Spray automated balancing of rotors: Methods and materials

The work described consists of two parts. In the first part, a survey is performed to assess the state of the art in rotor balancing technology as it applies to Army gas turbine engines and associated power transmission hardware. The second part evaluates thermal spray processes for balancing weight addition in an automated balancing procedure. The industry survey reveals that: (1) computerized balancing equipment is valuable to reduce errors, improve balance quality, and provide documentation; (2) slow-speed balancing is used exclusively, with no forseeable need for production high-speed balancing; (3) automated procedures are desired; and (4) thermal spray balancing is viewed with cautious optimism whereas laser balancing is viewed with concern for flight propulsion hardware. The FARE method (Fuel/Air Repetitive Explosion) was selected for experimental evaluation of bond strength and fatigue strength. Material combinations tested were tungsten carbide on stainless steel (17-4), Inconel 718 on Inconel 718, and Triballoy 800 on Inconel 718. Bond strengths were entirely adequate for use in balancing. Material combinations have been identified for use in hot and cold sections of an engine, with fatigue strengths equivalent to those for hand-ground materials

Modeling, design and scheduling of computer integrated manufacturing and demanufacturing systems

This doctoral dissertation work aims to provide a discrete-event system-based methodology for design, implementation, and operation of flexible and agile manufacturing and demanufacturing systems. After a review of the current academic and industrial activities in these fields, a Virtual Production Lines (VPLs) design methodology is proposed to facilitate a Manufacturing Execution System integrated with a shop floor system. A case study on a back-end semiconductor line is performed to demonstrate that the proposed methodology is effective to increase system throughput and decrease tardiness. An adaptive algorithm is proposed to deal with the machine failure and maintenance. To minimize the environmental impacts caused by end-of-life or faulty products, this research addresses the fundamental design and implementation issues of an integrated flexible demanufacturing system (IFDS). In virtue of the success of the VPL design and differences between disassembly and assembly, a systematic approach is developed for disassembly line design. This thesis presents a novel disassembly planning and demanufacturing scheduling method for such a system. Case studies on the disassembly of personal computers are performed illustrating how the proposed approaches work

Balancing and lot-sizing mixed-model lines in the footwear industry

This report describes the full research proposal for the project \Balancing and lot-sizing mixed-model lines in the footwear industry", to be developed as part of the master program in Engenharia Electrotécnica e de Computadores - Sistemas de Planeamento Industrial of the Instituto Superior de Engenharia do Porto. The Portuguese footwear industry is undergoing a period of great development and innovation. The numbers speak for themselves, Portugal footwear exported 71 million pairs of shoes to over 130 countries in 2012. It is a diverse sector, which covers different categories of women, men and children shoes, each of them with various models. New and technologically advanced mixed-model assembly lines are being projected and installed to replace traditional mass assembly lines. Obviously there is a need to manage them conveniently and to improve their operations. This work focuses on balancing and lot-sizing stitching mixed-model lines in a real world environment. For that purpose it will be fundamental to develop and evaluate adequate effective solution methods. Different objectives may be considered, which are relevant for the companies, such as minimizing the number of workstations, and minimizing the makespan, while taking into account a lot of practical restrictions. The solution approaches will be based on approximate methods, namely by resorting to metaheuristics. To show the impact of having different lots in production the initial maximum amount for each lot is changed and a Tabu Search based procedure is used to improve the solutions. The developed approaches will be evaluated and tested. A special attention will be given to the solution of real applied problems. Future work may include the study of other neighbourhood structures related to Tabu Search and the development of ways to speed up the evaluation of neighbours, as well as improving the balancing solution method

Fitness landscape analysis of the simple assembly line balancing problem type 1

As the simple assembly line balancing problem type 1 (SALBP1) has been proven to be NP-hard, heuristic and metaheuristic approaches are widely used for solving middle to large instances. Nevertheless, the characteristics (fitness landscape) of the problem’s search space have not been studied so far and no rigorous justification for implementing various metaheuristic methods has been presented. Aiming to fill this gap in the literature, this study presents the first comprehensive and in-depth Fitness Landscape Analysis (FLA) study for SALBP1. The FLA was performed by generating a population of 1000 random solutions and improving them to local optimal solution, and then measuring various statistical indices such as average distance, gap, entropy, amplitude, length of the walk, autocorrelation, and fitness-distance among all solutions, to understand the complexity, structure, and topology of the solution space. We solved 83 benchmark problems with various cycle times taken from Scholl’s dataset which required 83000 local searches from initial to optimal solutions. The analysis showed that locally optimal assembly line balances in SALBP1 are distributed nearly uniformly in the landscape of the problem, and the small average difference between the amplitudes of the initial and optimal solutions implies that the landscape was almost plain. In addition, the large average gap between local and global solutions showed that global optimum solutions in SALBP1 are difficult to find, but the problem can be effectively solved using a single-solution-based metaheuristic to near-optimality. In addition to the FLA, a new mathematical formulation for the entropy (diversity) of solutions in the search space for SALBP1 is also presented in this paper

A STUDY ON GENERAL ASSEMBLY LINE BALANCING MODELING METHODS AND TECHNIQUES

The borders of the assembly line balancing problem, as classically drawn, are as clear as any other operations research topic in production planning, with well-defined sets of assumptions, parameters, and objective functions. In application, however, these borders are frequently transgressed. Many of these deviations are internal to the assembly line balancing problem itself, arising from any of a wide array of physical or technological features in modern assembly lines. Other issues are founded in the tight coupling of assembly line balancing with external production planning and management problems, as assembly lines are at the intersection of multiple related problems in job sequencing, part flow logistics, worker safety, and quality. The field of General Assembly Line Balancing is devoted to studying the class of adapted and extended solution techniques necessary in order to model these applied line balancing problems. In this dissertation a complex line balancing problem is presented based on the real production environment of our industrial partner, featuring several extensions for task-to-task relationships, station characteristics limiting assignment, and parallel worker zoning interactions. A constructive heuristic is developed along with two improvement heuristics, as well as an integer programming model for the same problem. An experiment is conducted testing each of these new solution methods upon a battery of testbed problems, measuring solution quality, runtime, and achievement of feasibility. Additionally, a new method for measuring a secondary horizontal line balancing objective is established, based on the options-mix paradigm rather than the customary model-mix paradigm

A novel approach to assess minimally invasive surgical device failure utilizing adverse event outcome severity and design complexity.

Medical device failure and misuse have the potential to cause serious injury and death. Given the intricate nature of the instruments utilized specifically in minimally invasive surgery (MIS), users and manufacturers of surgical devices share a responsibility in preventing user error and device failure. A novel approach was presented for the evaluation of minimally invasive device failures, which involved assessing the severity of adverse event outcomes associated with the failures modes and investigating aspects of the devices’ design that may contribute to failure. The goals of this research were to 1) characterize the design attributes, failure modes, and adverse events associated with minimally invasive surgical devices and 2) describe the relationship between minimally invasive surgical device design complexity and the severity of adverse events. The types of failure modes, phases of operation in which failure occurs, severity of adverse event outcomes, and design complexity associated with four minimally invasive surgical devices were determined. An association was shown to exist between phases of surgical device operation and the severity of outcomes that occur in each phase (p \u3c 0.05). Across both device types, the majority of failure occurred during execution of the devices’ main function which involved securing and transecting tissue. The least amount of failures occurred during the results and post-op phase of operation; however, the failures that occurred during this phase resulted in the highest average outcome severity. The endoscopic staplers assessed resulted in overall higher average outcome severities relative to that of the tissue sealers. The methods employed are the first to evaluate medical device design, function, and failure outcomes from a complexity perspective. While statistical conclusions regarding the overall research goal could not be drawn, heuristic methods support development of the approach presented. The work herein assists the enhancement of risk awareness and prevention techniques and serves as a contribution to filling the knowledge gap regarding device use and failure outcomes. Bridging the gap between surgeons and engineers is crucial to the successful implementation and evaluation of new technology in the operating room, which was an essential component of this research

A scalable multi-core architecture with heterogeneous memory structures for Dynamic Neuromorphic Asynchronous Processors (DYNAPs)

Neuromorphic computing systems comprise networks of neurons that use asynchronous events for both computation and communication. This type of representation offers several advantages in terms of bandwidth and power consumption in neuromorphic electronic systems. However, managing the traffic of asynchronous events in large scale systems is a daunting task, both in terms of circuit complexity and memory requirements. Here we present a novel routing methodology that employs both hierarchical and mesh routing strategies and combines heterogeneous memory structures for minimizing both memory requirements and latency, while maximizing programming flexibility to support a wide range of event-based neural network architectures, through parameter configuration. We validated the proposed scheme in a prototype multi-core neuromorphic processor chip that employs hybrid analog/digital circuits for emulating synapse and neuron dynamics together with asynchronous digital circuits for managing the address-event traffic. We present a theoretical analysis of the proposed connectivity scheme, describe the methods and circuits used to implement such scheme, and characterize the prototype chip. Finally, we demonstrate the use of the neuromorphic processor with a convolutional neural network for the real-time classification of visual symbols being flashed to a dynamic vision sensor (DVS) at high speed.Comment: 17 pages, 14 figure

Research reports: 1991 NASA/ASEE Summer Faculty Fellowship Program

The basic objectives of the programs, which are in the 28th year of operation nationally, are: (1) to further the professional knowledge of qualified engineering and science faculty members; (2) to stimulate an exchange of ideas between participants and NASA; (3) to enrich and refresh the research and teaching activities of the participants' institutions; and (4) to contribute to the research objectives of the NASA Centers. The faculty fellows spent 10 weeks at MSFC engaged in a research project compatible with their interests and background and worked in collaboration with a NASA/MSFC colleague. This is a compilation of their research reports for summer 1991

A Multi-level Multi-Modular Flying Capacitor Voltage Source Converter for High Power Applications

Two vital and dynamically changing issues are arising in the electric grid - an increase in electrical power demand, and subsequent reduction in power quality. Power electronics based solutions such as the Static Synchronous Compensator are increasingly deployed to mitigate power quality issues while High Voltage DC Transmission converters are currently installed to support the existing grid transmission capacity. Both applications require high power and high voltage power converters using switching devices with limited voltage ratings. The advent of Modular Multilevel Converters (MMC) is one of the recent responses to this need. These use half or full H-bridge circuits stacked up to form a chain, and hence can withstand high voltages using lower-rated switching devices. This thesis introduces a new member into the MMC family, i.e the Modular Multi-level Flying Capacitor Converter (MMFCC). This uses a three-level flying capacitor full-bridge circuit as a sub-module and offers features of modularity, scalability and fault tolerance. The choice of FC topology in place of the simple H-bridge stems from the FC’s ability to offer two extra voltage levels in the sub-module output and hence more degrees of freedom per module in controlling the voltage waveform. A three-level full-bridge FC sub-module uses three capacitors - an outer one for supporting the sub-module voltage, and two inner floating ones with half of the outer one’s capacitance and voltage rating. This use of slightly more complex FC sub-modules gives the benefits of a modular structure but without using twice as many sub-modules with their associated capacitors for the same total voltage. The thesis presents the principles of this topology, switching states redundancies and a method for capacitor voltage balancing. Also discussed are: the configuration of MMCC including the MMFCC in Single-Star Bridge-Cell (SSBC) or Single-Delta Bridge-Cell (SDBC) for FACTS and Battery Energy Storage System (BESS) applications; and Double-Star Chopper-Cell (DSCC) or Double-Star Bridge-Cell (DSBC) for HVDC systems. A novel overlapping hexagon pulse width modulation scheme is introduced and discussed for switching control of the MMFCC. This uses multiple hexagons all centred on one point, the same in number as the cascaded FC sub-modules, which are phase displaced relative to each other. The approach simplifies the modulation algorithm and brings flexibility in shaping the output voltage waveforms for different applications. An MMFCC experimental rig was designed and built in-house to validate some of the simulation results obtained for the modulation of this new topology. Details of the rig as well as results captured are discussed