This paper introduces a systematic design framework that enables the flexible but thor ough development of automated assembly processes based on identified customer- and task-specific needs and their associated functions. The first step of this design procedure involves the identification of the base functions of the assembly task through the decomposition of a generic automated assembly process chain. These functions are integrated with the customer- and task-specific needs, forming a complete model of the requirements of a final process module. From these functions, problem areas are identified for testing by focusing on complex regions of interdependencies found within the process requirements. Process concepts corresponding to each of these problem areas are developed via a three-step procedure. First, solution concepts are generated through the exploration of existing techniques and technologies. Second, these solutions are screened by a qualitative evaluation of each concept's fulfillment of the requirements. Finally, the remaining concepts are systematically tested and evaluated for each's feasibility within its process block. These process concepts are merged into a combined process module incorporating the required elements of all preliminary tests. This process module represents one cohesive concept for the complete automated assembly process. Collectively, this investigation and practical validation of process components in a production-relevant environment determines a feasible automated assembly process concept and satisfies the requirements of Technology Readiness Level 5.
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