Analysis and control of complex collaborative design systems

This paper presents a novel method for modelling the complexity of collaborative design systems based on its analysis and proposes a solution to reducing complexity and improving performance of such systems. The interaction and interfacing properties among many components of a complex design system are analysed from different viewpoints and then a complexity model for collaborative design is established accordingly. In order to simplify complexity and improve performance of collaborative design, a general solution of decomposing a whole system into sub-systems and using unified interface mechanism between them has been proposed. This proposed solution has been tested with a case study. It has been shown that the proposed solution is meaningful and practical

Evaluation and recommendations for work group integration within the Materials and Processes Lab

The goal of this study was to evaluate and make recommendations for improving the level of integration of several work groups within the Materials and Processes Lab at the Marshall Space Flight Center. This evaluation has uncovered a variety of projects that could improve the efficiency and operation of the work groups as well as the overall integration of the system. In addition, this study provides the foundation for specification of a computer integrated manufacturing test bed environment in the Materials and Processes Lab

Variant-oriented Planning Models for Parts/Products Grouping, Sequencing and Operations

This research aims at developing novel methods for utilizing the commonality between part/product variants to make modern manufacturing systems more flexible, adaptable, and agile for dealing with less volume per variant and minimizing total changes in the setup between variants. Four models are developed for use in four important domains of manufacturing systems: production sequencing, product family formation, production flow, and products operations sequences retrieval. In all these domains, capitalizing on commonality between the part/product variants has a pivotal role. For production sequencing; a new policy based on setup similarity between product variants is proposed and its results are compared with a developed mathematical model in a permutation flow shop. The results show the proposed algorithm is capable of finding solutions in less than 0.02 seconds with an average error of 1.2%. For product family formation; a novel operation flow based similarity coefficient is developed for variants having networked structures and integrated with two other similarity coefficients, operation and volume similarity, to provide a more comprehensive similarity coefficient. Grouping variants based on the proposed integrated similarity coefficient improves changeover time and utilization of the system. A sequencing method, as a secondary application of this approach, is also developed. For production flow; a new mixed integer programing (MIP) model is developed to assign operations of a family of product variants to candidate machines and also to select the best place for each machine among the candidate locations. The final sequence of performing operations for each variant having networked structures is also determined. The objective is to minimize the total backtracking distance leading to an improvement in total throughput of the system (7.79% in the case study of three engine blocks). For operations sequences retrieval; two mathematical models and an algorithm are developed to construct a master operation sequence from the information of the existing variants belonging to a family of parts/products. This master operation sequence is used to develop the operation sequences for new variants which are sufficiently similar to existing variants. Using the proposed algorithm decreases time of developing the operations sequences of new variants to the seconds

A Novel Method for Adaptive Control of Manufacturing Equipment in Cloud Environments

The ability to adaptively control manufacturing equipment, both in local and distributed environments, is becoming increasingly more important for many manufacturing companies. One important reason for this is that manufacturing companies are facing increasing levels of changes, variations and uncertainty, caused by both internal and external factors, which can negatively impact their performance. Frequently changing consumer requirements and market demands usually lead to variations in manufacturing quantities, product design and shorter product life-cycles. Variations in manufacturing capability and functionality, such as equipment breakdowns, missing/worn/broken tools and delays, also contribute to a high level of uncertainty. The result is unpredictable manufacturing system performance, with an increased number of unforeseen events occurring in these systems. Events which are difficult for traditional planning and control systems to satisfactorily manage. For manufacturing scenarios such as these, the use of real-time manufacturing information and intelligence is necessary to enable manufacturing activities to be performed according to actual manufacturing conditions and requirements, and not according to a pre-determined process plan. Therefore, there is a need for an event-driven control approach to facilitate adaptive decision-making and dynamic control capabilities. Another reason driving the move for adaptive control of manufacturing equipment is the trend of increasing globalization, which forces manufacturing industry to focus on more cost-effective manufacturing systems and collaboration within global supply chains and manufacturing networks. Cloud Manufacturing is evolving as a new manufacturing paradigm to match this trend, enabling the mutually advantageous sharing of resources, knowledge and information between distributed companies and manufacturing units. One of the crucial objectives for Cloud Manufacturing is the coordinated planning, control and execution of discrete manufacturing operations in collaborative and networked environments. Therefore, there is also a need that such an event-driven control approach supports the control of distributed manufacturing equipment. The aim of this research study is to define and verify a novel and comprehensive method for adaptive control of manufacturing equipment in cloud environments. The presented research follows the Design Science Research methodology. From a review of research literature, problems regarding adaptive manufacturing equipment control have been identified. A control approach, building on a structure of event-driven Manufacturing Feature Function Blocks, supported by an Information Framework, has been formulated. The Function Block structure is constructed to generate real-time control instructions, triggered by events from the manufacturing environment. The Information Framework uses the concept of Ontologies and The Semantic Web to enable description and matching of manufacturing resource capabilities and manufacturing task requests in distributed environments, e.g. within Cloud Manufacturing. The suggested control approach has been designed and instantiated, implemented as prototype systems for both local and distributed manufacturing scenarios, in both real and virtual applications. In these systems, event-driven Assembly Feature Function Blocks for adaptive control of robotic assembly tasks have been used to demonstrate the applicability of the control approach. The utility and performance of these prototype systems have been tested, verified and evaluated for different assembly scenarios. The proposed control approach has many promising characteristics for use within both local and distributed environments, such as cloud environments. The biggest advantage compared to traditional control is that the required control is created at run-time according to actual manufacturing conditions. The biggest obstacle for being applicable to its full extent is manufacturing equipment controlled by proprietary control systems, with native control languages. To take the full advantage of the IEC Function Block control approach, controllers which can interface, interpret and execute these Function Blocks directly, are necessary

Incremental simulation modelling for Internet collaborative design

In order to support Web-based collaborative design in terms of transferring or updating models dynamically and efficiently, new incremental modelling and local updating strategies have been developed for simulation modelling application since simulation is more focused on visualisation effects than on geometry details. Based on an assembly connection concept, a drag-and-drop assembly method has also been proposed in simulation assembly. An assembly connection is defined as a group of assembly constraints and it makes assembly easier. A case study example is given to show the content of the proposed research

VR-PMS: a new approach for performance measurement and management of industrial systems

A new performance measurement and management framework based on value and risk is proposed. The proposed framework is applied to the modelling and evaluation of the a priori performance evaluation of manufacturing processes and to deciding on their alternatives. For this reason, it consistently integrates concepts relevant to objectives, activity, and risk in a single framework comprising a conceptual value/risk model, and it conceptualises the idea of value- and risk based performance management in a process context. In addition, a methodological framework is developed to provide guidelines for the decision-makers or performance evaluators of the processes. To facilitate the performance measurement and management process, this latter framework is organized in four phases: context establishment, performance modelling, performance assessment, and decision-making. Each phase of the framework is then instrumented with state of-the-art quantitative analysis tools and methods. For process design and evaluation, the deliverable of the value- and risk-based performance measurement and management system (VR-PMS) is a set of ranked solutions (i.e. alternative business processes) evaluated against the developed value and risk indicators. The proposed VR-PMS is illustrated with a case study from discrete parts manufacturing but is indeed applicable to a wide range of processes or systems

A Building-Block Approach to Industrial Controls Laboratories Using Programmable Logic Controllers

Industrial control systems design often incorporates reusable sections of prior design that can easily be adapted for new machine and process control systems. For instance, inclusion of a tri-mode control structure (Manual, Automatic and Set-up modes) often becomes a ‘cut and paste’ section from a previous control system design. The prior design is already proven, and development time is available for the newer aspects of the control system. This building-block method can also be used to structure university laboratory exercises for EET (Electrical Engineering Technology) industrial controls design courses. Reusing software sections from previous laboratories can enhance the student’s design capability by focusing lab time on the new problem instead of recreating the old structures. This paper describes a semester-long industrial controls laboratory using programmable logic controllers (PLC) as the primary lab equipment. It describes twelve increasingly difficult PLC laboratory experiments that generally build on the components of the prior labs. The final lab assignment is an open-ended team project to design a complete system for a typical industrial machine or process. All of the PLCs are networked to provide the students with communications content within the lab experience. The pedagogical features of the laboratory exercises are illustrated and results from student comments and numerical ratings of the effectiveness of the lab exercises and equipment are also included in the paper

An improved cell controller for the aerospace manufacturing

The aerospace manufacturing industry is unique in that production typically focuses on high variety and quality but low volume. Existing flexible manufacturing cells are limited to certain types of machines, robots and cells which makes it difficult to introduce any changes. In this paper idea of treating machines, robots, any hardware and software as resource has been introduced. It describes the development of the Flexa Cell Coordinator (FCC), a system that is providing a solution to manage cells and their resources in a new flexible manner. It can control, organise and coordinate between cells and resources and is capable of controlling remote cells because of its distributed nature. It also provides connectivity with company systems e.g., Enterprise Resource Planner (ERP). It is extendable and capable of adding multiple cells inside the system. In FCC resources (e.g., tracker) can also be shared between cells. The paper presents its development and results of initial successful testing

Web-based CBR (case-based reasoning) as a tool with the application to tooling selection

Over the past few years, manufacturing companies have had to deal with an increasing demand for feature-rich products at low costs. The pressures exerted on their existing manufacturing processes have lead manufacturers to investigate internet-based solutions, in order to cope with growing competition. The decentralisation phenomenon also came up as a reason to implement networked-application, which has been the starting point for internet/intranet–based systems. Today, the availability of powerful and low cost 3D tools, database backend systems, along with web-based technologies, provides interesting opportunities to the manufacturing community, with solutions directly implementable at the core of their businesses and organisations. In this paper a web-based engineering approach is presented to developing a design support system using case-based reasoning (CBR) technology for helping in the decision-making process when choosing cutting tools. The system aims to provide on-line intelligent support for determining the most suitable configuration for turning operations, based on initial parameters and requirements for the cutting operation. The system also features a user-driven 3D turning simulator which allows testing the chosen insert for several turning operations. The system aims to be a useful e-manufacturing tool being able to quickly and responsively provide tooling data in a highly interactive way

Development of Client-Server Application by Using UDP Socket Programming for Remotely Monitoring CNC Machine Environment in Fixture Process

The use of computer technology in manufacturing industries can improve manufacturing flexibility significantly, especially in manufacturing processes; many software applications have been utilized to improve machining performance. However, none of them has discussed the abilities to perform direct machining. In this paper, an integrated system for remote operation and monitoring of Computer Numerical Control (CNC) machines is put into consideration. The integrated system includes computerization, network technology, and improved holding mechanism. The work proposed by this research is mainly on the software development for such integrated system. It uses Java three-dimensional (3D) programming and Virtual Reality Modeling Language (VRML) at the client side for visualization of machining environment. This research is aimed at developing a control system to remotely operate and monitor a self-reconfiguration fixture mechanism of a CNC milling machine through internet connection and integration of Personal Computer (PC)-based CNC controller, a server side, a client side and CNC milling. The performance of the developed system was evaluated by testing with one type of common protocols particularly User Datagram Protocol (UDP). Using UDP, the developed system requires 3.9 seconds to complete the close clamping, less than 1 second to release the clamping and it can deliver 463 KiloByte