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Computer-aided fixture planning (CAFP) is an essential part of Computer-aided design and manufacturing (CAD/CAM) integration. Proper fixture planning can dramatically reduce the manufacturing cost, the lead-time, and labor skill requirements in product manufacturing. However, fixture planning is a highly experience-based activity. Due to the extreme diversity and complexity of manufacturing workpieces and processes, there are not many fixture planning tools available for industry applications. Moreover, existing CAFP methods rarely consider integrating fixture environmental factors into fixture planning. Automatic fixture planning using VR can provide a viable way for industries. This thesis develops automated approaches to fixture planning in a virtual environment (VE). It intends to address two important issues: automatic algorithms for fixture planning, and the VE to support high fidelity evaluation of fixture planning. The system consists of three parts including fixture assembly planning, feasibility analysis of assembly tools, and motion planning for fixture loading and unloading. The virtual fixture planning system provides the fixture designer a tool for fixture planning and evaluation. Geometrical algorithms are developed to facilitate the automatic reasoning. A Web-based VE for fixture planning is implemented. The three-dimensional (3D) model visualization enables the fixture simulation and validation effectively to investigate existing problems. Approaches to construct desktop-based large VEs are also investigated. Cell segmentation methods and dynamic loading strategies are investigated to improve the rendering performance. Case studies of virtual building navigation and product assembly simulations are conducted. The developed algorithms can successfully generate the assembly plan, validate the assembly tools, and generate moving paths for fixture design and applications. The VE is intuitive and sufficient to support fixture planning, as well as other virtual design and manufacturing tasks.

Computer-aided fixture planning (CAFP) is an essential part of Computer-aided design and manufacturing (CAD/CAM) integration. Proper fixture planning can dramatically reduce the manufacturing cost, the lead-time, and labor skill requirements in product manufacturing. However, fixture planning is a highly experience-based activity. Due to the extreme diversity and complexity of manufacturing workpieces and processes, there are not many fixture planning tools available for industry applications. Moreover, existing CAFP methods rarely consider integrating fixture environmental factors into fixture planning. Automatic fixture planning using VR can provide a viable way for industries. This thesis develops automated approaches to fixture planning in a virtual environment (VE). It intends to address two important issues: automatic algorithms for fixture planning, and the VE to support high fidelity evaluation of fixture planning. The system consists of three parts including fixture assembly planning, feasibility analysis of assembly tools, and motion planning for fixture loading and unloading. The virtual fixture planning system provides the fixture designer a tool for fixture planning and evaluation. Geometrical algorithms are developed to facilitate the automatic reasoning. A Web-based VE for fixture planning is implemented. The three-dimensional (3D) model visualization enables the fixture simulation and validation effectively to investigate existing problems. Approaches to construct desktop-based large VEs are also investigated. Cell segmentation methods and dynamic loading strategies are investigated to improve the rendering performance. Case studies of virtual building navigation and product assembly simulations are conducted. The developed algorithms can successfully generate the assembly plan, validate the assembly tools, and generate moving paths for fixture design and applications. The VE is intuitive and sufficient to support fixture planning, as well as other virtual design and manufacturing tasks.

<p>The unchangeable need of securing and locating parts during different manufacturing processes turned the fixtures to key elements in many part production industries. The iterations between design engineers and manufacturing planners because of late collision detection of the part/fixtures with robots cost a lot of time and money. The lead-time can be reduced by developing tools and/or methods for early verification of the fixtures during the simultaneous engineering phase. Different aspects of fixture designing, modeling and simulating is investigated as a base step to recognize the best practice work to do fixture planning in Process Simulate integrated PLM environment. The aim of the project is to use Process Simulate to design and validate modular fixtures at the same time and in a single environment. It also aims to investigate the possibility of adding kinematics, sensors, and actuating signals to the fixtures and utilize them to model the fixture behavior in a larger simulation study. The project narrows down its focus on the fixtures designed for robotic applications specifically in Automotive Body in White lines without losing generality. The document type stated at the title page and in the header of this page is master thesis work.</p>

The unchangeable need of securing and locating parts during different manufacturing processes turned the fixtures to key elements in many part production industries. The iterations between design engineers and manufacturing planners because of late collision detection of the part/fixtures with robots cost a lot of time and money. The lead-time can be reduced by developing tools and/or methods for early verification of the fixtures during the simultaneous engineering phase. Different aspects of fixture designing, modeling and simulating is investigated as a base step to recognize the best practice work to do fixture planning in Process Simulate integrated PLM environment. The aim of the project is to use Process Simulate to design and validate modular fixtures at the same time and in a single environment. It also aims to investigate the possibility of adding kinematics, sensors, and actuating signals to the fixtures and utilize them to model the fixture behavior in a larger simulation study. The project narrows down its focus on the fixtures designed for robotic applications specifically in Automotive Body in White lines without losing generality. The document type stated at the title page and in the header of this page is master thesis work.