Research - Dr Jody Muelaner

I’ve published research related to industrial measurement, mechanical design, aerospace manufacturing, automation and lean. Please use the database below to search my list of papers. You can click the + symbol next to the title to view the full details and the abstract. Click on the title to link to the full paper pdf download.

Publications List

Title	Year	Authors	In	Abstract	Type	Category
Large Scale Metrology in Aerospace Assembly	2008	J.E. Muelaner, P.G. Maropoulos	5th International Conference on Digital Enterprise Technology, 22-24 October, Nantes, France, p. 773-792	The paper presents a review of the principles and state of the art in instrumentation used to make large scale measurements within aerospace assembly. The ability to measure large artefacts accurately is a key enabling technology to improve quality and facilitate automation. Particular emphasis is placed on issues of uncertainty with the importance of acceptance criteria explained and verification standards compared and discussed. The fundamental technologies deployed are explained including laser trackers, indoor GPS and photogrammetry. Commercially available systems are compared in terms of uncertainty, range and deployment related issues.	Conference	Measurement
iGPS: An Initial Assessment Of Technical And Deployment Capability	2008	J E Muelaner, Z Wang, J Jamshidi, P G Maropoulos, A R Mileham	3rd International Conference on Manufacturing Engineering, Kassandra-Chalkidiki, Greece, p. 805-810	The indoor Global Positioning System (iGPS) is an innovative measurement system consisting of a network of Rotary-laser automatic theodolites (R-LATs) which provide a factory wide coordinate measurement system. The primary benefits of the system are that a theoretically unlimited number of sensors are able to simulatiously detect position using signals from a common network of transmitters and that the sensors are able to automatically regain connection to the network following a disruption of the line of sight. The basic functionality of this system is described together with a brief overview of work to verify its performance.	Conference	Measurement
Large Volume Metrology Instrument Selection And Measurability Analysis	2009	J E Muelaner, B Cai, P G Maropoulos	6th International Conference on Digital Enterprise Technology, Hong Kong, p. 1027-1041	Metrology processes used in the manufacture of large products include tool setting, product verification and flexible metrology enabled automation. The range of applications and instruments available makes the selection of the appropriate instrument for a given task highly complex. Since metrology is a key manufacturing process it should be considered in the early stages of design. This paper provides an overview of the important selection criteria for typical measurement processes and presents some novel selection strategies. Metrics which can be used to assess measurability are also discussed. A prototype instrument selection and measurability analysis application is presented with discussion of how this can be used as the basis for development of a more sophisticated measurement planning tool.	Conference	Measurement
Study of the Uncertainty of Angle Measurement for a Rotary Laser Automatic Theodolite (R-LAT)	2009	J E Muelaner, Z Wang, J Jamshidi, P G Maropoulos, A R Mileham, E B Hughes, and A B Forbes	IMechE, Part B: J. Engineering Manufacture, 223(B3): p. 217-229	This paper shows how the angular uncertainties can be determined for a rotary-laser automatic theodolite of the type used in (indoor-GPS) iGPS networks. Initially, the fundamental physics of the rotating head device is used to propagate uncertainties using Monte Carlo simulation. This theoretical element of the study shows how the angular uncertainty is affected by internal parameters, the actual values of which are estimated. Experiments are then carried out to determine the actual uncertainty in the azimuth angle. Results are presented that show that uncertainty decreases with sampling duration. Other significant findings are that uncertainty is relatively constant throughout the working volume and that the uncertainty value is not dependent on the size of the reference angle.	Journal	Measurement
Large Volume Metrology Instrument Selection and Measurability Analysis	2010	J E Muelaner, B Cai, P G Maropoulos	IMechE, Part B: J. Engineering Manufacture, 224(6): p. 853-868	A wide range of metrology processes are involved in the manufacture of large products. In addition to the traditional tool setting and product verification operations increasingly flexible metrology enabled automation is also being used. Faced with many possible measurement problems and a very large number of metrology instruments, employing diverse technologies, the selection of the appropriate instrument for a given task can be highly complex. Also, since metrology has become a key manufacturing process it should be considered in the early stages of design, and there is currently very little research to support this. This paper provides an overview of the important selection criteria for typical measurement processes and presents some novel selection strategies. Metrics which can be used to assess measurability are also discussed. A prototype instrument selection and measurability analysis application is also presented with discussion of how this can be used as the basis for development of a more sophisticated measurement planning tool.	Journal	Measurement
Estimation of Uncertainty in Three Dimensional Coordinate Measurement by Comparison with Calibrated Points	2010	J E Muelaner, Z Wang, O Martin, J Jamshidi, P G Maropoulos	Measurement Science and Technology, 21(2)	This paper details a method of estimating the uncertainty of dimensional measurement for a three dimensional coordinate measurement machine. An experimental procedure was developed to compare three dimensional coordinate measurements with calibrated reference points. The reference standard used to calibrate these reference points was a fringe counting interferometer with a multilateration like technique employed to establish three dimensional coordinates. This is an extension of the established technique of comparing measured lengths with calibrated lengths. Specifically a distributed coordinate measurement device was tested which consisted of a network of Rotary-Laser Automatic Theodolites (R-LATs), this system is known commercially as indoor GPS (iGPS). The method was found to be practical and was used to estimate that the uncertainty of measurement for the basic iGPS system is approximately 1 mm at a 95% confidence level.	Journal	Measurement
Design for Measurement Assisted Determinate Assembly (MADA) of Large Composite Structures	2010	J E Muelaner, P G Maropoulos	Journal of the Coordinate Metrology Systems Conference, 5(2): p. 18-25	This paper describes how Measurement Assisted Determinate Assembly (MADA) can facilitate the lean production of aerospace structures, provided that the structure is designed for MADA. A novel wingbox design and production process is used to illustrate this. The aerospace industry has not benefited from the significant reductions in production cost and cycle time that can result from greater assembly efficiency, part-to-part interchangeability and the use of flexible automation. This is largely due to the very high accuracies required across large scale assemblies. The use of metrology can reduce process steps, reduce the reliance on costly hard tooling, reduce the requirement for manually intensive and time consuming re-working at late stages of assembly, and allow low cost flexible automation to place tools to the required accuracies. The generic MADA process is presented together with guidelines for the design of structures to enable MADA.	Journal	Part-to-Part Assembly
Concepts for and Analysis of a High accuracy and High Capacity (HAHC) Aerospace Robot	2011	Muelaner, J.E., Z. Wang, and P.G. Maropoulos	IMechE, Part B: J. Engineering Manufacture, 255(8), p. 1393-1399	Case study work carried out within the aerospace sector has highlighted the requirement for highly accurate and high capacity robots in aerospace assembly; literature supports this observation. This paper presents the generic capabilities of such a system. These include the ability to rapidly locate itself within a large measurement volume using supplementary laser metrology systems, to carry out detailed inspection beyond the line of sight, and to accurately locate parts, drill holes and fettle interfaces. Concepts are presented for a standardized robot which would provide a flexible automation system able to carry out a full range of operations required in the assembly of large aerospace structures. Two possible solutions are detailed, one based on error mapping and one based on the physical isolation of encoders from structural loading using an exoskeleton approach.	Journal	Automation
Early design verification of complex assembly variability using a hybrid model based and physical testing methodology	2011	Maropoulos, P.G., P. Vichare, O. Martin, J.E. Muelaner, M. Summers, and A. Kayani		Design verification in the digital domain, using model-based principles, is a key research objective to address the industrial requirement for reduced physical testing and prototyping. For complex assemblies, the verification of the design intent and the associated production methods is currently fragmented, prolonged and sub-optimal, as it is based on the sequential consideration of various aspects in the digital and physical domains using a range of systems. This paper describes a novel hybrid design verification methodology that integrates model-based verification analysis with the measurement data and plans derived from the physical testing of prototype assemblies, in order to facilitate the early verification of complex designs from the perspective of satisfying key assembly criteria.	Journal	Quality Assurance
Verification of the Indoor GPS System, by Comparison with Calibrated Coordinates and by Angular Reference	2012	J E Muelaner, Z Wang, J Jamshidi, P G Maropoulos, A R Mileham, E B Hughes, and A B Forbes	The Journal of Intelligent Manufacturing, 23(6), p. 2323-2331	This paper details work carried out to verify the dimensional measurement performance of the Indoor GPS (iGPS) system; a network of Rotary-Laser Automatic Theodolites (R-LATs). Initially tests were carried out to determine the angular uncertainties on an individual R-LAT transmitter- receiver pair. A method is presented of determining the uncertainty of dimensional measurement for a three dimensional coordinate measurement machine. An experimental procedure was developed to compare three dimensional coordinate measurements with calibrated reference points. The reference standard used to calibrate these reference points was a fringe counting interferometer with the multilateration technique employed to establish three dimensional coordinates. This is an extension of the established technique of comparing measured lengths with calibrated lengths. The method was found to be practical and able to establish that the expanded uncertainty of the basic iGPS system was approximately 1 mm at a 95% confidence level. Further tests carried out on a highly optimized version of the iGPS system have shown that the coordinate uncertainty can be reduced to 0.25 mm at a 95% confidence level.	Journal	Measurement
A New Paradigm in Large Scale Assembly Research Priorities in Measurement Assisted Assembly	2014	P G Maropoulos, J E Muelaner, M D Summers, O C Martin	The International Journal of Advanced Manufacturing Technology, 70(1-4): p. 621-633	This paper presents for the first time the concept of Measurement Assisted Assembly (MAA) and outlines the research priorities of the realisation of this concept in industry. MAA denotes a paradigm shift in assembly for high value and complex products and encompasses the development and use of novel metrology processes for the holistic integration and capability enhancement of key assembly and ancillary processes. A complete framework for MAA is detailed showing how this can facilitate a step change in assembly process capability and efficiency for large and complex products, such as airframes, where traditional assembly processes exhibit the requirement for rectification and rework, use inflexible tooling and are largely manual, resulting in cost and cycle time pressures. The concept of MAA encompasses a range of innovative measurement-assisted processes which enable rapid part-to-part assembly, increased use of flexible automation, traceable quality assurance and control, reduced structure weight and improved levels of precision across the dimensional scales. A full scale industrial trial of MAA technologies has been carried out on an experimental aircraft wing demonstrating the viability of the approach while studies within 140 smaller companies have highlighted the need for better adoption of existing process capability and quality control standards. The identified research priorities for MAA include the development of both frameless and tooling embedded automated metrology networks. Other research priorities relate to the development of integrated dimensional variation management, thermal compensation algorithms as well as measurement planning and inspection algorithms linking design to measurement and process planning.	Journal	Part-to-Part Assembly
Verification Of The Indoor Gps System By Comparison With Points Calibrated Using A Network Of Laser Tracker Measurements	2009	J E Muelaner, Z Wang, J Jamshidi, P G Maropoulos	6th International Conference on Digital Enterprise Technology, Hong Kong	This paper details a method of determining the uncertainty of dimensional measurement for a three dimensional coordinate measurement machine. An experimental procedure was developed to compare three dimensional coordinate measurements with calibrated reference points. The reference standard used to calibrate these reference points was a fringe counting interferometer with the multilateration technique employed to establish three dimensional coordinates. This is an extension of the established technique of comparing measured lengths with calibrated lengths. Specifically a distributed coordinate measurement device was tested which consisted of a network of Rotary-Laser Automatic Theodolites (R-LATs), this system is known commercially as indoor GPS (iGPS). The method was found to be practical and able to establish that the expanded uncertainty of the basic iGPS system was approximately 1 mm at a 95% confidence level.	Conference	Measurement
Concepts for and Analysis of a High accuracy and High Capacity (HAHC) Aerospace Robot	2010	J E Muelaner, Z Wang, P G Maropoulos	The 21st International Computer-Aided Production Engineering Conference, 13-14 April, Edinburgh	Case study work carried out within the aerospace sector has highlighted the requirement for highly accurate and high capacity robots in aerospace assembly, literature supports this observation. This paper presents the generic capabilities of such a system. These include the ability to rapidly locate its-self within a large measurement volume using supplementary laser metrology systems, to carry out detailed inspection beyond the line of sight, and to accurately locate parts, drill holes and fettle interfaces. The concept presented is for a standardised robot which will provide a flexible automation system able to carry out a full range of operations required in the assembly of large aerospace structures.	Conference	Automation
The Metrology Enhanced Tooling for Aerospace (META) Framework	2010	O C Martin, J E Muelaner, P G Maropoulos		Aerospace manufacturers typically use monolithic steel fixtures to control the form of assemblies, this tooling is very expensive, has long lead times and has little ability to accommodate product variation and design changes. Since the tool setting and recertification process is manual and time consuming, monolithic structures are required in order to maintain the tooling tolerances for multiple years without recertification. This paper introduces the Metrology Enhanced Tooling for Aerospace (META) Framework which interfaces multiple metrology technologies with the tooling, components, workers and automation. This will allow rapid or even real-time fixture re-certification with improved product verification leading to a reduced risk of product non-conformance and increased fixture utilization while facilitating flexible fixtures.	Conference	Quality Assurance
Design for Measurement Assisted Determinate Assembly (MADA) of Large Composite Structures	2010	J E Muelaner, P G Maropoulos	Coordinate Metrology Systems Conference, Reno, Nevada	This paper describes how Measurement Assisted Determinate Assembly (MADA) can facilitate the lean production of aerospace structures, provided that the structure is designed for MADA. A novel wingbox design and production process is used to illustrate this. The aerospace industry has not benefited from the significant reductions in production cost and cycle time that can result from greater assembly efficiency, part-to-part interchangeability and the use of flexible automation. This is largely due to the very high accuracies required across large scale assemblies. The use of metrology can reduce process steps, reduce the reliance on costly hard tooling, reduce the requirement for manually intensive and time consuming re-working at late stages of assembly, and allow low cost flexible automation to place tools to the required accuracies. The generic MADA process is presented together with guidelines for the design of structures to enable MADA.	Conference	Part-to-Part Assembly
Measurability Characteristics Mapping for Large Volume Metrology Instruments Selection	2010	Cai, B., W. Dai, J.E. Muelaner, and P.G. Maropoulos	7th International Conference on Manufacturing Research, Warwick, UK, p. 438-442	Measurement and verification of products and processes during the early design is attracting increasing interest from high value manufacturing industries. Measurement planning is deemed as an effective means to facilitate the integration of the metrology activity into a wider range of production processes. However, the literature reveals that there are very few research efforts in this field, especially regarding large volume metrology. This paper presents a novel approach to accomplish instruments selection, the first stage of measurement planning process, by mapping measurability characteristics between specific measurement assignments and instruments.	Conference	Measurement
Metrology Enhanced Tooling for Aerospace (META): Strategies for Improved Accuracy of Jig Built Structures	2011	J E Muelaner, O C Martin, P G Maropoulos	SAE Aerotech 2011, Toulous, France	The accuracy of many aerospace structures is limited by the accuracy of assembly tooling which is in turn limited by the accuracy of the measurements used to set the tooling. Further loss of accuracy results from different rates of thermal expansion for the components and tooling. This paper describes improved tooling designs and setting processes which have the potential to significantly improve the accuracy of aerospace structures. The most advanced solution described is environmentally isolated interferometer networks embedded within tooling combined with active compensation of component pick-ups. This would eliminate environmental effects on measurements while also allowing compensation for thermal expansion. A more immediately realizable solution is the adjustment of component pick-ups using micrometer jacking screws allowing multilateration to be employed during the final stages of the setting process to generate the required offsets.	Conference	Measurement
Measurement Assisted Assembly and the Roadmap to Part-To-Part Assembly	2011	J.E. Muelaner, A. Kayani, O. Martin, and P.G. Maropoulos	7th International Conference on Digital Enterprise Technology, 2011. Athens, Greece. p. 11-19	Cycle times and production costs remain high in aerospace assembly processes largely due to extensive reworking within the assembly jig. Other industries replaced these craft based processes with part-to-part assembly facilitated by interchangeable parts. Due to very demanding interface tolerances and large flexible components it has not been possible to achieve the required interchangeability tolerances for most aerospace structures. Measurement assisted assembly processes can however deliver many of the advantages of part-to-part assembly without requiring interchangeable parts. This paper reviews assembly concepts such as interface management, oneway assembly, interchangeability, part-to-part assembly, jigless assembly and determinate assembly. The relationship between these processes is then detailed and they are organized into a roadmap leading to part-to-part assembly.	Conference	Part-to-Part Assembly
Integrated Dimensional Variation Management in the Digital Factory	2011	J E Muelaner, P G Maropoulos	7th International Conference on Digital Enterprise Technology, 2011. Athens, Greece. p. 39-46		Conference	Measurement
Metrology enhanced tooling for aerospace (META): A live fixturing Wing Box assembly case study	2011	O C Martin, J E Muelaner, Z Wang, A Kayani, D Tomlinson, P G Maropoulos, P Helgasson	7th International Conference on Digital Enterprise Technology, 2011. Athens, Greece. p. 83-92	Aerospace manufacturers typically use monolithic steel fixtures to control the form of assemblies; this tooling is very expensive to manufacture, has long lead times and has little ability to accommodate product variation and design changes. Traditionally, the tool setting and recertification process is manual and time consuming, monolithic structures are required in order to maintain the tooling tolerances for multiple years without recertification. As part of a growing requirement to speed up tool-setting procedures this report explores a coupon study of live fixturing; that is, automated: fixture setting, correction and measurement. The study aims to use a measurement instrument to control the position of an actuated tooling flag, the flag will automatically move until the Key Characteristic (KC) of the part/assembly is within tolerance of its nominal position. This paper updates developments with the Metrology Enhanced Tooling for Aerospace (META) Framework which interfaces multiple metrology technologies with the tooling, components, workers and automation. This will allow rapid or even real-time fixture re-certification with improved product verification leading to a reduced risk of product non-conformance and increased fixture utilization while facilitating flexible fixtures.	Conference	Quality Assurance
Achieving Low Cost and High Quality Aero Structure Assembly through Integrated Digital Metrology Systems	2013	J E Muelaner, O C Martin, P G Maropoulos			Conference	Part-to-Part Assembly
Rapid Machine Tool Verification	2014	J E Muelaner, B R Yang, C Davy, M R Verma, P G Maropoulos	8th International Conference on Digital Enterprise Technology, Stuttgart, Germany, Procedia CIRP. 25 p. 431-438		Conference	Machine Tool Measurement
Large Volume Metrology Technologies for the Light Controlled Factory	2014	J E Muelaner, P G Maropoulos	8th International Conference on Digital Enterprise Technology, Stuttgart, Germany, Procedia CIRP. 25 p. 169-176	In the Light Controlled Factory part-to-part assembly and reduced weight will be enabled through the use of predictive fitting processes; low cost high accuracy reconfigurable tooling will be made possible by active compensation; improved control will allow accurate robotic machining; and quality will be improved through the use of traceable uncertainty based quality control throughout the production system. A number of challenges must be overcome before this vision will be realized; 1) controlling industrial robots for accurate machining; 2) compensation of measurements for thermal expansion; 3) Compensation of measurements for refractive index changes; 4) development of Embedded Metrology Tooling for in-tooling measurement and active tooling compensation; and 5) development of Software for the Planning and Control of Integrated Metrology Networks based on Quality Control with Uncertainty Evaluation and control systems for predictive processes. This paper describes how these challenges are being addressed, in particular the central challenge of developing large volume measurement process models within an integrated dimensional variation management (IDVM) system.	Conference	Measurement
Uncertainty of the Measurement of Radial Runout, Axial Runout and Coning using an Industrial Axi-Symmetric Measurement Machine	2015	J E Muelaner, A J Francis, P G Maropoulos	38th MATADOR Conference, Taiwan, 28 March		Conference	Measurement
A hybrid Measurement Systems Analysis and Uncertainty of Measurement Approach for Industrial Measurement in the Light Controlled Factory	2015	J E Muelaner, A J Francis, M Chappell, P G Maropoulos	Second International Conference on Sustainable Design and Manufacturing, Seville, Spain, 12-14 April	The uncertainty of measurements must be quantified and considered in order to prove conformance with specifications and make other meaningful comparisons based on measurements. While there is a consistent methodology for the evaluation and expression of uncertainty within the metrology community industry frequently uses the alternative Measurement Systems Analysis methodology. This paper sets out to clarify the differences between uncertainty evaluation and MSA and presents a novel hybrid methodology for industrial measurement which enables a correct evaluation of measurement uncertainty while utilising the practical tools of MSA. In particular the use of Gage R&R ANOVA and Attribute Gage studies within a wider uncertainty evaluation framework is described. This enables in-line measurement data to be used to establish repeatability and reproducibility, without time consuming repeatability studies being carried out, while maintaining a complete consideration of all sources of uncertainty and therefore enabling conformance to be proven with a stated level of confidence. Such a rigorous approach to product verification will become increasingly important in the era of the Light Controlled Factory with metrology acting as the driving force to achieve the right first time and highly automated manufacture of high value large scale products such as aircraft, spacecraft and renewable power generation structures.	Conference	Measurement
Kinematic Analysis and Optimization of Bicycle Suspension	2015	J E Muelaner, T Knight, J Darling	Second International Conference on Sustainable Design and Manufacturing, Seville, Spain, 12-14 April	Bicycle suspension is increasingly used to improve performance and facilitate the use of smaller wheels for folding bicycles, unwanted activation due to pedalling and braking forces can however result in energy losses. This paper presents a kinematic analysis leading to a Suspension Activation Ratio (SAR) which is the ratio of the suspension activation force to the pedalling force and its experimental verification. The SAR may be used as a performance metric to compare suspension designs and an objective function for suspension design optimization where the SAR is minimized for all possible gear ratios. Suspension geometry thus optimized shows agreement with optimal pivot positions found by empirical studies. Previous work has involved dynamic simulation and experimentation to estimate energy losses; however it is difficult to apply this analysis to rapidly evaluate different suspension designs for performance evaluation or design optimization. The kinematic design approach presented here provides the first step in suspension design which should precede dynamic design to optimize spring and damping rates.	Conference	Design
Uncertainty Evaluation Method for Axi-Symmetric Measurement Machines	2016	J E Muelaner, P S Keogh	Int J of Metrology & Quality Eng., 7(2)		Journal	Measurement
Uncertainty of Measurement for Large Product Verification: Evaluation of a Large Aero Gas Turbine Engine	2016	J E Muelaner, Z Wang, P S Keogh, J Brownell, D Fisher	Meas. Sci. Technol, 27(11)	Understanding the uncertainty of dimensional measurements for large products such as aircraft, spacecraft and wind turbines is fundamental to improving efficiency in these products. Much work has been done to ascertain the uncertainty associated with the main types of instruments used, based on laser tracking and photogrammetry, and the propagation of this uncertainty through networked measurements. Unfortunately this is not sufficient to understand the combined uncertainty of industrial measurements, which include secondary tooling and datum structures used to locate the coordinate frame. This paper presents for the first time a complete evaluation of the uncertainty of large scale industrial measurement processes. Generic analysis and design rules are proven through uncertainty evaluation and optimization for the measurement of a large aero gas turbine engine. This shows how the instrument uncertainty can be considered to be negligible. Before optimization the dominant source of uncertainty was the tooling design, after optimization the dominant source was thermal expansion of the engine; meaning that no further improvement can be made without measurement in a temperature controlled environment. These results will have a significant impact on the ability of aircraft and wind turbines to improve efficiency and therefore reduce carbon emissions, as well as the improved reliability of these products.	Journal	Measurement
Comparative Performance between Two Photogrammetric Systems and a Reference Laser Tracker Network for Large?Volume Industrial Measurement	2016	O C Martin, S Robson, A Kayani, J E Muelaner, V Dhokia, P G Maropoulos	The Photogrammetric Record, 31(155): p. 348-360		Journal	Measurement
Measurement Assisted Fettling of Rib Feet to Maintain Cover Interface on the ALCAS Wing Box Demonstrator	2011	J E Muelaner, A Kayani P Maropoulos	SAE Aerotech 2011, Toulous, France	A novel measurement assisted assembly process has been used to maintain the interface between the wing box ribs and the upper cover on a demonstration composite wing box build. Measurements of the cover profile were used to generate machining paths for the fettling of rib feet. The machining of the rib feet was then carried out using a standard 6-axis industrial robot mounted on a gantry over the wing box. Feedback for closed loop control of the robot was provided by a photogrammetry system. Measurements of an initial roughing cut were used to apply corrections to the finishing cut in a process analogous to the iterative process of manual machining and measurement.	Conference	Automation
Improving Error Models of Machine Tools with Metrology Data	2016	J M Flynn, J M Muelaner, V Dhokia, S T Newman		As the manufacturing community embraces the use of a variety of metrology solutions, the availability and quantity of measurement data is increasing. The tendency towards connectedness between manufacturing resources may also provide a mechanism for communication and exploitation of metrology data like never before. This research aims to provide an insight into the opportunities that are associated with accessible, abundant and communicable manufacturing metrology data. Issues are raised and critically discussed in relation to one particular aspect of manufacturing metrology, namely, machine tool accuracy verification and calibration. Specifically, a methodology for relating CMM part measurements to individual machine tool geometric error sources is described. A novel Monte Carlo simulation-based method is used to estimate previously unmeasured error values without the use of further testing. Using this method, the advantage of using previously captured verification and calibration data to identify likely causes of part defects is shown. It is envisaged that the proposed method can be used to instruct targeted machine tool verification and calibration routines to reduce the number of tests required to monitor a machine tool's health. By using targeted tests, the need to measure all machine error sources is reduced, which in turn can improve productivity by reducing machine tool downtime.	Conference	Machine Tool Measurement
Thermal compensation for large volume metrology and structures	2017	B Yang, D Ross-Pinnock, J E Muelaner and G Mullineux	International Journal of Metrology and Quality Engineering, 8(21)		Journal	Measurement
Absolute Multilateration between Spheres	2017	J E Muelaner, W Wadsworth, M Azini, G Mullineux, B Hughes, and A Reichold	Meas. Sci. Technol, 28(4)		Journal	Measurement
Integrated calibration of a 3D attitude sensor in large-scale metrology	2017	Yang Gao, Jiarui Lin,Linghui Yang, Jody Muelaner, Jigui Zhu, Patrick Keogh	Meas. Sci. Technol, 28(7)		Journal	Measurement
Uncertainties in Dimensional Measurements due to Thermal Expansion	2017	J E Muelaner, D Ross-Pinnock, G Mullineux, and P S Keogh	Laser Metrology and Machine Performance XII. 2017. Renishaw Innovation Centre, UK	Thermal expansion is a source of uncertainty in dimensional measurements, which is often significant and in some cases dominant. Methods of evaluating and reducing this uncertainty are therefore of fundamental importance to product quality, safety and efficiency in many areas. Existing methods depend on the implicit assumption that thermal expansion is relatively uniform throughout the part and can, therefore, be corrected by scaling the measurement result. The uncertainty of this scale correction is then included in the uncertainty of the dimensional measurement. It is shown here that this assumption is not always valid due to thermal gradients resulting in significant shape changes. In some cases these are the dominant source of dimensional uncertainty. Methods are described to first determine whether shape change is significant. Where shape changes are negligible but thermal expansion remains significant then the established methods may be used. This paper describes the application of the Guide to the expression of Uncertainty in Measurement (GUM) uncertainty framework which provides an approximate solution for thermal expansion due to non-linearity and a non-Gaussian output function. The uncertainty associated with this approximation is rigorously evaluated by comparison with Monte Carlo Simulation over a wide range of parameter values. It is often necessary to estimate the expected uncertainty for a measurement which will be made in the future. It is shown that the current method for this is inadequate and an improved method is given.	Conference	Measurement
A Unified Approach to Uncertainty for Quality Improvement	2017		Laser Metrology and Machine Performance XII. 2017. Renishaw Innovation Centre, UK	To improve quality, process outputs must be measured. A measurement with no statement of its uncertainty gives no meaningful information. The Guide to the expression of Uncertainty in Measurement (GUM) aims to be a universal framework for uncertainty. However, to date, industry lacks such a common approach. A calibration certificate may state an Uncertainty or a Maximum Permissible Error. A gauge study gives the repeatability and reproducibility. Machines have an accuracy. Processes control aims to remove special cause variation and to monitor common cause variation. There are different names for comparable metrics and different methods to evaluate them. This leads to confusion. Small companies do not necessarily have experts able to implement all methods. This paper considers why multiple methods are currently used. It then gives a common language and approach for the use of uncertainty in all areas of manufacturing quality.	Conference	Quality Assurance
A Unified Uncertainty based Approach for Optimal Quality Decisions	2017	J E Muelaner	European Network for Business and Industrial Statistics 2017. Naples, Italy	To improve quality, process outputs must be measured. A measurement with no statement of its uncertainty gives no meaningful information. The Guide to the expression of Uncertainty in Measurement (GUM) aims to be a universal framework for uncertainty. However, to date, industry lacks such a common approach. A calibration certificate may state an Uncertainty or a Maximum Permissible Error. A gauge study gives the repeatability and reproducibility. Machines have an accuracy. Processes control aims to remove special cause variation and to monitor common cause variation. There are different names for comparable metrics and different methods to evaluate them. This leads to confusion. Small companies do not necessarily have experts able to implement all methods. This paper considers why multiple methods are currently used. It then gives a common language and approach for the use of uncertainty in all areas of manufacturing quality.	Conference	Quality Assurance
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Large Scale Metrology in Aerospace Assembly 2008 J.E. Muelaner, P.G. Maropoulos 5th International Conference on Digital Enterprise Technology, 22-24 October, Nantes, France, p. 773-792 The paper presents a review of the principles and state of the art in instrumentation used to make large scale measurements within aerospace assembly. The ability to measure large artefacts accurately is a key enabling technology to improve quality and facilitate automation. Particular emphasis is placed on issues of uncertainty with the importance of acceptance criteria explained and verification standards compared and discussed. The fundamental technologies deployed are explained including laser trackers, indoor GPS and photogrammetry. Commercially available systems are compared in terms of uncertainty, range and deployment related issues. Conference Measurement

iGPS: An Initial Assessment Of Technical And Deployment Capability 2008 J E Muelaner, Z Wang, J Jamshidi, P G Maropoulos, A R Mileham 3rd International Conference on Manufacturing Engineering, Kassandra-Chalkidiki, Greece, p. 805-810 The indoor Global Positioning System (iGPS) is an innovative measurement system consisting of a network of Rotary-laser automatic theodolites (R-LATs) which provide a factory wide coordinate measurement system. The primary benefits of the system are that a theoretically unlimited number of sensors are able to simulatiously detect position using signals from a common network of transmitters and that the sensors are able to automatically regain connection to the network following a disruption of the line of sight. The basic functionality of this system is described together with a brief overview of work to verify its performance. Conference Measurement

Large Volume Metrology Instrument Selection And Measurability Analysis 2009 J E Muelaner, B Cai, P G Maropoulos 6th International Conference on Digital Enterprise Technology, Hong Kong, p. 1027-1041 Metrology processes used in the manufacture of large products include tool setting, product verification and flexible metrology enabled automation. The range of applications and instruments available makes the selection of the appropriate instrument for a given task highly complex. Since metrology is a key manufacturing process it should be considered in the early stages of design. This paper provides an overview of the important selection criteria for typical measurement processes and presents some novel selection strategies. Metrics which can be used to assess measurability are also discussed. A prototype instrument selection and measurability analysis application is presented with discussion of how this can be used as the basis for development of a more sophisticated measurement planning tool. Conference Measurement

Study of the Uncertainty of Angle Measurement for a Rotary Laser Automatic Theodolite (R-LAT) 2009 J E Muelaner, Z Wang, J Jamshidi, P G Maropoulos, A R Mileham, E B Hughes, and A B Forbes IMechE, Part B: J. Engineering Manufacture, 223(B3): p. 217-229 This paper shows how the angular uncertainties can be determined for a rotary-laser automatic theodolite of the type used in (indoor-GPS) iGPS networks. Initially, the fundamental physics of the rotating head device is used to propagate uncertainties using Monte Carlo simulation. This theoretical element of the study shows how the angular uncertainty is affected by internal parameters, the actual values of which are estimated. Experiments are then carried out to determine the actual uncertainty in the azimuth angle. Results are presented that show that uncertainty decreases with sampling duration. Other significant findings are that uncertainty is relatively constant throughout the working volume and that the uncertainty value is not dependent on the size of the reference angle. Journal Measurement

Large Volume Metrology Instrument Selection and Measurability Analysis 2010 J E Muelaner, B Cai, P G Maropoulos IMechE, Part B: J. Engineering Manufacture, 224(6): p. 853-868 A wide range of metrology processes are involved in the manufacture of large products. In addition to the traditional tool setting and product verification operations increasingly flexible metrology enabled automation is also being used. Faced with many possible measurement problems and a very large number of metrology instruments, employing diverse technologies, the selection of the appropriate instrument for a given task can be highly complex. Also, since metrology has become a key manufacturing process it should be considered in the early stages of design, and there is currently very little research to support this. This paper provides an overview of the important selection criteria for typical measurement processes and presents some novel selection strategies. Metrics which can be used to assess measurability are also discussed. A prototype instrument selection and measurability analysis application is also presented with discussion of how this can be used as the basis for development of a more sophisticated measurement planning tool. Journal Measurement

Estimation of Uncertainty in Three Dimensional Coordinate Measurement by Comparison with Calibrated Points 2010 J E Muelaner, Z Wang, O Martin, J Jamshidi, P G Maropoulos Measurement Science and Technology, 21(2) This paper details a method of estimating the uncertainty of dimensional measurement for a three dimensional coordinate measurement machine. An experimental procedure was developed to compare three dimensional coordinate measurements with calibrated reference points. The reference standard used to calibrate these reference points was a fringe counting interferometer with a multilateration like technique employed to establish three dimensional coordinates. This is an extension of the established technique of comparing measured lengths with calibrated lengths. Specifically a distributed coordinate measurement device was tested which consisted of a network of Rotary-Laser Automatic Theodolites (R-LATs), this system is known commercially as indoor GPS (iGPS). The method was found to be practical and was used to estimate that the uncertainty of measurement for the basic iGPS system is approximately 1 mm at a 95% confidence level. Journal Measurement

Design for Measurement Assisted Determinate Assembly (MADA) of Large Composite Structures 2010 J E Muelaner, P G Maropoulos Journal of the Coordinate Metrology Systems Conference, 5(2): p. 18-25 This paper describes how Measurement Assisted Determinate Assembly (MADA) can facilitate the lean production of aerospace structures, provided that the structure is designed for MADA. A novel wingbox design and production process is used to illustrate this. The aerospace industry has not benefited from the significant reductions in production cost and cycle time that can result from greater assembly efficiency, part-to-part interchangeability and the use of flexible automation. This is largely due to the very high accuracies required across large scale assemblies. The use of metrology can reduce process steps, reduce the reliance on costly hard tooling, reduce the requirement for manually intensive and time consuming re-working at late stages of assembly, and allow low cost flexible automation to place tools to the required accuracies. The generic MADA process is presented together with guidelines for the design of structures to enable MADA. Journal Part-to-Part Assembly

Concepts for and Analysis of a High accuracy and High Capacity (HAHC) Aerospace Robot 2011 Muelaner, J.E., Z. Wang, and P.G. Maropoulos IMechE, Part B: J. Engineering Manufacture, 255(8), p. 1393-1399 Case study work carried out within the aerospace sector has highlighted the requirement for highly accurate and high capacity robots in aerospace assembly; literature supports this observation. This paper presents the generic capabilities of such a system. These include the ability to rapidly locate itself within a large measurement volume using supplementary laser metrology systems, to carry out detailed inspection beyond the line of sight, and to accurately locate parts, drill holes and fettle interfaces. Concepts are presented for a standardized robot which would provide a flexible automation system able to carry out a full range of operations required in the assembly of large aerospace structures. Two possible solutions are detailed, one based on error mapping and one based on the physical isolation of encoders from structural loading using an exoskeleton approach. Journal Automation

Early design verification of complex assembly variability using a hybrid model based and physical testing methodology 2011 Maropoulos, P.G., P. Vichare, O. Martin, J.E. Muelaner, M. Summers, and A. Kayani Design verification in the digital domain, using model-based principles, is a key research objective to address the industrial requirement for reduced physical testing and prototyping. For complex assemblies, the verification of the design intent and the associated production methods is currently fragmented, prolonged and sub-optimal, as it is based on the sequential consideration of various aspects in the digital and physical domains using a range of systems. This paper describes a novel hybrid design verification methodology that integrates model-based verification analysis with the measurement data and plans derived from the physical testing of prototype assemblies, in order to facilitate the early verification of complex designs from the perspective of satisfying key assembly criteria. Journal Quality Assurance

Verification of the Indoor GPS System, by Comparison with Calibrated Coordinates and by Angular Reference 2012 J E Muelaner, Z Wang, J Jamshidi, P G Maropoulos, A R Mileham, E B Hughes, and A B Forbes The Journal of Intelligent Manufacturing, 23(6), p. 2323-2331 This paper details work carried out to verify the dimensional measurement performance of the Indoor GPS (iGPS) system; a network of Rotary-Laser Automatic Theodolites (R-LATs). Initially tests were carried out to determine the angular uncertainties on an individual R-LAT transmitter- receiver pair. A method is presented of determining the uncertainty of dimensional measurement for a three dimensional coordinate measurement machine. An experimental procedure was developed to compare three dimensional coordinate measurements with calibrated reference points. The reference standard used to calibrate these reference points was a fringe counting interferometer with the multilateration technique employed to establish three dimensional coordinates. This is an extension of the established technique of comparing measured lengths with calibrated lengths. The method was found to be practical and able to establish that the expanded uncertainty of the basic iGPS system was approximately 1 mm at a 95% confidence level. Further tests carried out on a highly optimized version of the iGPS system have shown that the coordinate uncertainty can be reduced to 0.25 mm at a 95% confidence level. Journal Measurement

A New Paradigm in Large Scale Assembly Research Priorities in Measurement Assisted Assembly 2014 P G Maropoulos, J E Muelaner, M D Summers, O C Martin The International Journal of Advanced Manufacturing Technology, 70(1-4): p. 621-633 This paper presents for the first time the concept of Measurement Assisted Assembly (MAA) and outlines the research priorities of the realisation of this concept in industry. MAA denotes a paradigm shift in assembly for high value and complex products and encompasses the development and use of novel metrology processes for the holistic integration and capability enhancement of key assembly and ancillary processes. A complete framework for MAA is detailed showing how this can facilitate a step change in assembly process capability and efficiency for large and complex products, such as airframes, where traditional assembly processes exhibit the requirement for rectification and rework, use inflexible tooling and are largely manual, resulting in cost and cycle time pressures. The concept of MAA encompasses a range of innovative measurement-assisted processes which enable rapid part-to-part assembly, increased use of flexible automation, traceable quality assurance and control, reduced structure weight and improved levels of precision across the dimensional scales. A full scale industrial trial of MAA technologies has been carried out on an experimental aircraft wing demonstrating the viability of the approach while studies within 140 smaller companies have highlighted the need for better adoption of existing process capability and quality control standards. The identified research priorities for MAA include the development of both frameless and tooling embedded automated metrology networks. Other research priorities relate to the development of integrated dimensional variation management, thermal compensation algorithms as well as measurement planning and inspection algorithms linking design to measurement and process planning. Journal Part-to-Part Assembly

Verification Of The Indoor Gps System By Comparison With Points Calibrated Using A Network Of Laser Tracker Measurements 2009 J E Muelaner, Z Wang, J Jamshidi, P G Maropoulos 6th International Conference on Digital Enterprise Technology, Hong Kong This paper details a method of determining the uncertainty of dimensional measurement for a three dimensional coordinate measurement machine. An experimental procedure was developed to compare three dimensional coordinate measurements with calibrated reference points. The reference standard used to calibrate these reference points was a fringe counting interferometer with the multilateration technique employed to establish three dimensional coordinates. This is an extension of the established technique of comparing measured lengths with calibrated lengths. Specifically a distributed coordinate measurement device was tested which consisted of a network of Rotary-Laser Automatic Theodolites (R-LATs), this system is known commercially as indoor GPS (iGPS). The method was found to be practical and able to establish that the expanded uncertainty of the basic iGPS system was approximately 1 mm at a 95% confidence level. Conference Measurement

Concepts for and Analysis of a High accuracy and High Capacity (HAHC) Aerospace Robot 2010 J E Muelaner, Z Wang, P G Maropoulos The 21st International Computer-Aided Production Engineering Conference, 13-14 April, Edinburgh Case study work carried out within the aerospace sector has highlighted the requirement for highly accurate and high capacity robots in aerospace assembly, literature supports this observation. This paper presents the generic capabilities of such a system. These include the ability to rapidly locate its-self within a large measurement volume using supplementary laser metrology systems, to carry out detailed inspection beyond the line of sight, and to accurately locate parts, drill holes and fettle interfaces. The concept presented is for a standardised robot which will provide a flexible automation system able to carry out a full range of operations required in the assembly of large aerospace structures. Conference Automation

The Metrology Enhanced Tooling for Aerospace (META) Framework 2010 O C Martin, J E Muelaner, P G Maropoulos Aerospace manufacturers typically use monolithic steel fixtures to control the form of assemblies, this tooling is very expensive, has long lead times and has little ability to accommodate product variation and design changes. Since the tool setting and recertification process is manual and time consuming, monolithic structures are required in order to maintain the tooling tolerances for multiple years without recertification. This paper introduces the Metrology Enhanced Tooling for Aerospace (META) Framework which interfaces multiple metrology technologies with the tooling, components, workers and automation. This will allow rapid or even real-time fixture re-certification with improved product verification leading to a reduced risk of product non-conformance and increased fixture utilization while facilitating flexible fixtures. Conference Quality Assurance

Design for Measurement Assisted Determinate Assembly (MADA) of Large Composite Structures 2010 J E Muelaner, P G Maropoulos Coordinate Metrology Systems Conference, Reno, Nevada This paper describes how Measurement Assisted Determinate Assembly (MADA) can facilitate the lean production of aerospace structures, provided that the structure is designed for MADA. A novel wingbox design and production process is used to illustrate this. The aerospace industry has not benefited from the significant reductions in production cost and cycle time that can result from greater assembly efficiency, part-to-part interchangeability and the use of flexible automation. This is largely due to the very high accuracies required across large scale assemblies. The use of metrology can reduce process steps, reduce the reliance on costly hard tooling, reduce the requirement for manually intensive and time consuming re-working at late stages of assembly, and allow low cost flexible automation to place tools to the required accuracies. The generic MADA process is presented together with guidelines for the design of structures to enable MADA. Conference Part-to-Part Assembly

Measurability Characteristics Mapping for Large Volume Metrology Instruments Selection 2010 Cai, B., W. Dai, J.E. Muelaner, and P.G. Maropoulos 7th International Conference on Manufacturing Research, Warwick, UK, p. 438-442 Measurement and verification of products and processes during the early design is attracting increasing interest from high value manufacturing industries. Measurement planning is deemed as an effective means to facilitate the integration of the metrology activity into a wider range of production processes. However, the literature reveals that there are very few research efforts in this field, especially regarding large volume metrology. This paper presents a novel approach to accomplish instruments selection, the first stage of measurement planning process, by mapping measurability characteristics between specific measurement assignments and instruments. Conference Measurement

Metrology Enhanced Tooling for Aerospace (META): Strategies for Improved Accuracy of Jig Built Structures 2011 J E Muelaner, O C Martin, P G Maropoulos SAE Aerotech 2011, Toulous, France The accuracy of many aerospace structures is limited by the accuracy of assembly tooling which is in turn limited by the accuracy of the measurements used to set the tooling. Further loss of accuracy results from different rates of thermal expansion for the components and tooling. This paper describes improved tooling designs and setting processes which have the potential to significantly improve the accuracy of aerospace structures. The most advanced solution described is environmentally isolated interferometer networks embedded within tooling combined with active compensation of component pick-ups. This would eliminate environmental effects on measurements while also allowing compensation for thermal expansion. A more immediately realizable solution is the adjustment of component pick-ups using micrometer jacking screws allowing multilateration to be employed during the final stages of the setting process to generate the required offsets. Conference Measurement

Measurement Assisted Assembly and the Roadmap to Part-To-Part Assembly 2011 J.E. Muelaner, A. Kayani, O. Martin, and P.G. Maropoulos 7th International Conference on Digital Enterprise Technology, 2011. Athens, Greece. p. 11-19 Cycle times and production costs remain high in aerospace assembly processes largely due to extensive reworking within the assembly jig. Other industries replaced these craft based processes with part-to-part assembly facilitated by interchangeable parts. Due to very demanding interface tolerances and large flexible components it has not been possible to achieve the required interchangeability tolerances for most aerospace structures. Measurement assisted assembly processes can however deliver many of the advantages of part-to-part assembly without requiring interchangeable parts. This paper reviews assembly concepts such as interface management, oneway assembly, interchangeability, part-to-part assembly, jigless assembly and determinate assembly. The relationship between these processes is then detailed and they are organized into a roadmap leading to part-to-part assembly. Conference Part-to-Part Assembly

Integrated Dimensional Variation Management in the Digital Factory 2011 J E Muelaner, P G Maropoulos 7th International Conference on Digital Enterprise Technology, 2011. Athens, Greece. p. 39-46 Conference Measurement

Metrology enhanced tooling for aerospace (META): A live fixturing Wing Box assembly case study 2011 O C Martin, J E Muelaner, Z Wang, A Kayani, D Tomlinson, P G Maropoulos, P Helgasson 7th International Conference on Digital Enterprise Technology, 2011. Athens, Greece. p. 83-92 Aerospace manufacturers typically use monolithic steel fixtures to control the form of assemblies; this tooling is very expensive to manufacture, has long lead times and has little ability to accommodate product variation and design changes. Traditionally, the tool setting and recertification process is manual and time consuming, monolithic structures are required in order to maintain the tooling tolerances for multiple years without recertification. As part of a growing requirement to speed up tool-setting procedures this report explores a coupon study of live fixturing; that is, automated: fixture setting, correction and measurement. The study aims to use a measurement instrument to control the position of an actuated tooling flag, the flag will automatically move until the Key Characteristic (KC) of the part/assembly is within tolerance of its nominal position. This paper updates developments with the Metrology Enhanced Tooling for Aerospace (META) Framework which interfaces multiple metrology technologies with the tooling, components, workers and automation. This will allow rapid or even real-time fixture re-certification with improved product verification leading to a reduced risk of product non-conformance and increased fixture utilization while facilitating flexible fixtures. Conference Quality Assurance

Achieving Low Cost and High Quality Aero Structure Assembly through Integrated Digital Metrology Systems 2013 J E Muelaner, O C Martin, P G Maropoulos Conference Part-to-Part Assembly

Rapid Machine Tool Verification 2014 J E Muelaner, B R Yang, C Davy, M R Verma, P G Maropoulos 8th International Conference on Digital Enterprise Technology, Stuttgart, Germany, Procedia CIRP. 25 p. 431-438 Conference Machine Tool Measurement

Large Volume Metrology Technologies for the Light Controlled Factory 2014 J E Muelaner, P G Maropoulos 8th International Conference on Digital Enterprise Technology, Stuttgart, Germany, Procedia CIRP. 25 p. 169-176 In the Light Controlled Factory part-to-part assembly and reduced weight will be enabled through the use of predictive fitting processes; low cost high accuracy reconfigurable tooling will be made possible by active compensation; improved control will allow accurate robotic machining; and quality will be improved through the use of traceable uncertainty based quality control throughout the production system. A number of challenges must be overcome before this vision will be realized; 1) controlling industrial robots for accurate machining; 2) compensation of measurements for thermal expansion; 3) Compensation of measurements for refractive index changes; 4) development of Embedded Metrology Tooling for in-tooling measurement and active tooling compensation; and 5) development of Software for the Planning and Control of Integrated Metrology Networks based on Quality Control with Uncertainty Evaluation and control systems for predictive processes. This paper describes how these challenges are being addressed, in particular the central challenge of developing large volume measurement process models within an integrated dimensional variation management (IDVM) system. Conference Measurement

Uncertainty of the Measurement of Radial Runout, Axial Runout and Coning using an Industrial Axi-Symmetric Measurement Machine 2015 J E Muelaner, A J Francis, P G Maropoulos 38th MATADOR Conference, Taiwan, 28 March Conference Measurement

A hybrid Measurement Systems Analysis and Uncertainty of Measurement Approach for Industrial Measurement in the Light Controlled Factory 2015 J E Muelaner, A J Francis, M Chappell, P G Maropoulos Second International Conference on Sustainable Design and Manufacturing, Seville, Spain, 12-14 April The uncertainty of measurements must be quantified and considered in order to prove conformance with specifications and make other meaningful comparisons based on measurements. While there is a consistent methodology for the evaluation and expression of uncertainty within the metrology community industry frequently uses the alternative Measurement Systems Analysis methodology. This paper sets out to clarify the differences between uncertainty evaluation and MSA and presents a novel hybrid methodology for industrial measurement which enables a correct evaluation of measurement uncertainty while utilising the practical tools of MSA. In particular the use of Gage R&R ANOVA and Attribute Gage studies within a wider uncertainty evaluation framework is described. This enables in-line measurement data to be used to establish repeatability and reproducibility, without time consuming repeatability studies being carried out, while maintaining a complete consideration of all sources of uncertainty and therefore enabling conformance to be proven with a stated level of confidence. Such a rigorous approach to product verification will become increasingly important in the era of the Light Controlled Factory with metrology acting as the driving force to achieve the right first time and highly automated manufacture of high value large scale products such as aircraft, spacecraft and renewable power generation structures. Conference Measurement

Kinematic Analysis and Optimization of Bicycle Suspension 2015 J E Muelaner, T Knight, J Darling Second International Conference on Sustainable Design and Manufacturing, Seville, Spain, 12-14 April Bicycle suspension is increasingly used to improve performance and facilitate the use of smaller wheels for folding bicycles, unwanted activation due to pedalling and braking forces can however result in energy losses. This paper presents a kinematic analysis leading to a Suspension Activation Ratio (SAR) which is the ratio of the suspension activation force to the pedalling force and its experimental verification. The SAR may be used as a performance metric to compare suspension designs and an objective function for suspension design optimization where the SAR is minimized for all possible gear ratios. Suspension geometry thus optimized shows agreement with optimal pivot positions found by empirical studies. Previous work has involved dynamic simulation and experimentation to estimate energy losses; however it is difficult to apply this analysis to rapidly evaluate different suspension designs for performance evaluation or design optimization. The kinematic design approach presented here provides the first step in suspension design which should precede dynamic design to optimize spring and damping rates. Conference Design

Uncertainty Evaluation Method for Axi-Symmetric Measurement Machines 2016 J E Muelaner, P S Keogh Int J of Metrology & Quality Eng., 7(2) Journal Measurement

Uncertainty of Measurement for Large Product Verification: Evaluation of a Large Aero Gas Turbine Engine 2016 J E Muelaner, Z Wang, P S Keogh, J Brownell, D Fisher Meas. Sci. Technol, 27(11) Understanding the uncertainty of dimensional measurements for large products such as aircraft, spacecraft and wind turbines is fundamental to improving efficiency in these products. Much work has been done to ascertain the uncertainty associated with the main types of instruments used, based on laser tracking and photogrammetry, and the propagation of this uncertainty through networked measurements. Unfortunately this is not sufficient to understand the combined uncertainty of industrial measurements, which include secondary tooling and datum structures used to locate the coordinate frame. This paper presents for the first time a complete evaluation of the uncertainty of large scale industrial measurement processes. Generic analysis and design rules are proven through uncertainty evaluation and optimization for the measurement of a large aero gas turbine engine. This shows how the instrument uncertainty can be considered to be negligible. Before optimization the dominant source of uncertainty was the tooling design, after optimization the dominant source was thermal expansion of the engine; meaning that no further improvement can be made without measurement in a temperature controlled environment. These results will have a significant impact on the ability of aircraft and wind turbines to improve efficiency and therefore reduce carbon emissions, as well as the improved reliability of these products. Journal Measurement

Comparative Performance between Two Photogrammetric Systems and a Reference Laser Tracker Network for Large?Volume Industrial Measurement 2016 O C Martin, S Robson, A Kayani, J E Muelaner, V Dhokia, P G Maropoulos The Photogrammetric Record, 31(155): p. 348-360 Journal Measurement

Measurement Assisted Fettling of Rib Feet to Maintain Cover Interface on the ALCAS Wing Box Demonstrator 2011 J E Muelaner, A Kayani P Maropoulos SAE Aerotech 2011, Toulous, France A novel measurement assisted assembly process has been used to maintain the interface between the wing box ribs and the upper cover on a demonstration composite wing box build. Measurements of the cover profile were used to generate machining paths for the fettling of rib feet. The machining of the rib feet was then carried out using a standard 6-axis industrial robot mounted on a gantry over the wing box. Feedback for closed loop control of the robot was provided by a photogrammetry system. Measurements of an initial roughing cut were used to apply corrections to the finishing cut in a process analogous to the iterative process of manual machining and measurement. Conference Automation

Improving Error Models of Machine Tools with Metrology Data 2016 J M Flynn, J M Muelaner, V Dhokia, S T Newman As the manufacturing community embraces the use of a variety of metrology solutions, the availability and quantity of measurement data is increasing. The tendency towards connectedness between manufacturing resources may also provide a mechanism for communication and exploitation of metrology data like never before. This research aims to provide an insight into the opportunities that are associated with accessible, abundant and communicable manufacturing metrology data. Issues are raised and critically discussed in relation to one particular aspect of manufacturing metrology, namely, machine tool accuracy verification and calibration. Specifically, a methodology for relating CMM part measurements to individual machine tool geometric error sources is described. A novel Monte Carlo simulation-based method is used to estimate previously unmeasured error values without the use of further testing. Using this method, the advantage of using previously captured verification and calibration data to identify likely causes of part defects is shown. It is envisaged that the proposed method can be used to instruct targeted machine tool verification and calibration routines to reduce the number of tests required to monitor a machine tool's health. By using targeted tests, the need to measure all machine error sources is reduced, which in turn can improve productivity by reducing machine tool downtime. Conference Machine Tool Measurement

Thermal compensation for large volume metrology and structures 2017 B Yang, D Ross-Pinnock, J E Muelaner and G Mullineux International Journal of Metrology and Quality Engineering, 8(21) Journal Measurement

Absolute Multilateration between Spheres 2017 J E Muelaner, W Wadsworth, M Azini, G Mullineux, B Hughes, and A Reichold Meas. Sci. Technol, 28(4) Journal Measurement

Integrated calibration of a 3D attitude sensor in large-scale metrology 2017 Yang Gao, Jiarui Lin,Linghui Yang, Jody Muelaner, Jigui Zhu, Patrick Keogh Meas. Sci. Technol, 28(7) Journal Measurement

Uncertainties in Dimensional Measurements due to Thermal Expansion 2017 J E Muelaner, D Ross-Pinnock, G Mullineux, and P S Keogh Laser Metrology and Machine Performance XII. 2017. Renishaw Innovation Centre, UK Thermal expansion is a source of uncertainty in dimensional measurements, which is often significant and in some cases dominant. Methods of evaluating and reducing this uncertainty are therefore of fundamental importance to product quality, safety and efficiency in many areas. Existing methods depend on the implicit assumption that thermal expansion is relatively uniform throughout the part and can, therefore, be corrected by scaling the measurement result. The uncertainty of this scale correction is then included in the uncertainty of the dimensional measurement. It is shown here that this assumption is not always valid due to thermal gradients resulting in significant shape changes. In some cases these are the dominant source of dimensional uncertainty. Methods are described to first determine whether shape change is significant. Where shape changes are negligible but thermal expansion remains significant then the established methods may be used. This paper describes the application of the Guide to the expression of Uncertainty in Measurement (GUM) uncertainty framework which provides an approximate solution for thermal expansion due to non-linearity and a non-Gaussian output function. The uncertainty associated with this approximation is rigorously evaluated by comparison with Monte Carlo Simulation over a wide range of parameter values. It is often necessary to estimate the expected uncertainty for a measurement which will be made in the future. It is shown that the current method for this is inadequate and an improved method is given. Conference Measurement

A Unified Approach to Uncertainty for Quality Improvement 2017 Laser Metrology and Machine Performance XII. 2017. Renishaw Innovation Centre, UK To improve quality, process outputs must be measured. A measurement with no statement of its uncertainty gives no meaningful information. The Guide to the expression of Uncertainty in Measurement (GUM) aims to be a universal framework for uncertainty. However, to date, industry lacks such a common approach. A calibration certificate may state an Uncertainty or a Maximum Permissible Error. A gauge study gives the repeatability and reproducibility. Machines have an accuracy. Processes control aims to remove special cause variation and to monitor common cause variation. There are different names for comparable metrics and different methods to evaluate them. This leads to confusion. Small companies do not necessarily have experts able to implement all methods. This paper considers why multiple methods are currently used. It then gives a common language and approach for the use of uncertainty in all areas of manufacturing quality. Conference Quality Assurance

A Unified Uncertainty based Approach for Optimal Quality Decisions 2017 J E Muelaner European Network for Business and Industrial Statistics 2017. Naples, Italy To improve quality, process outputs must be measured. A measurement with no statement of its uncertainty gives no meaningful information. The Guide to the expression of Uncertainty in Measurement (GUM) aims to be a universal framework for uncertainty. However, to date, industry lacks such a common approach. A calibration certificate may state an Uncertainty or a Maximum Permissible Error. A gauge study gives the repeatability and reproducibility. Machines have an accuracy. Processes control aims to remove special cause variation and to monitor common cause variation. There are different names for comparable metrics and different methods to evaluate them. This leads to confusion. Small companies do not necessarily have experts able to implement all methods. This paper considers why multiple methods are currently used. It then gives a common language and approach for the use of uncertainty in all areas of manufacturing quality. Conference Quality Assurance

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