Special IssueArticle
Development of a virtual
manufacturing assembly simulation
system
Abdulrahman M Al-Ahmari1,2, Mustufa H Abidi1, Ali Ahmad3 and Saber Darmoul2
Abstract
Advancesin Mechanical Engineering 2016, Vol. 8(3) 1–13
Oacute; The Author(s) 2016
DOI: 10.1177/1687814016639824 aime.sagepub.com
Assembly operations are a key component of modern manufacturing systems. Designing, planning, and conducting assembly operations represent an important part of the cost of a product. Virtual reality provides an efficient and cost- effective solution to manufacturing design, planning, and prototyping. Still there are certain issues (such as data transla- tion, integration of various hardware and software systems, and real-time collision detection) faced while applying this advanced technology to the assembly domain. For example, existing works focus on using virtual reality systems and environments mainly to design new productsand to plan for assembly. Little focus hasbeen given to develop virtual real-
ity environments that contribute to train operators on assembly operations and to bridge the gap between design and
implementation/execution of assembly. Therefore, the research work presented in this article focuses on developing a fully functional virtual manufacturing assembly simulation system that solves the issues related to virtual reality environ- ments. The proposed system usesavirtual environment to create an interactive workbench that can be used for evaluat-
ing assembly decisions and training assembly operations. It is a comprehensive system that provides visual, auditory,
tactile, as well asforce feedback. The system works successfully even with large components.
Keywords
Virtual reality, virtual assembly, virtual environment, haptics, assembly
Date received: 22 November 2015; accepted: 26 February 2016 Academic Editor: Teen-HangMeen
Introduction
In the era of globalization, one of the significant factors for manufacturing organization to remain competent and flourish in the market is to provide cost-effective and innovative products. Therefore, to fulfill the cus- tomersrsquo; demands, these industries are always looking for advancements in the technological domain. The technological requirements of these firms are very straightforward, such as, for manufacturing industries, the technology should assist in either providing design- ing innovative products or it helps them to improve their processes in terms of time and cost. Mitigation of product development cycle time and cost have been
areas of strategic focus of the industry.1 Quality
requirements have also led to an increased emphasis on product and process validation and require efficient
1FARCAMT CHAIR, Advanced ManufacturingInstitute, KingSaud
University, Riyadh, Saudi Arabia
2Industrial EngineeringDepartment, College of Engineering, KingSaud
University, Riyadh, Saudi Arabia
3Department of EngineeringTechnology, Northwestern State University,
Natchitoches, LA, USA
Corresponding author:
MustufaH Abidi, FARCAMT CHAIR, Advanced ManufacturingInstitute, KingSaud University, P.O. Box 800, Riyadh 11421, Saudi Arabia.
Email: mabidi@ksu.edu.sa
Creative Commons CC-BY: This article is distributed under the terms of the Creative Commons Attribution 3.0 License (http://www.creativecommons.org/licenses/by/3.0/) which permits any use, reproduction and distribution of the work without
further permission provided the original work is attributed as specified on the SAGE and Open Access pages (https://us.sagepub.com/en-us/nam/
open-access-at-sage).
2 Advancesin Mechanical Engineering
and effective product design changes.2 Assembly opera- tions are a key component of modern manufacturing systems.3 It has been estimated that assembly processes account for a large part of time and cost of product development.4 Planning and training assembly opera- tions during the early stages of product design can ensure that a product is manufactured in the most effi- cient way. The principle of design for assembly is con- cerned with making assembly decisions during the early product design stages4,5 and is an integral part of computer-aided process planning.6,7 Assembly sequence planning plays an important role in a successful assem- bly procedure, and an efficient sequence will result in improvements in terms of time and cost. Traditionally, assembly planning is achieved using two-dimensional (2D) drawings or costly physical prototypes.8 Increase in product complexity make it difficult to make sequence planning manually; thus, computer-aided pro- cesses are applied.9
In this context, virtual reality (VR) appeared as a
technology that enables advanced forms of human– computer interaction based on a wide range of inputs, such as voice recognition and movement tracking, and an even wider range of outputs, such as advanced gra- phics, auditory displays, and haptic interfaces.3,10,11 Therefore, VR-based systems are becoming popular in the manufacturing field.12 VR can be applied to differ- ent domains of manufacturing, such as design, proto- typing, assembly, and maintenance.9,13–21
At the present time, VR is recognized as a capable tool for examining the overall performance of a prod- uct, and it can prevail over the limitations in conven- tional processes of designing and manufacturing.22 Manufacturing assembly processes impact product quality, time to market, and cost;3 consequently, they can benefit from VR applications development. The VR applications can support the integration of natural human interaction into a computer-aided assembly planning system.23 There have been several notable contributions in the development of VR applications for manufacturing, inc
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In the era of globalization, one of the significant factors for manufacturing organization to remain competent and flourish in the market is to provide cost-effective and innovative products. Therefore, to fulfill the customersrsquo; demands, these industries are always looking for advancements in the technological domain. The technological requirements of these firms are very straightforward, such as, for manufacturing industries, the technology should assist in either providing designing innovative products or it helps them to improve their processes in terms of time and cost. Mitigation of product development cycle time and cost have been areas of strategic focus of the industry. Quality requirements have also led to an increased emphasis on product and process validation and require efficient and effective product design changes. Assembly operations are a key component of modern manufacturing systems. It has been estimated that assembly processes account for a large part of time and cost of product development. Planning and training assembly operations during the early stages of product design can ensure that a product is manufactured in the most efficient way. The principle of design for assembly is concerned with making assembly decisions during the early product design stages, and is an integral part of computer-aided process planning. Assembly sequence planning plays an important role in a successful assembly procedure, and an efficient sequence will result in improvements in terms of time and cost. Traditionally, assembly planning is achieved using two-dimensional (2D) drawings or costly physical prototypes. Increase in product complexity make it difficult to make sequence planning manually; thus, computer-aided processes are applied.
在全球化时代，制造业组织在市场上保持竞争力和蓬勃发展的重要因素之一是提供具有成本效益的创新产品。因此，为了满足客户的需求，这些行业一直在寻求技术领域的进步。这些公司的技术要求非常简单，例如，对于制造业而言，该技术应该有助于提供设计创新产品，或者帮助他们在时间和成本方面改进流程。减少产品开发时间周期和成本一直是该行业的战略重点领域。质量要求也导致了对产品和工艺验证的重视，并要求高效和有效的产品设计变更。装配操作是现代制造系统的关键组成部分。据估计，装配过程占了产品开发的大部分时间和成本。在产品设计的早期阶段规划和培训装配操作可以确保产品以最高效的方式制造。装配设计的原则是在产品设计早期阶段进行装配决策，是计算机辅助工艺规划的一个组成部分。装配顺序规划在成功装配过程中扮演着重要角色，而高效的顺序将会缩短时间和成本。传统上，使用二维（2D）图纸或昂贵的物理原型来实现装配计划。产品复杂性的增加使得手动进行顺序计划变得困难，因此，应用了计算机辅助程序。
In this context, virtual reality (VR) appeared as a technology that enables advanced forms of human– computer interaction based on a wide range of inputs, such as voice recognition and movement tracking, and an even wider range of outputs, such as advanced graphics, auditory displays, and haptics interfaces. Therefore, VR-based systems are becoming popular in the manufacturing field.12 VR can be applied to different domains of manufacturing, such as design, proto- typing, assembly, and maintenance.
在这种情况下，虚拟现实（VR）技术出现了，它能够基于各种输入（如语音识别和移动跟踪）以及更广泛的输出（如高级图形，听觉显示和触觉界面）来实现高级形式的人机交互。因此，基于VR的系统在制造领域正变得越来越流行。VR可以应用于不同的制造领域，例如设计，原型设计，装配和维护。
At the present time, VR is recognized as a capable tool for examining the overall performance of a product, and it can prevail over the limitations in conventional processes of designing and manufacturing. Manufacturing assembly processes impact product quality, time to market, and cost; consequently, they can benefit from VR applications development. The VR applications can support the integration of natural human interaction into a computer-aided assembly planning system. There have been several notable contributions in the development of VR applications for manufacturing, including virtual assembly, disassembly reasoning, assembly and maintenance verification, the virtual assembly design environment(VADE),immersive virtual assembly, process simulation, and product assemblability analysis.
目前，VR被认为是检查产品整体性能的有力工具，它可以极大地克服传统设计和制造过程中的局限性。制造组装流程会影响产品质量，上市时间和成本; 因此，他们可以从VR应用程序开发中受益。VR应用程序可以支持将自然人机交互集成到计算机辅助组装计划系统中。虚拟装配，拆卸推理，装配和维护验证，虚拟装配设计环境（VADE），沉浸式虚拟装配，流程模拟和产品组装设计分析等在制造VR应用程序的开发方面有几个显着的贡献。
VR research in manufacturing in general, and assembly operations in particular, has focused on applications development. Existing works focus on using VR systems and environments mainly to design new products and to plan for assembly. Little focus has been given to developing VR environments that contribute to train operators on assembly operations and to bridge the gap between design and implementation execution of assembly operations. Technologies that allow using virtual assembly as an analysis, evaluation, assessment, training and operator skill acquisition, and improvement tool are not yet fully utilized by industry. Although this emerging technology is not completely understood in regard to applications within commercial industries, the technology as a whole is viewed as viable and valuable. There are several issues associated with the proper development of virtual environments (VEs) in manufacturing assembly simulation, including the translation of data generated by computer-aided design (CAD) systems, modeling the physical behavior and constraints of objects, collision detection, integration of various hardware peripherals and software platforms, and sometime limited field of view make VE unrealistic to user. Therefore, there is a need to develop a comprehensive VR-based assembly planning system that takes into consideration product CAD data, provides physical modeling, and offers intuitive feedback to users.
一般制造业的虚拟现实研究，尤其是装配业务，一直专注于应用开发。现有的作品着重于使用VR系统和环境来主要设计新产品和计划组装。开发虚拟现实环境的重点不多，这些虚拟现实环境有助于培训操作员进行装配操作，并弥合装配操作的设计和实施执行之间的差距。允许使用虚拟装配作为分析、评定、评估、培训和操作员技能获取以及改进工具的技术尚未得到工业界的充分利用。虽然这种新兴技术在商业行业的应用方面还没有完全理解，但整个技术被认为是可行和有价值的。在制造装配仿真中，虚拟环境（VE）的正确开发涉及到几个问题，包括计算机辅助设计（CAD）系统生成的数据转换，物体的物理行为和约束建模、碰撞检测、各种硬件外设和软件平台以及有限的视野使VE对用户不切实际。因此，需要开发综合的基于VR的装配计划系统，该系统考虑产品CAD数据，提供物理建模，并向用户提供直观的反馈。
Therefore, this research work focuses on developing a fully functional system for virtual manufacturing assembly simulation system (VMASS), which is mainly intended to bridge the gap between assembly design and planning on one hand and assembly training, implementation, and execution on the other
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