CATS 2008 Coordinate Controlled Fixturing for Affordable Reconfigurable Tooling

M. Jonsson 1 , H. Kihlman1, G.Ossbahr1

Abstract:

The design and manufacturing of fixtures and other dedicated tooling for positioning of workpieces are among the major cost drivers in product industrialization. The high cost is paired with the need to shorten lead time too allow rapid response to market changes and customer demands. This paper presents Coordinate Controlled Fixturing in relation to other fixturing methods, and to the earlier presented ART (Affordable Reconfigurable Tooling) concept. Coordinate Controlled Fixturing relies on a metrology system to control the positioning of either a fixture or the workpiece itself during fixture build-up. The ART-technology enables solutions for Coordinate Controlled Fixturing by means of flexible supports, so called Flexapods, attached in an easily reconfigurable frame - called BoxJoint. It can be adapted to both large and small changes of the workpiece. The advantage of this approach is that only the device in direct contact with the product needs to be configured accurately and that it can be done so online and onsite at low cost. Developed in collaboration with the aircraft industry (Saab AB and Airbus UK), the ART-concept is now applied and tried on other sectors, such as automotive and commercial vehicle together with other forms of Coordinate Controlled Fixturing.

Keywords: Flexible fixtures, Reconfigurable fixtures, Modular fixtures, Fixtures, Tooling, Flexible manufacturing systems

1 Background
The increase in global competition and more rapid changes in customer demands results in a trend of higher product variety and innovation, shorter product
1

Division of Production Engineering, Department of Management and Engineering,

Linkping University, Linkping. SE-585 81, Sweden.

M. Jonsson, H. Kihlman, G. Ossbahr

lifecycle, lower unit cost and thus shorter lead time. This has spurred companies to adapt new flexible approaches to manufacturing and automation, such as FMS (Flexible Manufacturing Systems) and RMS (Reconfigurable Manufacturing Systems) (ElMaraghy 2005, Mehrabi, et al., 2000) During the course of manufacturing processes, such as machining, assembly or inspection, it is necessary to locate, support and immobilize the workpiece or product. This is referred to as workholding or fixturing. Traditionally, workholding devices are designed and manufactured intended for a specific part and operation, i.e. the fixtures are dedicated. This single-purpose approach is costly due to the long lead time and effort required for design and manufacture, but also often due to manual set-up or modifications when a manufacturing process is completed or parts and operations are modified. Cost is also induced by the need to store and retrieve dedicated fixtures. For a manufacturing system to be truly flexible, all of its components have to be flexible, including the fixtures. In the manufacturing industry the design and manufacture of fixtures and other dedicated tooling for locating and positioning workpieces or products are among the major cost drivers in product industrialization. The design and manufacture of dedicated fixtures typically amount to 10-20 % of total manufacturing cost (Gandhi & Thompson 1986). For the automotive industry the cost of redesigning, manufacturing and installing fixtures is on the order of $ 100 million/plant/year (Bone & Capson 2003). The research on the area regarding the process of designing a fixture and of different, flexible fixture solutions is vast. Some review articles on this area include: (Bi & Zhang 2001, Hazen & Wright 1990, Shirinzadeh 1995). Shirinzadeh (1995) presents a comprehensive schematic of different approaches to flexible fixturing which include sensory based assembly, modular and reconfigurable fixtures, programmable clamps, adaptable clamps and phase-change fixtures. Bi and Zhang (2001) on the other hand, classify fixtures according to their structure, and separates between modular structure systems (which includes different modular kits and reconfigurable fixtures) and single structure systems (which includes phase change fixtures and adaptive clamps). 1.1 Modular Fixtures Modular fixture kits for machining, assembly and inspection operations are the areas which have received the most research and commercial attention and several solutions are available in the retail market (see Figure 1).

Fig. 1. Left, a typical modular fixturing kit for machining (Gandhi & Thompson 1986). Right: A modular kit for assembly (courtesy of Volvo Cars)

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Machining solutions often consists of elements such as V-blocks, rectangular blocks and clamps bolted on a T-slotted plate or on a base plate with plain or tapped holes. Both research and commercial interest has focused on rather simple 2D or 3D geometries. The modular elements are manufactured with high tolerances and a full kit is an expensive investment. Modular tooling kits for assembly and control operations are often made up of aluminium profiles and different add-on parts. Successful fixture build for either machining or assembly require skilled personnel and, due to several iterative steps between building, measuring and correcting the fixture, the process also consumes a large amount of time. 1.2 Reconfigurable Fixtures A modular fixture has to be rebuilt to fit a specific part while a reconfigurable fixture is, as the name implies, able to be reconfigured in between parts in the same family. Rebuilding means to physically detach or reattach fixture components while reconfiguring implies that some parts are adjustable. A reconfigurable fixture may be limited in the amount of different geometries it can conform to, but reconfiguration can be done faster. This is often achieved by using some sort of online measuring system, such as a robot, a CNC-machine or some type of actuators. The line between modular and reconfigurable fixtures is not clear cut and a reconfigurable fixture is often made up of modular parts, but also has adjustable features that can be used to adapt to limited changes in product geometry. Several attempts have been made to design reconfigurable fixtures, and the most common way to build the fixture and reconfigure the locations of the datum points is by using a robot. Shirinzadeh and Tie (1995) describe a reconfigurable fixturing system for assembly operations which is built using a robot. The accuracy of the assembled fixture is researched and, for many applications, found to be too inaccurate due to the robots own positioning error. Chan, et al. (1990) presents a robot assembled, reconfigurable fixture for layered assembly incorporating sensors for verification of proper insertion of fixture component, detection of workpiece presence and control of the clamping process.

Fig. 2. Example of Bed of Nail fixture for sheet metal (source: MTorres)

M. Jonsson, H. Kihlman, G. Ossbahr

Asada and By (1985) utilize a robot for placing fixture components on a magnetic base-plate. Yousef-Toumi and Buitrago (1989) presents a modular robot configured fixture consisting of surface adaptive components. Yousef-Toumi, et al. (1988) presents a robot assembled fixture for sheet metal parts. In Shen, et al. (2006) modular fixture parts are assembled on a magnetic chuck by the NCmachine itself with satisfactory results regarding accuracy and repeatability. One example of an actuator fixture is the manipulator presented in Lee and Yien (1989) which consists of three servo motor driven arms used for both workholding and workhandling. Another is the large bed of nail structures used in the aircraft industry for drilling of large sheet-metal structures (se Figure 2). These fixtures are able to quickly reconfigure between different geometries, however, the need for precision in all parts makes them expensive. 1.3 Sensor/Vision Guided Assembly It is also possible to use a robot as a fixture, as in RFA Robotic Fixtureless Assembly first introduced by Hoska (1988). In RFA the robot and the gripper may be seen as an active fixture. Bone and Capson (2003) built an RFA assembly cell for automotive parts using 2D vision for part pickup and 3D vision for part alignment. This approach has also been tried in the aircraft industry, as described in Jayaweera and Webb (2007) where robots are used to position compliant parts. As of yet the RFA applications in research have been limited to sheet metal or similar components that are not subject to any amount of force in the joining process. 1.4 Limitations of Existing Solutions Modular tooling kits are expensive investments that require skill and time to pay off. They have also limited flexibility and are not developed for more complex geometries. They also have limited performance such as accuracy, stiffness, and convenience of loading and unloading. Reconfigurable fixtures have often an inherent need for precision in every element, and in many cases their applicability is limited.

2. Coordinate Controlled Fixturing - Coofix

Coordinate Controlled Fixturing (from heron denoted CooFix) is a vision that minimizes the iterative process in fixture build, the need for narrow tolerances in fixture parts and skilled personnel but still emphasizes the generic approach of modular fixturing, where a discreet number of parts that can be combined to suit a large variety of geometries. Although all fixtures are coordinate controlled the key in CooFix is by using an external measuring system, to control a point as close to the product as possible or maybe the product itself. This approach lessens the need for accurate fixture components, since it is actually only the point in contact with the object (or the object itself) to be positioned that has to be measured. This leaves issues of rigidity and stability to be solved by fixture components. Several fixture solutions already employ CooFix to some extent (se Figure 3). For example some vision guided assembly solutions, where the robot grasps the part and by using a

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vision approach and positions the part correctly in space, thus limiting the need for an accurate gripper. The fixture solution presented in this paper is based on ART the Affordable Reconfigurable Tooling concept, as described below.

Fig. 3. Schematics of Coordinate Controlled Fixturing

2.1 Current Status of ART Affordable Reconfigurable Tooling As presented in (Kihlman 2005) ART is a concept for flexible, reconfigurable fixturing developed for the aircraft industry in collaboration with SAAB Aerostructures, Sweden. The ART-concept fuses modularity with reconfigurability by combining an inaccurate modular framework called BoxJoint, with reconfigurable units called Flexapods (see Figure 4). This combination makes it possible for the system to conform to a large variety of different geometries since the fixture can both be rebuilt and reconfigured.

Fig. 4. An overview of current ART-concept

M. Jonsson, H. Kihlman, G. Ossbahr

2.1.1 BoxJoint BoxJoint is a modular kit made up of steel beams connected by patented joints. The joints utilize friction to hold the beams together, eliminating the need for welds and enabling seamless adjustment of the beams. The joint is made up of fixing plates placed on either side of the beam which are bolted together using standardized bolts (see Figure 5). The joints are not only used for holding beams together, but also for attaching Flexapods to the framework structure. Since all elements are standardized they can be combined, making it easy to build suitable a BoxJoint frame.

Fig. 5. The BoxJoint principle

2.1.2 Flexapods The BoxJoint frame is robust but inaccurate. To come to terms with the lack of accuracy without the iterative process of measuring and adjusting, the BoxJoint system is combined with a reconfigurable unit named the Flexapod. Several different Flexapods have been developed for use in airframe assembly applications, two examples are shown in Figure 6, the Flexapod 6 and the LiU Module. The latter is intended for complex assembly where component access is a critical issue. The Flexapod 6 has six links connected in parallel between the top and the bottom plate and resembles a parallel kinematic machine but without the actuators and encoders. The links can be locked in position by a hub-shaft connection mechanism and the resulting device has six degrees of freedom. At the top of the Flexapod 6 an interface called a Coromant Capto is attached. The Coromant Capto interface serves as the docking point for a positioning robot, for a metrology probe and for the pick up interface that will hold the part. The Capto system is robust and has a repetitive accuracy of 2 m and was originally designed for holding cutting tools in CNC machines, hence they are mass-produced and relatively cheap. The LiU Module is a serial linked mechanism with similar capabilities; sixdegrees of freedom, a hub-shaft connection mechanism and the Coromant Capto interface. This Flexapods are attached to the BoxJoint frame and positioned either manually or by using a robot which then docks to the Coromant Capto unit. Successful trials have been conducted using a six-degree-of-freedom measuring system to improve robot accuracy when positioning a Flexapod (Kihlman 2005). In

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the manual case an operator positions the Flexapod while getting feedback from the measuring system via a screen.

Fig. 6. Different Flexapods; left: Flexapod6, right: the LiU Pogo

2.1.3 Current Applications of ART The ART-technology is being employed at SAAB Aerostructures in Sweden for building components to the unmanned aircraft Neuron. A prototype cell capable of fixturing all required building steps is being developed. Different seizes of Flexapod 6 will be used throughout the fixture which will be reconfigured and repositioned when required between assembly steps. Since this is a prototype build automation is too expensive and therefore the Flexapods will be configured manually by an operator. To facilitate fixture design and Flexapod adjustment an add-on program called a Configurator has been researched and successfully employed.

3. New Challenges for ART

The ART-concept is now applied in other sectors. Early results from this work are presented below, together with information on this project. 3.1 The CooFix-Project As stated earlier the current layout of ART is developed for aircraft applications. In order to research it applicability in other areas the CooFix-project was launched in 2006. The project, which is funded by Vinnova (the Swedish Governmental Agency for Innovation Systems), aims to broaden the usefulness of ART and the thought behind Coordinate Controlled Fixturing into other areas. Several companies participate in the project including an automotive manufacturer and a manufacturer of heavy-duty transport equipment.

M. Jonsson, H. Kihlman, G. Ossbahr

3.2 Automotive Industry The ART-concept and Coordinate Controlled Fixturing has been evaluated in a case study at the pilot plant of an automotive manufacturer in Sweden (Biln & Sderberg 2007). The facility manufactures test series of about 50-100 cars in a production flow that resembles the main factory, although with less automation. The ART-concept was applied on the base fixture used when mating the three main structures of the car floor. This fixture is also used when installing elements for attaching of other equipment, such as electrical wiring, interior etc. The mating is done by a robot equipped with a spot welding gun and the same robot is used for installing the attachment elements. The fixtures are built in the traditional way; by manually building, then measuring the result and adjusting the fixture to fit desired tolerances. The accuracy required is +/- 0,15mm. in x, y and z.

Fig. 7. Simulation result from case study conducted at Volvo Cars, Sweden (Biln & Sderberg 2007)

FE-calculations to determine structural strength of the Flexapods and simulations to determine reachability where conducted using the CATIA and DELMIA software packages (one example of a simulation is presented in Figure 7). Although spot welding does not induce high thermal stresses that may actuate forces on the fixture it has to be robust and sturdy due to the potential for collisions between the robot and the Flexapods. There are many welds and attachment elements to be processed and reachability for the robot is crucial. In the case study the existing Flexapod components of ART were found to be too bulky or weak. In this application the 6 DOF of the existing Flexapods are excessive and 3 DOF (translation in x, y and z respectively) is sufficient. The fixture may be built to act as a cradle constraining 5 DOF but leaving the option for the product to easily be lifted out of the fixture. 3.3 Heavy-duty Industry Other industries besides aerospace and automotive have shown great interest in the ART concept, namely heavy-duty industry. Fixturing within this industry is a challenge, the product volumes are relatively small and there are often many variants on the same product. In this case study the ART concept is tried in manual welding of thick steel plates. A common welding application may be described as;

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1. 2. 3. 4. 5.

Loading parts into fixture Tack welding (Unloading) Welding (Unloading)

The part may be unloaded after step 2 and welded outside of the fixture but, for some cases, the part has to be wholly or partly fixtured during the welding operation in order to meet quality demands. Also parts may be loaded and welded in sequence due to reachability issues, meaning that steps 1-4 may be carried out several times before unloading. Often a workpiece positioner is used during welding to keep the part in the most beneficial position for the weld process. Welding operations may be manual or automated and, although the demands for accuracy of the fixture is lower than in aircraft industry (in the range of +/-0,5 mm), the fixture has to be robust enough to withstand the distortion stresses induced by weld cooling but still allow access for the weld gun. It is also possible to use robots as a workpiece positioner or even to pick, place and hold the parts to be welded.

Fig. 8. Simplifed mockup of current ART applied in heavy duty industry

When applying BoxJoint and ART to construct a welding fixture the preliminary results seem to indicate that the existing ART Flexapods are also too bulky and weak (see Figure 8). In welding applications it is common to use simple vertical locator and hydraulic clamps to fixate the workpiece and existing Flexapods (as the Flexapod 6) are designed to constrain a maximum of 6 DOF. The ART concept has also shown great potential for prototype and variant manufacturing, since it can be rebuilt and reconfigured to suit the product at hand. In these cases automation is too expensive and the positioning of the Flexapods has to be conducted manually.

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M. Jonsson, H. Kihlman, G. Ossbahr

3.4 Further Research The two case studies have indicated that the ART concept has to be broadened to encompass other, more sturdy and compact devices. For both the automotive and the heavy duty applications devices with less than 6 DOF are sufficient. Therefore: A new type of Flexapod for the automotive industry is being researched and developed. Simpler Flexapods for the heavy duty sector is being developed. The manual configuration method for Flexapod 6 is being developed

Also a servo driven Flexapod 6 will be developed. Unlike a robot, which has built-in encoders for positioning, the Flexapod will rely on an external measuring device and mechatronic system. This ensures that no built in accuracy are needed and this Flexapod will still be an affordable solution.

4. Conclusion
This paper has presented Coordinate Controlled fixturing in relation to ART and other fixturing methods. By combining the benefits of modular tooling with different kinds of reconfigurable Flexapods and the simplicity of the CooFix vision low cost fixturing can be realised. Industry has already shown interest for this technology but research is needed to develop new Flexapods to suit different industry needs and conditions.

5. References
Asada, H. & By, A.B. 1985, "Kinematic Analysis of Workpart Fixturing for flexible assembly with Automatically Reconfigurable Fixtures", IEEE Journal of Robotics and Automation, vol. RA-1, no. 2, pp. 86-94. Bi, Z.M. & Zhang, W.J. 2001, "Flexible fixture design and automation: Review, issues and future directions", International Journal of Production Research, vol. 39, no. 13, pp. 2867-2894. Biln, T. & Sderberg, R. 2007, Flexible fixtures Within Volvo Cars' Pilot Plant, Institutionen fr ekonomisk och Industriell utveckling. Bone, G.M. & Capson, D. 2003, "Vision-guided fixtureless assembly of automotive components", Robotics and Computer Integrated Manufacturing, vol. 19, no. 1, pp. 7987. Chan, K.C., Benhabib, B. & Dai, M.Q. 1990, "A Reconfigurable Fixture System for Robotic Assembly", Journal of Manufacturing Systems, vol. 9, no. 3, pp. 206-221. ElMaraghy, H.A. 2005, "Flexible and reconfigurable manufacturing systems paradigms", International Journal of Flexible Manufacturing Systems, vol. 17, no. 4, pp. 261-276. Gandhi, M.V. & Thompson, B.S. 1986, "Automated design of modular fixtures for flexible manufacturing systems", Journal of Manufacturing Systems, vol. 5, no. 4, pp. 243-252. Hazen, F.B. & Wright, P.K. 1990, "Workholding Automation: Innovations in Analysis, Design, and Planning", Manufacturing Review, vol. 3, no. 4, pp. 224-237. Hoska, D.R. 1988, "Fixtureless assembly manufacturing", Manufacturing Engineering, vol. 100, pp. 49-54.

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Jayaweera, N. & Webb, P. 2007, "Adaptive robotic assembly of compliant aero-structure components", Robotics and Computer-Integrated Manufacturing, vol. 23, no. 2, pp. 180-194. Kihlman, H. 2005, Affordable Automation for Airframe Assembly - Development of Key Enabling Technologies, Department of Mechanical Engineering. Lee, K. & Yien, C. 1989, "Design and Control of a Prototype Platform Manipulator for Workholding and Workhandling Applications", Journal of Mechanical Working Technology, vol. 20, pp. 305-314. Mehrabi, M.G., Ulsoy, A.G. & Koren, Y. 2000, "Reconfigurable manufacturing systems: key to future manufacturing", Journal of Intelligent Manufacturing, vol. 11, no. 4, pp. 403-419. Shen, C.-., Lin, Y.-., Agapiou, J.S. & Bandyopadhyay, P. 2006, Reconfigurable Fixtures for Automotive Engine Machining and Assembly Applications. Shirinzadeh, B. 1995, "Flexible and automated workholding systems", Industrial Robot: An International Journal, vol. 22, no. 2, pp. 29-34. Shirinzadeh, B. & Tie, Y. 1995, "Experimental investigation of the performance of a reconfigurable fixturing system", The International Journal of Advanced Manufacturing Technology, vol. 10, no. 5, pp. 330-341. Yousef-Toumi, K., Liu, W.S. & Asada, H. 1988, "Computer-Aided Analysis of Reconfigurable Fixtures and Sheet Metal Parts for Robotic Drilling", Robotics and Computer Integrated Manufacturing, vol. 4, no. 3/4, pp. 387-393. Yousef-Toumi, K. & Buitrago, J.H. 1989, "Design and Implementation of Robot-Operated Adaptable and Modular Fixtures", Robotics and Computer Integrated Manufacturing, vol. 5, no. 4, pp. 343-356.