Challenges of model-based definition for high-value manufacturing

Manufacturing Industry is moving towards adoption of 3D models as the ultimate authoritative source for complete product definition replacing 2D drawings, which is called “Model-Based Definition”. Starting its journey from geometric information on design, manufacturing, and inspection, the targets are to achieve the ultimate goal of lifecycle model based enterprise, requiring MBD to be more comprehensive and challenging structure of information instead of just a geometric model. The industry has not yet fully achieved implementation of MBD to whole product lifecycle. This journey is long and tough, and we are still at an early stage, but it will be a decisive factor in gaining competitive advantage by the early adopters, especially in high-value manufacturing. Complete adoption of MBD has several issues and challenges that need to be addressed. This paper presents a review of current literature, intending to cover present state of knowledge, issues, challenges, and future research directions, in the development and adoption of MBD

Trends in model-based definition based assembly information in high-value manufacturing

3D modelling is in use for the last many decades at various stages of the product lifecycle i.e., design, analysis, manufacturing, and inspection. In the modern era of Industry 4.0 where the high-value manufacturing industry is aiming at the digital thread, Model-Based Definition (MBD) has been considered as the heart of this transformation. However, MBD needs to be realized throughout the product lifecycle to get full advantage. In literature, considerable work has been found focusing on a shift from traditional 2D drawings to MBD. The majority of this work concentrates on design, manufacturing, and inspection stages, whereas, there is a lack of work in the area of MBD based assembly information. This paper focuses on the current state of knowledge in MBD based assembly information, trends, challenges, and future research directions

Process monitoring and industrial informatics for on-line optimization of Welding Procedure Specifications (WPS) in Gas Tungsten Arc Welding (GTAW) – Industry 4.0 for robotic additive re-manufacturing of aeroengine components

Industry 4.0, the scheme that drives the fourth industrial revolution, has been, since its conception, reshaping the manufacturing industry. To advance current industrial chains into the smart factories of the future, cyber-physical systems are monitored and communicate with each other to ensure transparent interoperability, giving birth to the emerging field of industrial informatics. To enable the repair and recycling of high value jet engine compressor blades, additive manufacturing is utilized. The complex geometries and asymmetrical wear of the blades require robotic welding systems to be trained by experienced human welding engineers in order to be able to adapt to differing components. Demonstrated in this paper, process monitoring and industrial informatics are introduced to the adaption of Welding Procedure Specifications (WPS) utilized by a developing robotic system for the additive re-manufacturing of aeroengine components. Using a novel variant of Gas Tungsten Arc Welding (GTAW), the robotic welding system under development is a product of an industry-academia collaboration between the Enabling Sciences for Intelligent Manufacturing Group (ESIM) of the University of Sheffield and VBC Instrument Engineering Ltd

Engineering Support Systems for Industrial Machines and Plants

In the business of industrial machines and plants, rapid and detailed estimates for planning installation, replacement of equipment, or maintenance work are key requirements for meeting the demands for greater reliability, lower costs and for maintaining safe and secure operation. These demands have been addressed by developing technology driven by IT. When replacing equipment at complex building or plants with high equipment density, the existing state of the installation locations and transportation routes for old and new equipment need to be properly measured. We have met this need by developing parts recognition technology based on 3D measurement, and by developing high-speed calculation technology of optimal routes for installation parts. This chapter provides an overview of these development projects with some real business application results

An uncertainty management framework to support model-based definition and enterprise

In pursuit of industrial digitalisation, the manufacturing industry is going through a transformation in the methods for product definition from the traditional two-dimensional drawing to three-dimensional digital model known as the model-based definition (MBD). The real benefit of this digitalisation lies in the adoption of model-based definition across all stages of the product lifecycles throughout the enterprise and its supply chain which is termed as model-based enterprise (MBE). However, the current application of this technology is partial, due to the involvement of several associated uncertainties. This paper proposes a novel framework for the management of uncertainties in the adoption of the model-based definition and presents a system in support of the proposed framework. The development commenced with the collaboration of two major aerospace industries. The framework comprises five phases including the preliminary phase, identification, assessment, analysis, and response phase. A systematic process is followed in developing the framework while Numeral, Spread, Assessment, and Pedigree (NUSAP), and Analytical Hierarchy Process (AHP) are used in the assessment of uncertainties. The developed system consists of a user interface, a database of uncertainties, an assessment module, an analysis and prioritisation module, and a knowledge base of mitigation strategies for key uncertainties. The system facilitates the analyst to select the relevant uncertainties from a defined list, systematically assess and analyse each of the uncertainty and obtain recommendations for mitigation of the prioritised uncertainties in the project. The framework and the developed system were validated through expert interviews with two world-class aerospace companies. This system facilitates identifying the various types of uncertainties of MBD, quantifying their impact on the project rationally, and formulating a suitable management strategy for achieving the status of a model-based enterprise

An uncertainty management framework to support model-based definition and enterprise

In pursuit of industrial digitalisation, the manufacturing industry is going through a transformation in the methods for product definition from the traditional two-dimensional drawing to three-dimensional digital model known as the model-based definition (MBD). The real benefit of this digitalisation lies in the adoption of model-based definition across all stages of the product lifecycles throughout the enterprise and its supply chain which is termed as model-based enterprise (MBE). However, the current application of this technology is partial, due to the involvement of several associated uncertainties. This paper proposes a novel framework for the management of uncertainties in the adoption of the model-based definition and presents a system in support of the proposed framework. The development commenced with the collaboration of two major aerospace industries. The framework comprises five phases including the preliminary phase, identification, assessment, analysis, and response phase. A systematic process is followed in developing the framework while Numeral, Spread, Assessment, and Pedigree (NUSAP), and Analytical Hierarchy Process (AHP) are used in the assessment of uncertainties. The developed system consists of a user interface, a database of uncertainties, an assessment module, an analysis and prioritisation module, and a knowledge base of mitigation strategies for key uncertainties. The system facilitates the analyst to select the relevant uncertainties from a defined list, systematically assess and analyse each of the uncertainty and obtain recommendations for mitigation of the prioritised uncertainties in the project. The framework and the developed system were validated through expert interviews with two world-class aerospace companies. This system facilitates identifying the various types of uncertainties of MBD, quantifying their impact on the project rationally, and formulating a suitable management strategy for achieving the status of a model-based enterprise.Higher Education Commission (HEC), Pakistan and Cranfield University

Advanced titanium welding in particle physics and aerospace engineering

The quest for answers that will unlock the mysteries of the cosmos and broaden our perception and understanding of the physical laws that govern the universe, demands studying particle collisions of high energies at particle accelerators. Monitoring of these collisions requires complex detectors whose development pushes the boundaries of engineering. In the present study advanced titanium welding is explored in the development of the new ATLAS Inner Tracker detector to be installed in line with the High-Luminosity Large Hadron Collider at CERN. Pulsed welding currents are employed to join thin titanium pipes used in the detector’s evaporative CO2 cooling system. The benefits of the low heat input enabled by the welding process are utilised in the repair and remanufacturing industry of aerospace applications. Wire arc additive manufacturing is applied in the regeneration of aerospace components providing successive material deposition on a layer-upon-layer manner. To this extent investigations and implementations related to Pulsed Gas Tungsten Arc Welding are explored in the presented work aiming to further understand, implement and advance the welding process. Assurance of the weld quality is furthered studied, as the outcome of the process depends on maintaining input parameters and welding conditions at optimum levels for the whole duration of the process. By implementing process monitoring methodologies, invaluable data are recorded whose analysis can be utilised in the detection of process disturbances and weld quality assessment

Decision support method for contracting of non-original equipment manufacturer aero engine maintenance repair and overhaul service providers.

Non-Original Equipment Manufacturer (Non-OEM) Maintenance Repair and Overhaul (MRO) service providers of aero-engines are facing challenges resulting from the rapidly changing MRO market. They need to offer innovative service solutions to airlines through, for example, PSS (Product Service Systems) offerings that combine service(s) and products. PSS can be achieved by either servitisation to add service offerings to products or productisation to add tangible products to service offerings. Currently, however, MRO contracts that include PSS offerings have been prepared based on experiences and intuitions. Ideally, these contracts should be designed to bring about a win-win situation for both airlines (as customers) and MRO service providers. This research aims to develop a new robust, scientific method to prepare contracts for decision makers of non-OEM MRO service providers. The research began with studying current general situation of the PSS in the aero-engine MRO market as well as, in particular, of a Non-OEM MRO service provider. From these, this research first identified sufficient key parameters that describe MRO operations with regard to flight operations of customer airline. A computer-based simulation model was built to assess the capacity and capability of the shop floor operations taking flight operations of the customer into consideration using the discrete event simulation. The simulation model was run over a set of systematically and exhaustively created combinations of different types of services and products. This has helped in selecting the most favourable combinations services and products, which can lead to the win-win situation for both the airlines and the MRO service providers.PhD in Manufacturin