Thesis (M.S.)--University of Wisconsin-- Madison, 1985. / Typescript. eContent provider-neutral record in process. Description based on print version record. Includes bibliographical references (leaves 138-140).

Metrology and Tooling are considered as discrete disciplines within Manufacturing Engineering, however, assembly tooling often acts as a checking mechanism. Assembly tooling has the primary function of controlling part location during assembly; with a secondary requirement as a quality gate. In-tool checks are manual mechanical checks of the assembly, these gauging checks assume the tooling has the correct, nominal geometry. Tooling conformance is certified periodically; however these intervals can be up to three years. Further examination of the metrology requirements within the aerospace industry with respect to large scale assembly tooling identify a requirement to: reduce manual metrology checks, reduce tooling recertification time, and enable greater automation. Currently, there is a lack of integration between metrology and Wing-box assembly tooling. This research investigates how to increase manufacturing confidence with respect to tooling conformance; and, ultimately improve the manufacturing process for aero-structures, through the increased and enhanced use of metrology in the assembly tooling environment. The Metrology Enhanced Tooling for Aerospace (META) framework has been created to provide a robust framework for deploying metrology in the tooling environment. The major elements of the framework are subsequently detailed and demonstrated in three chapters: i) large volume metrology networks, for the measurement of tooling structures; testing instrument performance, quantifying and improving the uncertainty estimation, and ultimately, establishing a rapid measurement process for assembly tooling; ii) embedded metrology systems demonstrates how local measurement systems can be utilised to replace and improve on, traditional in-tool checks; and iii) metrology feedback presents an example of an automated tooling pick-up that manipulates the assembly to achieve the design intent. The contributions can be summarised as: firstly, the creation of the META framework for the deployment of metrology in assembly tooling environment, accommodating and facilitating a number of the future tooling and assembly requirements. Secondly, the establishment of a generic commissioning methodology and measurement strategy for the rapid measurement of assembly tooling to increase tooling confidence. The research output was demonstrated in a case study, through a combination of physical measurement and digital automation simulation to prove the process time was greatly decreased from current methods.

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Published Article / The efficient design and manufacturing of injection moulds (and other tooling), requires collaboration between multi-disciplinary, geographically separated units and companies, including the company that orders plastic parts, the ones that design and/or produce the moulds and/or mould-components, and those that use injection moulding machines to produce components. Distributed collaborative tooling design and manufacturing, while being a great concept, is still difficult to implement in today's complex environment. This is clear as more functional groups become involved in the total product development process earlier to meet time-to-market and cost objectives. <br>Although internal design and manufacturing groups may have experience in collaborating with different degrees of success, the global trend is towards greater outsourcing of activities and inclusion of complementary organisations. The requirement for extended collaboration - the process of securely and selectively exchanging, reviewing, and managing the change of product information with other internal participants and external groups such as customers, design partners, suppliers and distributed manufacturing companies - presents huge challenges. <br>Delivering these capabilities in today's global product development processes requires a different approach to doing business than a few years ago. Companies must be willing to share more information, which "is hard because we are competitors." The toolmaking companies' in South Africa (of which 90% are small and medium size enterprises (SMEs)) concern for success in delivering these capabilities, can also be greatly impacted by the underlying software or information technology infrastructure required for supporting the entire product development process. <br>This article provides a perspective for SMEs and others that might participate in collaborative tool design and manufacture in South Africa today or in the future.

Published Article / A key lever for unlocking the economic potential of any nation is a competitive tooling industry. Like other sectors of the South African economy, the tooling industry has experienced a marked decline in the skills base and requisite expertise needed in a globalised economy. Furthermore, over the past few years, there have been low levels of capital investment among tooling companies in South Africa to keep pace with global trends. This paper will highlight the Department of Science and Technology's (DST) response to the unacceptable decline in the competitiveness and innovative capacity of the tooling industry in the country. Through the Tshumisano Trust, its implementation agency, the DST has launched three Institutes for Advanced Tooling (IATs) over the past year. These institutes are meant to stimulate the development of innovative products, processes and services through tooling to accelerate economic growth in South Africa. The potential impact of IATs on high growth and innovation-driven industries such as automotives and chemicals will be discussed.

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This thesis provides the design process for a new tooling ball detection method to calibrate moulds in automatic TIG welding. A mechanical component is designed to locate the tooling ball and convert the position information into analog signals. An electrical component is designed to process signals from the mechanical component and achieve the signal communication process. Finally, the computational component is designed and programmed to receive bits from the electrical component and convert information into position values for the tooling ball. The homogeneous transformation process is mathematically modeled for position computation in a robot system. The method is significantly different from current methods that have been developed and applied. Firstly, it uses a mechanical-touch style operation to locate the tooling ball with only a one-time detection operation. Secondly, it introduces a new approach for utilizing the joystick. Rather than as a manually operated direction controller for mobile control of devices, the joystick is used as a passive detection angle sensor. In order to properly use the joystick as an angle sensor, the joystick calibration method is also designed and tested. The designs of the three components are all implemented and tested separately. The results of these tests prove the feasibility of the new detecting method; however, the accuracy of detection is not yet acceptable and further improvements need to be made. In addition, a vision-based detecting method is also discussed at the end of the thesis. Compared to mechanical touch-style detection, the vision-based detecting method is designed to obtain better performance in a high temperature environment and to automate the tooling ball detecting process.

This thesis provides the design process for a new tooling ball detection method to calibrate moulds in automatic TIG welding. A mechanical component is designed to locate the tooling ball and convert the position information into analog signals. An electrical component is designed to process signals from the mechanical component and achieve the signal communication process. Finally, the computational component is designed and programmed to receive bits from the electrical component and convert information into position values for the tooling ball. The homogeneous transformation process is mathematically modeled for position computation in a robot system. The method is significantly different from current methods that have been developed and applied. Firstly, it uses a mechanical-touch style operation to locate the tooling ball with only a one-time detection operation. Secondly, it introduces a new approach for utilizing the joystick. Rather than as a manually operated direction controller for mobile control of devices, the joystick is used as a passive detection angle sensor. In order to properly use the joystick as an angle sensor, the joystick calibration method is also designed and tested. The designs of the three components are all implemented and tested separately. The results of these tests prove the feasibility of the new detecting method; however, the accuracy of detection is not yet acceptable and further improvements need to be made. In addition, a vision-based detecting method is also discussed at the end of the thesis. Compared to mechanical touch-style detection, the vision-based detecting method is designed to obtain better performance in a high temperature environment and to automate the tooling ball detecting process.

Thesis (MScIng)--University of Stellenbosch, 2005. / Bibliography. Also available via the Internet.