Dissertation/Thesis Abstract

Demonstration of a Closed Loop Digitally Enabled Manufacturing Process Using Advanced Metrology Techniques
by Erickson, Michael, M.S., The University of North Carolina at Charlotte, 2018, 94; 10811012
Abstract (Summary)

This thesis details the use of advanced coordinate metrology techniques to digitally enable manufacturing through the demonstration of predictive shimming in the assembly of a power plant generator Frame and Stator Core. A process was developed to create digital models of the as-built generator components, calculate the desired gap dimensions, and pre-manufacture shims to maintain these gaps. The research illustrates a potential to reduce cost, improve product quality, and increase productivity in large scale manufacturing.

The geometric features of the components were measured with a laser tracker and analyzed in metrology software to perform digital assembly. Shim comparisons were made between those that were actually used in the generator assembly and those that were predicted digitally. After performing an experiment and finite element analysis to evaluate a generator Frame, it was found that the component’s shape was largely affected by its support condition and gravitational sag. Mitigation strategies were suggested to force the Frame into its desired shape during measurement.

In total, six generator assemblies were measured and two assembly tests using pre-manufactured shims were conducted. Each test successfully produced in-tolerance alignments and demonstrated the benefits and feasibility of the digitally enabled process. Basic metrics were used to evaluate the quality and repeatability of the project’s measurements and it was found that the activities in the surrounding shop environment affected the measurement quality.

Indexing (document details)
Advisor: Ziegert, John
Commitee: Morse, Edward, Schmitz, Tony
School: The University of North Carolina at Charlotte
Department: Engineering
School Location: United States -- North Carolina
Source: MAI 57/05M(E), Masters Abstracts International
Subjects: Engineering, Mechanical engineering
Keywords: Digital assembly, Industry, Large scale, Metrology
Publication Number: 10811012
ISBN: 9780355915204
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