99 results on '"Francesco Leali"'
Search Results
2. Development of a Computer-Aided integrated method for the tolerance-cost multi-disciplinary optimization of an automotive engine
- Author
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Fabio Pini, Francesco Leali, and Andrea Petruccioli
- Subjects
Modeling and Simulation ,Industrial and Manufacturing Engineering - Published
- 2022
3. Directed Energy Deposition Process Simulation to Sustain Design for Additive Remanufacturing Approaches
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Fabio Pini, Francesco Leali, and Enrico Dalpadulo
- Published
- 2023
4. Interoperability Framework for a Computer-Aided Approach of Tolerance-Cost Optimization
- Author
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Fabio Pini, Francesco Leali, and Andrea Petruccioli
- Published
- 2022
5. Surface Grinding of Borosilicate Crown Glass Optics via a Robotic Approach Based on Superposed Trajectories
- Author
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Eugenio Tamassia, Fabio Pini, Tim Grunwald, Thomas Bergs, and Francesco Leali
- Published
- 2022
6. User-Centered Design for Manufacturing and Assembly: An Application in the Early Design Stages
- Author
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Francesco Leali and Cristina Renzi
- Published
- 2022
7. Design for welding: an application in top class cars chassis
- Author
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Cristina Renzi and Francesco Leali
- Abstract
High quality standards and components downsizing are two main quests of the engineering designers in the nowadays automotive industry. To this aim, lightweight materials as aluminum are used. Moreover, most parts of the automotive chassis made of aluminum are assembled by means of welding techniques. Lightweight materials, such as aluminum, are more and more adopted in chassis design even if the assembly process represents a challenge from a technological point of view, especially due to the distortions caused by the welding process. In case of thin aluminum structures, non-convenient distortions occur due to a combination of effects of fixturing and cooling (after welding) process. The reduction of distortions or almost their prediction is still a very challenging issue, so that no conclusive technique has been found to exclusively fix the problem yet. In this paper, a “design for welding” approach is proposed as an integrated product design and process simulation method, with the aim of predicting the final distortion of an aluminum welded automotive chassis. Thermal-Elastic-Plastic (TEP) finite element analyses (FEA) simulations are capable to provide acceptable results, but require high computational efforts, especially in case of complex geometries as car chassis. To overcome this problem, in this paper, the local-global FEA approach has been adopted with satisfactory results. A top-class car automotive aluminum chassis has been chosen as a case study.
- Published
- 2022
8. A methodology for out of position occupant identification from pressure sensors embedded in a vehicle seat
- Author
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Alberto Vergnano and Francesco Leali
- Subjects
Microcontroller ,Computer science ,Inertial measurement unit ,Software deployment ,law ,Airbag ,Control unit ,Out of position ,Crash ,Car seat . Intelligentvehicle .Pressure sensor .Safetysystem .Drivingexperiment .Drivermonitoring .Outofposition ,Pressure sensor ,Automotive engineering ,law.invention - Abstract
The airbag deployment against an out of position (OP) occupant is critical. The OP condition can be hardly expected during design, while a too close airbag deployment can cause serious injuries instead of mitigating the crash effects. An adaptive airbag system would be capable to adjust its deployment to the inside scenario. However, the integration between human passengers and intelligent vehicle requires the airbag control unit to be aware of the actual occupant(s) position. In the present research, a methodology for monitoring the occupant(s) position is developed and tested with a seat prototype. A layout of thin film sensors monitors the interface pressure between the occupant and the seat cover. An inertial measurement unit (IMU) monitors the accelerations of the vehicle, considered the reference moving platform. A microcontroller is programmed for pressure sensors calibration, IMU alignment with the vehicle reference system, signals processing, OP detection, and identification. Real driving experiments on a race track were performed in the correct position and in three different OPs. The comparison of the pressure center in longitudinal and transversal directions with the vehicle acceleration enables to identify the OPs.
- Published
- 2020
9. Additive Remanufacturing Integrated Design Approach for Performance Improvement of Automotive Components
- Author
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Enrico Dalpadulo, Fabio Pini, and Francesco Leali
- Abstract
Metal Additive Manufacturing technologies provide many advantages among industrial sectors. Most applications exploit design freedom for functional design enabled by Powder Bed Fusion processes, while Directed Energy Deposition systems are mainly restricted to the construction of large parts and reparation of damaged components. Nevertheless, the latter provide not only high deposition rates, but also high flexibility, and the possibility to process multi-materials, to grade and combine their characteristics for enhanced features and performance. Therefore, a rising application is the remanufacturing of existing components to produce functional design variants. Those parts can integrate different features and materials through direct deposition of metals over bounded areas. This work concerns the development of a Design for Additive Remanufacturing methodology for existing components with improved performances to be produced by the laser-based Direct Metal Deposition process. It relies on the use of CAD platforms for the integrated design of products and the associated processes. The design approach is based on the integration of CAE structural analysis and Topology Optimization, to define the location and the morphology of deposited structures. The design of an automotive suspension arm with enhanced performances is the use case to demonstrate the effectiveness of the approach, which could be extended to the remanufacturing of several bodies and chassis automotive subsystems.
- Published
- 2022
10. Synergic Product and Process Design for Additive Fabrication of Lightweight Vehicles
- Author
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Enrico Dalpadulo, Andrea Petruccioli, Fabio Pini, and Francesco LEALI
- Published
- 2022
11. Assessment of close-range photogrammetry for the low cost development of 3D models of car bodywork components
- Author
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Francesco Leali, Francesco Gherardini, and Andrea Petruccioli
- Subjects
3D capturing ,3D digital model ,car body panel ,Classic vehicle restoration ,Close-range photogrammetry ,Geometric inspection ,Modeling and Simulation ,Industrial and Manufacturing Engineering - Published
- 2022
12. Investigation of Warpage and Tolerances in Injection Moulding Components Based on Simulation and Experimental Validation
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Francesco Leali, Giovanni Garlaschelli, Francesco Gherardini, and Simone Malagola
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Design of Experiments ,Injection moulding ,Simulation-based design approach ,Tolerances ,Warpage ,Materials science ,Mechanical engineering ,Experimental validation - Published
- 2021
13. Model-Based Approach for Optimal Allocation of GD&T
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Fabio Pini, Francesco Leali, and Andrea Petruccioli
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Geometric dimensioning and tolerancing (GD&T) ,Product manufacturing information ,Mathematical optimization ,Computer science ,Model-based definition ,Optimal allocation ,Tolerance-cost optimization ,Geometric dimensioning and tolerancing (GD&T); Model-based definition - Published
- 2021
14. An Analytical Model for Robot-Based Grinding of Axisymmetric Mold Inserts Using a Rotary Unit
- Author
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Fabio Pini, Eugenio Tamassia, Thomas Bergs, Tim Grunwald, Sebastian Hähnel, and Francesco Leali
- Subjects
Materials science ,Mold ,medicine ,Rotational symmetry ,Robot ,Mechanical engineering ,medicine.disease_cause ,Unit (ring theory) ,Grinding - Published
- 2021
15. Optimization of an Engine Piston Through CAD Platforms and Additive Manufacturing Based Systematic Product Redesign
- Author
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Fabio Pini, Francesco Leali, and Enrico Dalpadulo
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Automotive ,Design for additive manufacturing ,Design method ,Re-design ,Topology optimization - Published
- 2021
16. Components Residual Stress and Deformation Reduction: An Integrated Process Design for Additive Manufacturing
- Author
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Enrico Dalpadulo, Fabio Pini, and Francesco Leali
- Subjects
Process simulation ,Additive manufacturing ,Automotive ,Design method ,Powder bed fusion ,Process optimization - Abstract
Additive Manufacturing (AM) is a key technology in current industrial transformations thanks to the significant benefits that can bring to high-level sectors. Nevertheless, AM-based design approaches require improvements that are fundamental to exploit the potentials of the technology and reduce the lack of process consistency. This work focuses on integrated Design for Additive Manufacturing (DfAM) approaches for product-process design, to meet both functional and technological targets. The key aspects of process design and issues are summarized and the design method to perform metal AM process optimization is presented. The aim is therefore to minimize process-induced defects and flaws of AM-based manufacturing of metal products, such as residual stress and distortions. The approach consists of industrialization task improvement based on modelling optimization and build optimization sub-phases supported by numerical process simulation. Integration of CAD platforms allows embedding these steps to be performed downstream of the product design, which can be achieved through functional or multifunctional optimization techniques as well (e.g. topology optimization, latticing, graded structures/materials). The design method is finally applied to perform the industrialization phase of a high-performance automotive component. The case study is a formula SAE topology optimized brake caliper to be produced by Selective Laser Melting (SLM) process. Process simulation-driven studies on modelling and build preparation subphases (i.e. orientation definition, supports generation, model distortion compensation) are conducted to support the process design. The study demonstrates the part scale level method’s suitability to industrial context to improve industrialization in the redesign of components to be produced by metal AM.
- Published
- 2021
17. Correction to: Assessment of close-range photogrammetry for the low cost development of 3D models of car bodywork components
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Andrea Petruccioli, Francesco Gherardini, and Francesco Leali
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Modeling and Simulation ,Industrial and Manufacturing Engineering - Published
- 2022
18. Augmented reality based approach for on-line quality assessment of polished surfaces
- Author
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Fabio Pini, Franck Messmer, Thomas Gale, Chiara Storchi, Francesco Leali, Cesare Fantuzzi, and Federica Ferraguti
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0209 industrial biotechnology ,Computer science ,General Mathematics ,media_common.quotation_subject ,020208 electrical & electronic engineering ,Process (computing) ,Polishing ,Control engineering ,02 engineering and technology ,Industrial and Manufacturing Engineering ,Computer Science Applications ,Metrology ,020901 industrial engineering & automation ,Operator (computer programming) ,Control and Systems Engineering ,Component (UML) ,0202 electrical engineering, electronic engineering, information engineering ,Robot ,Augmented reality ,Industrial robotic solutions ,Robotic polishing ,Software ,Mathematics (all) ,Computer Science Applications1707 Computer Vision and Pattern Recognition ,Quality (business) ,media_common - Abstract
Augmented reality is considered one of the enabling technologies of the fourth industrial revolution, within the Industry 4.0 program and beyond. Indeed, augmented reality solutions can increase the working quality and the productivity and allow a better use of the human resources. This technology can help the operator in the industrial applications during the crucial phases of the processes. Since the quality assessment of the surfaces is recognized to be a key phase in the polishing process, in this paper we propose a novel method that exploits augmented reality to support the operators during this phase. The metrology data measured by a surface measurement system are directly projected on the polished component through an augmented reality headset worn by the operators and used to assess the quality of the worked surfaces. Rather than imagine how a certain parameter change can affect the result achieved, the information is directly there on the component’s surface. Users can see from the data where refinements are required and make better and faster decisions, which is compelling for its potential beyond industrial polishing. The proposed method is implemented and validated on an industrial cell, where the robot automatically perform the polishing task and move the head of the surface measurement system along the surface to measure the metrology parameters. Thanks to the proposed approach, the end-user and the operator can directly see on the component if the quality reached satisfies the specifications or if some parts of the surface require further refinements through additional polishing steps.
- Published
- 2019
19. A Co-Design Method for the Additive Manufacturing of Customised Assistive Devices for Hand Pathologies
- Author
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Francesco Leali, Valentina Bettelli, Francesco Gherardini, and Maria Teresa Mascia
- Subjects
Co-design ,Occupational therapy ,medicine.medical_specialty ,Computer science ,Human–computer interaction ,Additive Manufacturing technologies ,Assistive device ,Parametric modelling ,Rheumatoid arthritis ,General Engineering ,medicine - Published
- 2019
20. MÉTODO INTEGRADO ASISTIDO POR ORDENADOR PARA EL DESARROLLO EFECTIVO DE PROCESOS DE SOLDADURA ROBÓTICA EN EL MONTAJE DE CHASIS DE AUTOMÓVILES
- Author
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Francesco Leali, Davide Panari, and Fabio Pini
- Subjects
General Engineering - Abstract
Las companias fabricantes de automoviles continuamente promueven la innovacion de los productos de automocion y los procesos de fabricacion relacionados, basandose principalmente en metodos dedicados para el diseno de chasis de automocion y en los procesos de montaje con soldadura relacionados a ese diseno. Los primeros de ellos buscan mejorar la calidad final de todo el chasis a traves de optimizacion del ratio rigidez/ peso y a traves del uso de materiales de alto rendimiento. Los segundos buscan mejorar el rendimiento del chasis y reducir los costes de produccion total reduciendo los residuos mediante lineas de soldadura roboticas reconfigurables. Por consiguiente, se requieren nuevas metodologias de diseno integradas que tengan en cuenta las restricciones y especificaciones de las fases de diseno del proceso/producto, a la vez que se sugiere un uso concurrente de metodologias numericas y herramientas de simulacion para evaluar la configuracion de los sistemas roboticos y la programacion de los robots. Esta investigacion presenta una metodologia de diseno novedosa que busca reducir las desventajas de las actuales metodologias por medio de la evaluacion de operaciones de ensamblado antes de diseno en detalle del chasis y del diseno conceptual del sistema de fijacion, explotando las herramientas asistidas por ordenador. En particular este trabajo se centra en la fase de proceso de la metodologia de diseno, que busca integrar las herramientas de programacion offline de robots, para predecir las distorsiones de soldadura debido a la modificacion de los parametros de entrada del robot de acuerdo con los valores de tolerancia requeridos. Los resultados experimentales en relativos al submontaje de un chasis de referencia que se une siguiendo procesos de soldadura basados en herramientas asistidas por ordenador demuestran la efectividad del metodo propuesto. Palabras clave: Metodo integrado basado en CAD, analisis de tolerancia acumuladas, prediccion de distorsiones de soldadura, ensamblaje de soldadura robotica.
- Published
- 2019
21. Survey on human–robot collaboration in industrial settings: Safety, intuitive interfaces and applications
- Author
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Fabio Pini, Valeria Villani, Cristian Secchi, and Francesco Leali
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User interfaces ,0209 industrial biotechnology ,Collaborative robots ,Computer science ,02 engineering and technology ,Human–robot interaction ,020901 industrial engineering & automation ,Human–computer interaction ,0202 electrical engineering, electronic engineering, information engineering ,Industrial robotics ,Cognitive skill ,Electrical and Electronic Engineering ,Flexibility (engineering) ,Focus (computing) ,Human-robot collaboration ,Mechanical Engineering ,Collaborative robotics ,Industrial applications ,Computer Science Applications1707 Computer Vision and Pattern Recognition ,Computer Science Applications ,Control and Systems Engineering ,Intuitive robot programming ,Safety ,Robot ,020201 artificial intelligence & image processing ,User interface - Abstract
Easy-to-use collaborative robotics solutions, where human workers and robots share their skills, are entering the market, thus becoming the new frontier in industrial robotics. They allow to combine the advantages of robots, which enjoy high levels of accuracy, speed and repeatability, with the flexibility and cognitive skills of human workers. However, to achieve an efficient human–robot collaboration, several challenges need to be tackled. First, a safe interaction must be guaranteed to prevent harming humans having a direct contact with the moving robot. Additionally, to take full advantage of human skills, it is important that intuitive user interfaces are properly designed, so that human operators can easily program and interact with the robot. In this survey paper, an extensive review on human–robot collaboration in industrial environment is provided, with specific focus on issues related to physical and cognitive interaction. The commercially available solutions are also presented and the main industrial applications where collaborative robotic is advantageous are discussed, highlighting how collaborative solutions are intended to improve the efficiency of the system and which the open issue are.
- Published
- 2018
22. Computer-Aided Tolerancing Analysis of a High-Performance Car Engine Assembly
- Author
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Francesco Gherardini, Davide Panari, Francesco Leali, and Andrea Petruccioli
- Subjects
Automotive assembly ,Tolerance analysis method ,business.industry ,Computer science ,Geodetic datum ,Functional requirement ,Car engine ,Computer-Aided Tolerancing ,Geometric dimensioning and tolerancing (GD&T); Tolerance analysis method ,Reliability engineering ,Cost reduction ,Geometric dimensioning and tolerancing (GD&T) ,Software ,Product (mathematics) ,Computer-aided ,business - Abstract
This paper proposes the analysis of the tolerances (values, types, datum) and their effects on a mechanical assembly, as a high-performance car engine, by means of a Computer-Aided Tolerancing software. The 3D tolerance stack-ups are investigated to assess the fulfillment of the functional requirements as well as the performance specifications of the assembly. Moreover, after identifying the tolerances that mainly affect the product variability, we finally propose some corrective actions on the tolerances and assess their functional allocation, tightening or relaxing their values, ensuring assemblability and cost reduction.
- Published
- 2021
23. Assessment of computer-aided design tools for topology optimization of additively manufactured automotive components
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Enrico Dalpadulo, Francesco Leali, Fabio Pini, Dalpadulo E., Pini F., and Leali F.
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Technology ,Computer aided design tool ,QH301-705.5 ,Computer science ,QC1-999 ,Automotive industry ,Automotive ,computer.software_genre ,computer aided design tools ,Computer aided design tools ,design methods ,Computer Aided Design ,General Materials Science ,Topology optimization ,Biology (General) ,Design methods ,QD1-999 ,Instrumentation ,Design for additive manufacturing ,Fluid Flow and Transfer Processes ,business.industry ,Physics ,Process Chemistry and Technology ,Principal (computer security) ,General Engineering ,Usability ,Engineering (General). Civil engineering (General) ,Manufacturing engineering ,Design method ,Computer Science Applications ,Chemistry ,Workflow ,Software design ,TA1-2040 ,business ,computer - Abstract
The use of Topology Optimization techniques has seen a great development since the last decade. The principal contributor to this trend is the widespread use of Additive Manufacturing technologies to effectively build complex and performant structures over different settings. Nevertheless, the use of Topology Optimization in Design for Additive Manufacturing processes is not simple and research aims to fill the gap between theory and practice by evolving at the same time both approaches, workflows, and design software that allow their implementation. Since a strong connection between methodologies and tools exists, this work proposes a method to assess computer-aided design tools or platforms. This can be applied to sustain the key phase for selection and adoption of the computer-aided tools in industrial settings embracing Additive Manufacturing. The workflow for Topology Optimization implementation, the structure of the proposed evaluation approach, and its application, are presented to demonstrate effective usability. The automotive case study is the redesign of internal combustion engine piston to benefit of metal Additive Manufacturing based enhanced product performance. A preliminary finite element model is defined and a Topology Optimization based redesign is concurrently set up through four different commercial computer-based platforms. The method accounting for the assessment of required operations for the design optimization is applied to perform the tools selection phase.
- Published
- 2021
24. TOLERANCE SPECIFICATION MODEL FOR SYSTEMATIC APPLICATION OF GD&T IN PRODUCT DESIGN
- Author
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Andrea Petruccioli, Fabio Pini, and Francesco Leali
- Subjects
Geometric dimensioning and tolerancing (gd&t) ,Design for tolerancing (DFT) ,Dimensional management (dm) ,Geometric dimensioning and tolerancing (gd&t); Product design ,Product design - Abstract
The Dimensional Management (DM) is well known as the reference methodology for the management of dimensional and geometric variations of industrial products. Over the years, it has assumed a central role, thanks to the development of a specific design approach, known as Design for Tolerancing (DfT). Based on the Geometric Dimensioning and Tolerancing (GD&T) symbolic language, DfT allows to check and verify functional and qualitative requirements from the early design phases. Although its strength and potential to improve design optimization, DfT industrial application is still limited. Consolidated design practices, complexity of tolerance specification process, lack of support from Computer-Aided tools still limit the tolerance specification to final validation of product design. The paper aims to define a tolerance specification model for systematic application of GD&T specification. The model formalizes the identification and translation of product requirements on the components geometry, through the definition of the main step of tolerance design. Based on the integration between the GD&T-based approach and parametric three-dimensional CAD modelling, the model has been applied to validate the GD&T and the tolerance specification of two mechanical assemblies with common features. The methodology proves its general effectiveness to support engineers in tolerance design and selection of the most suitable GD&T schemes.
- Published
- 2021
25. Simulation and Experimental Validation of Secondary Dendrite Arm Spacing for AlSi7Mg0.3 Chassis Parts in Low Pressure Die Casting
- Author
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Paolo Veronesi, Alberto Vergnano, Umberto Bergamini, Francesco Leali, Daniele Bianchi, and Roberto Spagnolo
- Subjects
Integrated design ,Secondary Dendrite Arm Spacing ,Materials science ,Chassis ,Integrated Design ,Simulation modeling ,Mechanical engineering ,Experimental validation ,Dendrite (crystal) ,Secondary Dendrite Arm Spacing, Integrated Design, Simulation, Low Pressure Die Casting ,Pressure die casting ,Simulation ,Size effect on structural strength ,Low Pressure Die Casting - Abstract
The structural properties of cast aluminum parts are strongly affected by the solidification in the production process. The solidification dynamics determines the Secondary Dendrite Arm Spacing (SDAS), directly affecting the structural strength of the alloy. Simulation techniques enable the integrated design of chassis parts and their production equipment. However, in order to effectively predict the SDAS formation, the simulation models need to be investigated and calibrated. The present research investigates the SDAS formation models and identifies a robust relation to be used in Design by Simulation phases for AlSi7Mg0.3 parts.
- Published
- 2021
26. Modular Car Seat for Monitoring the Pressure Distribution on Regions of Pan and Backrest
- Author
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Andrea Piras, Alberto Vergnano, and Francesco Leali
- Subjects
Driver profiling ,Safety system ,Line-of-sight ,Distribution (number theory) ,Weight scale system ,business.industry ,Computer science ,Occupant classification ,Out of position ,Modular design ,Intelligent vehicle ,Pressure sensor ,Automotive engineering ,Car seat ,Driver monitoring ,Seat regions ,Modular car seat ,business ,Car seat pressure ,Fast measurement - Abstract
Car driver and occupants monitoring is important for safety and comfort. The systems using vision sensors for monitoring the line of sight can be integrated with pressure sensors embedded in the seats to identify critical Out of Position conditions. A new modular car seat is here proposed to monitor the pressure distribution on different significant regions. The solution improves the limitations of existing technologies embedded in seats. The proportional and fast measurement enables online complex evaluations, while the layout reduces the risk of errors. The experiments proved the effectiveness of the prototype.
- Published
- 2020
27. Systematic Integration of Topology Optimization Techniques in Design for Additive Manufacturing Methodologies Applied to Automotive Settings
- Author
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Enrico Dalpadulo, Fabio Pini, Francesco Leali, Dalpadulo, Enrico, Pini, Fabio, and Leali, Francesco
- Subjects
Topology Optimization ,business.industry ,Computer science ,Automotive ,Design methods ,DfAM ,Design for additive manufacturing ,Topology optimization ,Automotive industry ,Control engineering ,Topology (electrical circuits) ,DfAM, Topology Optimization, Design methods, Automotive ,business - Abstract
Additive Manufacturing is having a great trend since its implementation possible benefits have been widely discussed and efforts in technology improvements are having impact on process reliability and industrial application. The aims of this work are to analyze the current and forthcoming scenario of methods for the specific development of parts to be produced by metal AM including topology optimization as a basic design step and to demonstrate that systematical design approaches can be introduced in order to better exploit potentials offered by AM implementation. The general framework composed by the main tasks is introduced and discussed. Key factors such as advance in different design solutions exploration, product-related and process-related design constraint implementation in the design phase and method effectiveness in product development lead time minimization are presented. Linear and iterative workflows are described, considering features, decision making points, pros and cons, possible variants and research hints. A strong connection between methods and actual means is highlighted and workflow implementation using standard and integrated commercial tools is considered. Such methods are related to several automotive case studies presented in order to demonstrate their applicability and to show actual results and possible further development.
- Published
- 2020
28. CAD-platform-based Process optimization Design Method by Selective Laser Melting Simulation
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Francesco Leali, Fabio Pini, Enrico Dalpadulo, Dalpadulo E., Pini F., and Leali F.
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Computer science ,business.industry ,industrialization ,Process (computing) ,design for additive manufacturing ,CAD ,Solid modeling ,process simulation ,powder bed fusion ,Residual stress ,selective laser melting ,Process optimization ,CAD platform ,Process simulation ,Selective laser melting ,Process engineering ,business ,Energy source ,CAD platforms - Abstract
Additive Manufacturing based on Powder Bed Fusion processes enables the construction of end-use functional metal components, making it feasible to design several level of geometrical complexity. Nevertheless, the printing process leads to material and shape defects, residual stress and induced distortions on final components that mainly are caused by the high thermal gradients associated to the intense and nonuniform power energy sources used to selectively melt metal powders. In this paper, techniques to reduce or prevent these effects are summarized. The more broadly Design for Additive Manufacturing approach based on the use on CAD platforms for product-process design is the backbone upon this research is based on. Specifically, the work presents a design method to predict drawbacks and improve the industrialization subphase. Laser-based Powder Bed Fusion technique is considered and the implementation and validation of the Selective Laser Melting process simulation is performed in order to support the method. Two case studies are presented. The former demonstrates the simulation implementation feasibility through a CAD platform. The latter validates the simulation results compared to experimental data for further method application.
- Published
- 2020
29. Computer-Aided Assessment of Safety Countermeasures for Industrial Human-Robot Collaborative Applications
- Author
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Fabio Pini and Francesco Leali
- Subjects
0209 industrial biotechnology ,Human-robot collaboration ,Exploit ,Computer science ,Replica ,Safey countermeasures ,System safety ,Indutrial robots ,02 engineering and technology ,Computer-aided assessment ,Speed and separation monitoring ,Human–robot interaction ,020901 industrial engineering & automation ,Control theory ,0202 electrical engineering, electronic engineering, information engineering ,Systems engineering ,Robot ,020201 artificial intelligence & image processing ,Collaborative method - Abstract
Human and robot collaboration represents an interesting development direction for traditional industrial robotic solutions. Especially for those cases where the operations are difficult to automate or burdensome for manual execution, the mutual exchange of human sensitivity and robot repeatability represents an effective approach. Nevertheless, industrial robots are poorly involved for collaborative tasks since specific safety countermeasures are required to avoid all the potential hazards. Consequently, the design and assessment of safety solutions represents a fundamental phase to estimate feasibility of industrial collaborative solutions. The presented work proposes a computer-aided approach to identify, assess and optimize the safety systems that enables the collaborative usage of industrial robots. It exploits the capabilities of virtual controller-based offline programming packages to design in advance the safety countermeasures. An initial consistency test validates the response of the selected tool with respect to the safety functionalities. Subsequently, a virtual replica of a potential industrial collaborative solution has been developed. As a result, it has been possible to mimic the behaviour of such a system with respect to Speed and Separation Monitoring collaborative method.
- Published
- 2020
30. Automotive Design Engineering: Material and Processes Selection Problems
- Author
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Luca Di Angelo, Cristina Renzi, and Francesco Leali
- Subjects
0209 industrial biotechnology ,Computer science ,Material selection ,02 engineering and technology ,021001 nanoscience & nanotechnology ,Multiple-criteria decision analysis ,Manufacturing engineering ,Automotive design ,Detail design ,Multicriteria decision making ,020901 industrial engineering & automation ,0210 nano-technology ,Engineering design process ,Selection (genetic algorithm) - Abstract
Multicrieria Decision-making methods (MCDM) are efficiently used as a support to engineering design, even if tested procedures and experience-based approaches are often preferred in SMEs and several industrial contexts.
- Published
- 2020
31. Effective integration of Cobots and additive manufacturing for reconfigurable assembly solutions of biomedical products
- Author
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Enrico Dalpadulo, Francesco Gherardini, Filippo Rossi, Fabio Pini, Andrea Carlesimo, Francesco Blumetti, Francesco Leali, Rossi F., Pini F., Carlesimo A., Dalpadulo E., Blumetti F., Gherardini F., and Leali F.
- Subjects
0209 industrial biotechnology ,Collaborative robot ,Workstation ,Industry 4.0 ,Process (engineering) ,Computer science ,Additive manufacturing ,Fused filament fabrication ,02 engineering and technology ,Industrial and Manufacturing Engineering ,law.invention ,020901 industrial engineering & automation ,law ,Industrial design ,0202 electrical engineering, electronic engineering, information engineering ,Flexibility (engineering) ,business.industry ,Biomedical components ,Design approach ,Automation ,Manufacturing engineering ,Modeling and Simulation ,Biomedical component ,020201 artificial intelligence & image processing ,Engineering design process ,business - Abstract
Collaborative robotics and additive manufacturing are two enabling technologies of the Industry 4.0 manufacturing paradigm. Their synergic integration requires novel and effective design approaches, aiming to the development of new reconfigurable solutions for customised processes and products. This work presents an integrated approach that exploits the capabilities of Cobots to mimic the repetitive and exhausting operator’s movements as well as the competitive advantages offered by additive manufacturing to realize tailored equipment. In particular, the case study shows the development of a customised device for the manipulation of biomedical components by means of a Cobot, which is introduced in a workstation to replace manual operations. Moreover, the flexibility and the effectiveness of a Cobot can be improved thanks to customised devices for gripping and pick-and-place operations based on a specific application. During the development phase, we simulated the assembly process, and tested different options. The final configuration, with conformal circuits and suction cups, can pick, manipulate and assembly the biomedical components, and thanks to a Fused Filament Fabrication technology is additively manufactured. In conclusion, this developed prototypal solution proves the real capabilities offered by integrating Cobots and additive manufacturing for the lean automation of a biomedical workstation.
- Published
- 2020
32. Human-robot coexistence and interaction in open industrial cells
- Author
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Federica Ferraguti, Fabio Pini, Alessandro De Luca, Emanuele Magrini, Andrea Jacopo Ronga, and Francesco Leali
- Subjects
0209 industrial biotechnology ,Computer science ,General Mathematics ,Interface (computing) ,Context (language use) ,02 engineering and technology ,Collaborative robotics ,Depth sensing ,Human-machine interface ,Industrial cell ,Polishing ,Safe human–robot interaction ,Industrial and Manufacturing Engineering ,Human–robot interaction ,020901 industrial engineering & automation ,Human–computer interaction ,0202 electrical engineering, electronic engineering, information engineering ,020208 electrical & electronic engineering ,Computer Science Applications ,Robot control ,Control and Systems Engineering ,Gesture recognition ,Robot ,Behavior-based robotics ,Communications protocol ,Software - Abstract
Recent research results on human–robot interaction and collaborative robotics are leaving behind the traditional paradigm of robots living in a separated space inside safety cages, allowing humans and robot to work together for completing an increasing number of complex industrial tasks. In this context, safety of the human operator is a main concern. In this paper, we present a framework for ensuring human safety in a robotic cell that allows human–robot coexistence and dependable interaction. The framework is based on a layered control architecture that exploits an effective algorithm for online monitoring of relative human–robot distance using depth sensors. This method allows to modify in real time the robot behavior depending on the user position, without limiting the operative robot workspace in a too conservative way. In order to guarantee redundancy and diversity at the safety level, additional certified laser scanners monitor human–robot proximity in the cell and safe communication protocols and logical units are used for the smooth integration with an industrial software for safe low-level robot control. The implemented concept includes a smart human-machine interface to support in-process collaborative activities and for a contactless interaction with gesture recognition of operator commands. Coexistence and interaction are illustrated and tested in an industrial cell, in which a robot moves a tool that measures the quality of a polished metallic part while the operator performs a close evaluation of the same workpiece.
- Published
- 2020
33. Integrated CAD platform approach for Design for Additive Manufacturing of high performance automotive components
- Author
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Francesco Leali, Enrico Dalpadulo, Fabio Pini, Dalpadulo E., Pini F., and Leali F.
- Subjects
0209 industrial biotechnology ,Computer science ,business.industry ,020209 energy ,High performance automotive components ,Topology optimization ,Automotive industry ,High performance automotive component ,CAD ,02 engineering and technology ,Industrial and Manufacturing Engineering ,Manufacturing engineering ,Powder Bed Fusion ,Design for Additive Manufactruing ,020901 industrial engineering & automation ,Workflow ,Industrial design ,Modeling and Simulation ,Component (UML) ,0202 electrical engineering, electronic engineering, information engineering ,CAD based integrated platform ,Process simulation ,Engineering design process ,business - Abstract
Use of Additive Manufacturing provides great potentials to settings focused on high performance products. It allows feasibility of sundry innovative features to completely rethink geometries and shapes and it leads to embrace new design approaches. The enhanced design freedom can be exploited to optimize products, using techniques such as topology optimization. The study of methods for development of optimized components to be produced by AM becomes therefore fundamental. A framework for the methodological approach to operations to be carried out from the concept model to the printed component has been analyzed and it is clear that issues and research efforts relapse both the global level of the workflow and the local level of singular tasks to be performed. Problems related to management of Design for Additive Manufacturing workflow can be solved with holistic approach, through the use of computer aided integrated tools. The aim of this work is to test the effectiveness at local level of such tools with respect to operations for both design and industrialization optimization, working on an automotive case study. In particular, specific tools for topology optimization, product simulation, printing preparation and process simulation are taken as reference and results obtained with an integrated CAD platform are discussed.
- Published
- 2020
34. Design Tools and Methods in Industrial Engineering
- Author
-
Angelo Oreste Andrisano, Francesco Gherardini, Fabio Pini, Alberto Vergnano, Rizzi Caterina, and Francesco Leali
- Subjects
Engineering ,business.industry ,business ,Manufacturing engineering - Published
- 2020
35. A preliminary approach on point cloud reconstruction of bronze statues through oriented photogrammetry: the 'Principe Ellenistico' case
- Author
-
Francesco Leali, Michele Bici, Francesco Gherardini, and Francesca Campana
- Subjects
Systematic approach ,bronze statue ,Bronze statue ,business.industry ,principe ellenistico ,Point cloud ,engineering.material ,Close-Range Photogrammetry, 3D acquisition, Systematic approach, Bronze statue, Principe Ellenistico ,Close-Range Photogrammetry ,Photogrammetry ,close-range photogrammetry ,systematic approach ,3d acquisition ,Principe Ellenistico ,engineering ,Bronze ,business ,3D acquisition ,Remote sensing - Abstract
Close-Range Photogrammetry is a widespread and efficient technique in the 3D acquisition of artefacts, particularly in fields like Cultural Heritage. Despite this wide usage, also due to a convenient quality/cost ratio, it shows some limitations due to light conditions as well as the artefact surface finishing. In this paper, we would like to report the assessment of a photogrammetry approach to 3D capture metal reflective surfaces, such as bronze, which is a widely used material in ancient statues. To this aim, we propose a photogrammetry workflow based on systematic steps capable of overcome some of the main issues of reflective surfaces. To validate this approach, the developed 3D model is compared to a more accurate model of the same artefact, obtained with a 3D scanner. As a case study, we selected the Principe Ellenistico, an ancient bronze statue conserved in the Museo Nazionale Romano (Rome, Italy), of which a photogrammetric model is firstly developed and then compared to the scanned one.
- Published
- 2020
36. The Systematic Design of Industrial Products through Design Archetypes: An Application on Mechanical Transmissions
- Author
-
Alberto Vergnano, Francesco Gherardini, and Francesco Leali
- Subjects
lcsh:T ,systematic design method ,design archetype ,knowledge-based engineering ,CAD-based tool ,mechanical transmissions ,lcsh:Technology ,lcsh:QC1-999 ,lcsh:Chemistry ,lcsh:Biology (General) ,lcsh:QD1-999 ,lcsh:TA1-2040 ,lcsh:Engineering (General). Civil engineering (General) ,lcsh:QH301-705.5 ,lcsh:Physics - Abstract
Engineering design is a knowledge intensive activity for both new and mature technical systems, such as mechanical transmissions. However, design knowledge is often transferred with conservative and unstructured approaches, although knowledge management would be of the utmost importance for modern industries. In this work, we introduce a design tool, called design archetype, for collecting and managing knowledge in systematic design processes. The design archetype addresses input design requirements for different design concepts, therefore, improving awareness of the design process by interactively modifying the design solution due to different input requirements. Finally, the design archetype updates the parameters of a first embodiment computer-aided design model of the concept. A method for the development of design archetypes is presented and applied to two case studies of mechanical transmission subassemblies. The results demonstrate the effectiveness of a systematic design method based on design archetypes stored in the company database.
- Published
- 2020
37. CAD-based risk assessment approach for safe scheduling of HRC operations for parts produced by laser powder bed fusion
- Author
-
Fabio Pini, Enrico Dalpadulo, Francesco Leali, Pini F., Dalpadulo E., and Leali F.
- Subjects
CAD-based methods ,Additive Manufacturing ,Human Robot Collaboration ,Safety index ,Task scheduling ,Computer science ,CAD ,CAD-based method ,Replicate ,computer.software_genre ,Human–robot interaction ,Scheduling (computing) ,Reliability engineering ,Virtual machine ,Robot ,Manufacturing operations ,Risk assessment ,computer - Abstract
The presented paper suggests a design method which seeks to identify the best scheduling of human robot collaborative (HRC) operations with respect to a required safety level. The human behavior along manufacturing scenarios is effectively forecasted through dedicated computer-aided tools. Consequently, this method stresses the usage of virtual environment to replicate both human postures and robot encumbrances over the manufacturing operations. Moreover, it proposes a safety index formulation for HRC systems based on the minimum distance between human and robot (H-R). As results, the approach returns the safety index for every possible combination of H-R operations. Subsequently, a scheduling algorithm suggests the operations sequence depending on the expected value of the safety index, providing an evaluation of the time needed to complete the process. The method is validated on surface control phase involved in post-processing of parts produced by laser powder bed fusion (L-PBF) Additive Manufacturing.
- Published
- 2020
38. Correction to: Intelligent Human Systems Integration 2020
- Author
-
Waldemar Karwowski, Francesco Leali, Tareq Z. Ahram, Redha Taiar, and Alberto Vergnano
- Subjects
Computer science ,Systems engineering ,Human factors integration - Published
- 2020
39. A methodological approach for the design of inclusive assistive devices by integrating co-design and additive manufacturing technologies
- Author
-
Valentina Bettelli, Francesco Gherardini, Maria Teresa Mascia, Andrea Petruccioli, Francesco Leali, Enrico Dalpadulo, Gherardini F., Petruccioli A., Dalpadulo E., Bettelli V., Mascia M.T., and Leali F.
- Subjects
Co-design ,Occupational therapy ,medicine.medical_specialty ,Assistive device ,Active involvement ,Activities of daily living ,Therapeutic effectiveness ,Inclusive method ,Computer science ,Additive Manufacturing ,CAD ,Hand pathologies ,Parametric modelling ,Personalization ,Risk analysis (engineering) ,medicine ,Hand pathologie ,Product (category theory) - Abstract
Additive Manufacturing is a widespread technology that may enhance product customization based on specific users’ needs, as in the case of assistive devices. Many chronic physical progressively disabling diseases, but also ageing, may cause severe limitations in daily life, which can be overcome by highly customized aids. Literature shows that the active involvement of the patient in the development of assistive devices through co-design allows for their greater therapeutic effectiveness and acceptance. Therefore, this paper proposes a methodological approach for the development of inclusive assistive devices to support daily activities in persons with disabling diseases of the upper-limb. The approach integrates co-design, standardized tools, and low- and high-tech prototyping techniques and tools, which lead to significant feedbacks from patients. The patients are encouraged to interact with conceptual prototypes through direct 3D CAD modelling and touch screen devices. Assessment tests highlight the suitability of the method to achieve the expected goals.
- Published
- 2020
40. A design methodology for an innovative racing mini motorcycle frame
- Author
-
Cristina Renzi, Francesco Leali, Paolo DiStefano, and Luca DiAngelo
- Subjects
Topological optimization ,Computational Mathematics ,Engineering drawing ,Design methodology ,Racing motorcycle frame design ,Computer science ,Frame (networking) ,Computational Mechanics ,Design methods ,Computer Graphics and Computer-Aided Design - Published
- 2020
41. A method for yield and cycle time improvements in Al alloy casting with enhanced conductivity steel for die construction
- Author
-
Alberto Vergnano, Emanuele Salvati, Andrea Magistrelli, Edoardo Brambilla, Paolo Veronesi, and Francesco Leali
- Subjects
Gravity die casting ,cost optimisation ,material selection ,steel conductivity ,cycle time ,process yield ,Industrial and Manufacturing Engineering - Abstract
A die for Al alloy casting must be designed to achieve the expected quality levels. Moreover, the casting unit cost must be regarded as the objective function to be minimised. It can be expressed as a function of the quantity of materials and energy to be used, cycle time and equipment investment. This work compares the performance of the die with inserts manufactured using the usual 1.2343 steel with that of the innovative 1.2383. The latter is considered due to its enhanced thermal conductivity, despite being more expensive. Simulation experiments are designed to evaluate different die layouts. The quality design solutions are evaluated against the cost objective function in order to identify the optimal die choice. A case study on gravity die casting (GDC) of an AlSi7Mg0.3 engine head shows faster solidification dynamics when using 1.2383 instead of 1.2343 steel. This reduces the feeder volume, thus increasing the production yield and speeding up the cycle time with a leverage effect. The higher investment cost for the inserts is rapidly returned thanks to the reduction in variable costs. The Return On Investment (ROI) with the improved die in the new solution is short compared with the life of the die.
- Published
- 2022
42. Métodos para la toma de decisiones en el diseño de ingenieria de un punto de vista orientado al diseñador
- Author
-
Francesco Leali and Cristina Renzi
- Subjects
General Business, Management and Accounting - Abstract
El uso de métodos decisionales para la solución de problemas de diseño de ingeniería debe abordarse en un punto de vista "humano". Por lo tanto, lo fundamental es la identificac ón de problemas y necesidades de diseño, que se convierten en un punto de vista orientado al diseñador. Los métodos basados en la decisión se clasifican sistemáticamente en métodos MCDM, Métodos de Diseño Estructurado y Métodos de Estructuración de Problemas. Los resultados están organizados para ofrecer una primera referencia al diseñador en una selección preliminar de métodos basados en la decisión. El documento muestra el uso heterogéneo de los métodos basados en decisiones, que tradicionalmente se espera que resuelvan algunos otros problemas de diseño específicos, que también se han usado en diferentes contextos de diseño. Además, varios problemas de diseño, que surgieron durante el proceso de revisión, se han señalado y discutido en consecuencia. De esta revisión surgieron resultados útiles para la ampliación del estado del arte en los métodos de diseño basado en decisiones en un contexto de diseño de ingeniería.
- Published
- 2017
43. The multiple roles of universities in U-I collaborations: The case of Emilia–Romagna motor vehicle industry
- Author
-
Gianluca Marchi, Francesco Leali, Francesco Gherardini, and Giulia Tagliazucchi
- Subjects
Underpinning ,Information Systems and Management ,Process management ,Strategy and Management ,Industrial relations ,General Engineering ,Innovation process ,Technology transfer Academic engagement Automotive industry Regional innovation system ,Business ,Management Science and Operations Research ,Local industry - Abstract
This paper investigates the development of collaboration modes between university and local industry, within a regional system having a diffused innovation process. As a case study, we analyse into an appreciative framework the roles of a medium-sized university as producer of knowledge, intermediary organisation and regional orchestrator over time, ultimately assuming a leading role in two specific university-industry programmes supporting the motor vehicle industry of Emilia–Romagna (IT). The paper contributes to the University-Industry stream of research by identifying the factors and mechanisms underpinning the evolution of university’s role in its collaboration with local industry, by the time assuming a leading and central role in spreading innovative technology into the regional system. Our findings provide managerial and policy makers contributions, and could be extended to other similar medium-tech industry for supporting diffusion of knowledge and innovation processes.
- Published
- 2021
44. Reciprocal Frames in Temporary Structures: An Aesthetical and Parametric Investigation
- Author
-
Francesco Leali and Francesco Gherardini
- Subjects
Engineering drawing ,Tessellation ,Visual Arts and Performing Arts ,General Mathematics ,Constraint (computer-aided design) ,0211 other engineering and technologies ,Aesthetics ,Architectural pavilions ,Natural form ,Parametric modelling ,Reciprocal Frame ,Shell structure ,020101 civil engineering ,Geometry ,02 engineering and technology ,Grid ,0201 civil engineering ,021105 building & construction ,Architecture ,Frame (artificial intelligence) ,Point (geometry) ,Reciprocal ,Generative grammar ,Parametric statistics ,Mathematics - Abstract
This paper deals with the use of reciprocal frames in temporary gridshell structures, such as architectural pavilions in expositions and installations. These architectural examples can benefit from the use of short, easy to handle, generally joint-free, and repeatable “modules” in order to create particular self-supporting structures. The lightweight and interwoven grid obtained by connecting short elements according to the reciprocity principle is structurally efficient and, at the same time, aesthetically pleasing, mainly due to the resulting tessellation. The paper firstly investigates the connection between efficiency and aesthetics. The last part of the paper investigates some temporary architectural pavilions from both an aesthetical and parametric point of view. In order to deepen our understanding of these structures, they are re-modelled according to a bottom-up approach by means of a constraint-based parametric CAD modeller. In this way, a reciprocal frame can be explored and modified by the parametric arrangement of its generative elements, which, like a natural organism, grows in self-generating forms.
- Published
- 2017
45. Vibration-Assisted Face Grinding of Mould Steel
- Author
-
Thomas Bergs, Francesco Leali, Sebastian Hähnel, Tim Grunwald, and Fabio Pini
- Subjects
Grinding process ,0209 industrial biotechnology ,Materials science ,Mechanical engineering ,02 engineering and technology ,010501 environmental sciences ,01 natural sciences ,Grinding ,Vibration ,020901 industrial engineering & automation ,Machining ,Finishing ,Moulds ,Vibration-assisted ,Face (geometry) ,Robot ,Reduction (mathematics) ,0105 earth and related environmental sciences - Abstract
This work investigates vibration-supported, force-controlled fine machining with elastic bonded mounted points for automated fine processing of mould steel samples. The aim is to compare conventional robot- or machine-tool-based face grinding with a vibration-supported grinding process. The influence of vibration support on the surface topography is investigated primarily to minimize kinematically caused grinding traces. First, the state of the art for the production of tool moulds and vibration-supported fine machining is explained. On this basis, the potentials for the reduction of grinding marks through vibration support for an increase in the degree of automation are derived and the experimental procedure is introduced. Subsequently, robot-based grinding tests with vibration support are carried out and compared with conventional grinding tests. After the tests carried out, the results are evaluated using tactile and optical measuring methods.
- Published
- 2019
46. Assessment of Design for Additive Manufacturing Based on CAD Platforms
- Author
-
Fabio Pini, Francesco Leali, Enrico Dalpadulo, Dalpadulo E., Pini F., and Leali F.
- Subjects
0209 industrial biotechnology ,Computer science ,business.industry ,Process (engineering) ,Topology optimization ,Automotive ,CAD platform ,Design for Additive Manufacturing ,Automotive industry ,CAD ,02 engineering and technology ,021001 nanoscience & nanotechnology ,Manufacturing engineering ,020901 industrial engineering & automation ,Workflow ,Component (UML) ,New product development ,Selective laser melting ,0210 nano-technology ,business - Abstract
The aim of this paper is to analyze some critical issues in the Design for Additive Manufacturing workflow and evaluate the introduction of CAD platforms as backbone tools to shorten product development time and raise its efficiency. It is focused on the design of components to be printed by Powder Bed Fusion metal Additive Manufacturing. Even though the use of additive technologies firmly joins a CAD mathematical model and the actually printed component, the workflow from the concept to the definitive job may result in many sequential steps which have complex and slow relationships. Currently, at the state of art for the production of components specifically designed to be produced by additive manufacturing, there are issues both with the adoption of STL as interchange files and the not reversible sequence of tasks. For example, if a problem occurs in the part re-design during component industrialization, usually one must restart the work from the beginning. Thus, an improvement of the design workflow that could shorten time to product and improve both product performances and process quality and reliability, is necessary. In particular, the use of CAD platforms that integrates CAD and CAE tools has been investigated. An automotive case study, originally made by traditional subtractive technology (CNC milling), has been re-designed with topology optimization in order to be printed by Selective Laser Melting process with benefit of weight reduction. Design and industrialization tasks have been tested with respect to the selected integrated CAD platform, and potential improvements have been evaluated.
- Published
- 2019
47. A CAE-Based Model of Aluminium Alloys Welded T-Joints for TEP Analysis
- Author
-
Francesco Leali, Fabio Pini, and Federico Ruini
- Subjects
0209 industrial biotechnology ,Chassis ,Materials science ,CAE-based model ,Automotive industry ,chemistry.chemical_element ,Mechanical engineering ,02 engineering and technology ,Welding ,law.invention ,020901 industrial engineering & automation ,TEP analysis ,Termo-elasto-plastic model ,Aluminium ,Residual stress ,law ,medicine ,Welding process ,business.industry ,Process (computing) ,Stiffness ,021001 nanoscience & nanotechnology ,Finite element method ,chemistry ,medicine.symptom ,0210 nano-technology ,business - Abstract
Continuous innovation in the field of high-end motor vehicle chassis demands optimization of the weight/stiffness ratio and to achieve high quality standards. The use of light materials, such as aluminum alloys, is therefore increasingly common in the design of the chassis, whose assembly process represents a technological challenge. Welding joining processes, and in particular robot-based welding, are widely used in automotive field despite causing distortions. To predict these deformations, finite element analyzes are performed, in particular thermo-elasto-plastic simulations, which are able to satisfactorily replicate the behavior of residual stresses and strains after cooling. However, such analyzes are computationally expensive making their application difficult to complex structures. This work would investigate an alternative solution to predict distortions that effectively returns the behavior of welded assemblies. A CAE-based model for TEP analysis of welded joints is proposed. As a case study, the T-welded junction between two aluminum alloy plates (T-Joint) was considered. The model is validated by a preliminary experimental campaign.
- Published
- 2019
48. Robust Parameter Analysis of Compliant Part Models for Computer Aided Tolerancing
- Author
-
Andrea Petruccioli, Enrico Bonazzi, Francesco Gherardini, Alberto Vergnano, Francesco Leali, Vergnano A., Gherardini F., Petruccioli A., Bonazzi E., and Leali F.
- Subjects
0209 industrial biotechnology ,Tolerance analysis ,Computer science ,Automotive industry ,Mechanical engineering ,Computer Aided Tolerancing, Design method, 3D tolerances, Compliant parts, Robust analysis ,02 engineering and technology ,Compliant parts ,Fixture ,3D tolerance ,020901 industrial engineering & automation ,Compliant part ,3D tolerances ,0202 electrical engineering, electronic engineering, information engineering ,Robust analysis ,business.industry ,Design of experiments ,Fender ,020207 software engineering ,Computer Aided Tolerancing ,Finite element method ,Clamping ,Design method ,visual_art ,visual_art.visual_art_medium ,Sheet metal ,business - Abstract
Sheet metal parts are widely used in automotive, aerospace, ship and consumer goods industries. The final dimensions of a sheet metal assembly result from the parts deformation, which in turn is affected by many variations in material, thickness and single parts dimensions. The tolerance analysis on sheet metal assemblies improve the knowledge about the process. Advanced simulations enable the optimization of product features, GD&T scheme and assembly process. Moreover, Variational Models of both the product and the assembly system enable to assess the sources of 3D error propagation from the different contributors. However, the simulation results are very affected by the modelling approach of critical components, such as the Fixture Systems. The present paper firstly introduces a strategy to model the Fixture System and the assembly process for compliant parts. Then, a robust analysis of the variations in the model with respect to the modelling factors is performed by a Design of Experiments. A case study on an automotive fender is discussed. The results demonstrate that the modelling strategy of the clamping operation have the main effects, while the modelling of locators scheme, spot joints and FEM meshing are less important.
- Published
- 2019
49. Sensor Matrix Robustness for Monitoring the Interface Pressure Between Car Driver and Seat
- Author
-
Alberto Vergnano, Alberto Muscio, and Francesco Leali
- Subjects
Sensor system ,Computer science ,Sensor matrix ,Car seat ,Sensor matrix, Pressure, Driver monitoring, Car seat, Comfort, Advanced Driver Assistance Systems ,Advanced driver assistance systems ,Pressure sensor ,Comfort ,Automotive engineering ,Driver monitoring ,Robustness (computer science) ,Interface pressure ,Pressure ,Contact area ,Advanced Driver Assistance Systems - Abstract
An effective sensor system for monitoring the pressure distribution on a car seat would enable researches on Advanced Driver Assistance Systems (ADAS) and comfort of occupants. However, the irregularities of the seat shape or those of the occupant clothes challenge the robustness of such a sensor system. Moreover, the position identification of bodies of different percentiles by few pressure sensors is difficult. So, a higher resolution pressure pad has been developed. The number of sensors is significantly increased by means of a matrix scan strategy. Tests on the pressure pad with different occupants proves its robustness in scanning the contact area.
- Published
- 2019
50. Out of Position Driver Monitoring from Seat Pressure in Dynamic Maneuvers
- Author
-
Alberto Vergnano and Francesco Leali
- Subjects
Acceleration ,Noise ,Software deployment ,Computer science ,law ,Airbag ,Out of position ,Control unit ,Out of Position · Driver Monitoring · Intelligent Vehicle · Safety System · Driving Experiment ,Accelerometer ,Pressure sensor ,Automotive engineering ,law.invention - Abstract
An airbag system is designed to reduce the accident outcome on the car occupants. The airbags deployment against manikins is severely tested according to international regulations. The accident scenarios with Out of Position (OP) occupants are critical since they can be hardly expected during design. The airbag deployment in these scenarios can be improved by developing adaptive strategies, provided that the Airbag Control Unit must be aware of the actual occupant position. The present research investigates a sensor system to monitor the occupants in an interactive Human-Car system. The driver position is monitored by pressure sensors, while an accelerometer enables to compensate for acceleration and noise. Real driving experiments in dynamic conditions are reported. The results prove that three OP conditions are effectively identified.
- Published
- 2019
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