.- 6.2.3 Internal Robot Data Representation.- 6.2.4 Task Decomposition and Execution.- 6.2.5 Data Flow and Computational Concept.- 6.2.6 Conclusion.- 6.3 Graphical Simulation Techniques for Planning and Programming of Robot Based Manufacturing Cells.- 6.3.1 Introduction.- 6.3.2 System Structure for Interactive Planning with a Graphic Simulator.- 6.3.3 Conclusion.- 6.4 Advanced Computer Architectures (5th Generation).- 6.4.1 Introduction.- 6.4.2 Components of 5th Generation Computers.- 6.4.3 Applications of 5th Generation Computers.- 6.4.4 The Basic Software System and Programming Languages.- 6.4.5 Computer Architecture of the 5th Generation Computer Systems.- 6.4.6 Conclusion.- 6.5 References.- 7 Programming of Robot Systems.- 7.1 Robot Languages in the Eighties.- 7.1.1 Introduction.- 7.1.2 Robot Programming.- 7.1.3 Languages and Software Environments.- 7.1.4 Functional Language and Logic Programming.- 7.1.5 European Robot Languages.- 7.1.6 Conclusions.- 7.2 Programming Languages for Manipulation and Vision in Industrial Robots.- 7.2.1 Introduction.- 7.2.2 How to Classify Robot Programming Languages.- 7.2.3 Joint-Level Languages: The Example of MAL.- 7.2.4 Manipulator-Level Languages: Mathematical Foundations.- 7.2.5 Object Representation in Robot Programming Languages.- 7.2.6 At the Object Level: AL and Vision.- 7.2.7 Object and Task Levels: Problems.- 7.2.8 Conclusions.- 7.3 Programming a Vision System.- 7.3.1 Introduction.- 7.3.2 A Vision System for Industrial Applications.- 7.3.3 Logical Organization of GYPSY.- 7.3.4 LIVIA: The User Programming Language.- 7.3.5 Examples of LIVIA Programs.- 7.3.6 Additional Position-Independent Features for Blobs and Models.- 7.4 Towards Automatic Error Recovery in Robot Programs.- 7.4.1 Introduction.- 7.4.2 A Method for Automatic Error Recovery.- 7.4.2.1 Dynamic Model.- 7.4.2.2 Semantics.- 7.4.2.3 Knowledge Base.- 7.4.2.4 Recovery Procedure.- 7.4.3 Concluding Remarks.- 7.5 References.- 8 Present State and Future Trends in the Development of Programming Languages for Manufacturing.- 8.1 Introduction.- 8.2 Programming of Machine Tools.- 8.2.1 The APT Language.- 8.2.2 The EXAPT Programming System.- 8.2.3 Interactive Symbolic Programming.- 8.2.4 Special Purpose Languages.- 8.2.5 Generative Programming by the Machine Tool Control.- 8.3 Programming Languages for Robots.- 8.3.1 General Requirements for Programming Languages for Robots.- 8.3.2 Programming Methods for Robots.- 8.3.2.1 Manual Programming.- 8.3.2.2 Programming with the Help of the Robot's Brake System.- 8.3.2.3 Sequential Optical or Tactile Programming.- 8.3.2.4 Master-Slave Programming.- 8.3.2.5 Teach-In-Method.- 8.3.2.6 Textual Programming.- 8.3.2.7 Acoustic Programming.- 8.3.2.8 Design Considerations for a High Order Language.- 8.3.3 A Survey of Existing Programming Languages.- 8.3.4 Concepts for New Programming Languages.- 8.3.5 Programming with a Natural Language.- 8.3.6 Implicit Programming Languages.- 8.3.7 Programming Aids.- 8.4 Process Control.- 8.4.1 Extensions of Existing Programming Languages.- 8.4.2 PEARL - A Process and Experiment Automatic Realtime Language.- 8.4.3 ADA.- 8.4.4 Tools for the Development of Process Control Systems.- 8.5 Commercial Data Processing.- 8.6 Future Trends.- 8.7 References.- 9 Quality Assurance and Machine Vision for Inspection.- 9.1 Introduction.- 9.2 Quality Assurance: Functions, Problems and Realizations.- 9.2.1 Quality Assurance Functions.- 9.2.2 Design of a Computer Integrated QA System.- 9.2.3 Hierarchical Computer Systems for Quality Assurance.- 9.2.4 Architecture of a Data Acquisition System.- 9.2.5 Quality Assurance Methods.- 9.2.6 Measuring Methods for Quality Assurance.- 9.2.6.1 Contact Measurement.- 9.2.6.2 Non-Contact Measurements.- 9.2.6.3 Manual Input.- 9.2.7 Computer Languages for Test Applications.- 9.2.8 Implementation of a QA Computer System.- 9.3 Machine Vision: Inspection Techniques, Mensuration and Robotics.- 9.3.1 Visual Inspection Tasks.- 9.3.2 Machine Vision Techniques for Inspection.- 9.3.2.1 Template Matching.- 9.3.2.2 Decision-Theoretic Approach.- 9.3.2.3 Syntactical Approach.- 9.3.3 Automated Microscopic Material Testing.- 9.3.4 Laser Based Measurements and Inspection.- 9.3.4.1 Quantitative Mensuration.- 9.3.4.2 Semi-Quantitative Mensuration (Scanner).- 9.3.5 Synthetic Images for Defect Classification.- 9.3.6 Robot Vision for Recognition and Sorting.- 9.3.6.1 Interfacing of a Vision System with an Assembly Robot.- 9.3.6.2 Sorting of Castings.- 9.4 References.- 10 Production Control and Information Systems.- 10.1 Strategies for the Selection of Software Packages in Production.- 10.2 Data Management Requirements for Production Control.- 10.2.1 Development of a Data Base Scheme for Primary Data.- 10.2.1.1 Bill of Materials.- 10.2.1.2 Work Descriptions.- 10.2.1.3 Manufacturing Equipment.- 10.2.2 Special Cases of Variant Production.- 10.2.3 Data Management with Software Packages.- 10.2.3.1 Conventional File Management.- 10.2.3.2 Specialized Data Base Systems.- 10.2.3.3 General Data Base Systems.- 10.2.3.4 System-Independent Data Bases.- 10.2.4 Future Developments in Data Management.- 10.3 Planning Strategies for the Implementation of Production Control Systems.- 10.3.1 Planning Stages.- 10.3.1.1 Master Production Scheduling.- 10.3.1.2 Material Requirement Planning.- 10.3.1.3 Capacity Planning.- 10.3.1.4 Job Shop Control.- 10.3.1.5 Data Collection.- 10.3.2 Implementation Strategies.- 10.4 The Interface Between CAD and Production Control.- 10.5 The Interface Between Production Control and Marketing.- 10.5.1 Master Production Scheduling.- 10.5.2 Order Handling.- 10.6 Factors Influencing the Acceptance of Production Control Software.- 11 Economic Analysis of Computer Integrated Manufacturing Systems.- 11.1 Introduction.- 11.2 Process Planning.- 11.3 Capacity Analysis Using CAN-Q.- 11.4 Capital and Labour Requirements.- 11.5 Payback, Capital Cost, and Taxes.- 11.6 Cost Comparisons.- 11.7 System Efficiency.- 11.8 Justification and Automation Equipment.- 11.9 Summary.- 11.10 References.- 11.11 Appendix.- Contributors.