Intelligent systems in manufacturing: current developments and future prospects

Global competition and rapidly changing customer requirements are demanding increasing changes in manufacturing environments. Enterprises are required to constantly redesign their products and continuously reconfigure their manufacturing systems. Traditional approaches to manufacturing systems do not fully satisfy this new situation. Many authors have proposed that artificial intelligence will bring the flexibility and efficiency needed by manufacturing systems. This paper is a review of artificial intelligence techniques used in manufacturing systems. The paper first defines the components of a simplified intelligent manufacturing systems (IMS), the different Artificial Intelligence (AI) techniques to be considered and then shows how these AI techniques are used for the components of IMS

Approach Tolerance in the Assemblies of Evolutionary Hybrid Prototypes

A new answer is proposed to replace the traditional “one shot” prototype (manufactured in one piece with one process): the hybrid rapid prototype. It is used to highly reduce time, cost and increase reactivity during the development times of new products. The part is decomposed in several components which can quickly be changed and can be manufactured with a process the most adapted. The main objective of the presented method is to propose an available technological assembly between the different components of the part in the respect of technological and topological function, and initial tolerance. Using a graph of representation, fuzzy logic and a tolerance point of view, some entities are associated with a CIA (Assembly Identity Card) in accordance with evolutionary and manufacturing analysis. This work will be illustrated by an industrial tooling for plastic injection.Mechanical Engineerin

Micro-manufacturing : research, technology outcomes and development issues

Besides continuing effort in developing MEMS-based manufacturing techniques, latest effort in Micro-manufacturing is also in Non-MEMS-based manufacturing. Research and technological development (RTD) in this field is encouraged by the increased demand on micro-components as well as promised development in the scaling down of the traditional macro-manufacturing processes for micro-length-scale manufacturing. This paper highlights some EU funded research activities in micro/nano-manufacturing, and gives examples of the latest development in micro-manufacturing methods/techniques, process chains, hybrid-processes, manufacturing equipment and supporting technologies/device, etc., which is followed by a summary of the achievements of the EU MASMICRO project. Finally, concluding remarks are given, which raise several issues concerning further development in micro-manufacturing

Influence of the ratio on the mechanical properties of epoxy resin composite with diapers waste as fillers for partition panel application

Materials play significant role in the domestic economy and defense with the fast growth of science and technology field. New materials are the core of fresh technologies and the three pillars of modern science and technology are materials science, power technology and data science. The prior properties of the partition panel by using recycled diapers waste depend on the origin of waste deposits and its chemical constituents. This study presents the influence of the ratio on the mechanical properties of polymer in diapers waste reinforced with binder matrix for partition panel application. The aim of this study was to investigate the influence of different ratio of diapers waste polymer reinforced epoxy-matrix with regards to mechanical properties and morphology analysis. The polymer includes polypropylene, polystyrene, polyethylene and superabsorbent polymer (SAP) were used as reinforcing material. The tensile and bending resistance for ratio of 0.4 diapers waste polymers indicated the optimum ratio for fabricating the partition panel. Samples with 0.4 ratios of diapers waste polymers have highest stiffness of elasticity reading with 76.06 MPa. A correlation between the micro structural analysis using scanning electron microscope (SEM) and the mechanical properties of the material has been discussed

From computer-aided to intelligent machining: Recent advances in computer numerical control machining research

The aim of this paper is to provide an introduction and overview of recent advances in the key technologies and the supporting computerized systems, and to indicate the trend of research and development in the area of computational numerical control machining. Three main themes of recent research in CNC machining are simulation, optimization and automation, which form the key aspects of intelligent manufacturing in the digital and knowledge based manufacturing era. As the information and knowledge carrier, feature is the efficacious way to achieve intelligent manufacturing. From the regular shaped feature to freeform surface feature, the feature technology has been used in manufacturing of complex parts, such as aircraft structural parts. The authors’ latest research in intelligent machining is presented through a new concept of multi-perspective dynamic feature (MpDF), for future discussion and communication with readers of this special issue. The MpDF concept has been implemented and tested in real examples from the aerospace industry, and has the potential to make promising impact on the future research in the new paradigm of intelligent machining. The authors of this paper are the guest editors of this special issue on computational numerical control machining. The guest editors have extensive and complementary experiences in both academia and industry, gained in China, USA and UK

A Survey of Automated Process Planning Approaches in Machining

Global industrial trend is shifting towards next industrial revolution Industry 4.0. It is becoming increasingly important for modern manufacturing industries to develop a Computer Integrated Manufacturing (CIM) system by integrating the various operational and information processing functions in design and manufacturing. In spite of being active in research for almost four decades, it is clear that new functionalities are needed to integrate and realize a completely optimal process planning which can be fully compliant towards Smart Factory. In order to develop a CIM system, Computer Aided Process Planning (CAPP) plays a key role and therefore it has been the focus of many researchers. In order to gain insight into the current state-of-the-art of CAPP methodologies, 96 research papers have been reviewed. Subsequent sections discuss the different CAPP approaches adopted by researchers to automate different process planning tasks. This paper aims at addressing the key approaches involved and future directions towards Smart Manufacturing

Major challenges in prognostics: study on benchmarking prognostic datasets

Even though prognostics has been defined to be one of the most difficult tasks in Condition Based Maintenance (CBM), many studies have reported promising results in recent years. The nature of the prognostics problem is different from diagnostics with its own challenges. There exist two major approaches to prognostics: data-driven and physics-based models. This paper aims to present the major challenges in both of these approaches by examining a number of published datasets for their suitability for analysis. Data-driven methods require sufficient samples that were run until failure whereas physics-based methods need physics of failure progression

AI and OR in management of operations: history and trends

The last decade has seen a considerable growth in the use of Artificial Intelligence (AI) for operations management with the aim of finding solutions to problems that are increasing in complexity and scale. This paper begins by setting the context for the survey through a historical perspective of OR and AI. An extensive survey of applications of AI techniques for operations management, covering a total of over 1200 papers published from 1995 to 2004 is then presented. The survey utilizes Elsevier's ScienceDirect database as a source. Hence, the survey may not cover all the relevant journals but includes a sufficiently wide range of publications to make it representative of the research in the field. The papers are categorized into four areas of operations management: (a) design, (b) scheduling, (c) process planning and control and (d) quality, maintenance and fault diagnosis. Each of the four areas is categorized in terms of the AI techniques used: genetic algorithms, case-based reasoning, knowledge-based systems, fuzzy logic and hybrid techniques. The trends over the last decade are identified, discussed with respect to expected trends and directions for future work suggested

Online Tool Condition Monitoring Based on Parsimonious Ensemble+

Accurate diagnosis of tool wear in metal turning process remains an open challenge for both scientists and industrial practitioners because of inhomogeneities in workpiece material, nonstationary machining settings to suit production requirements, and nonlinear relations between measured variables and tool wear. Common methodologies for tool condition monitoring still rely on batch approaches which cannot cope with a fast sampling rate of metal cutting process. Furthermore they require a retraining process to be completed from scratch when dealing with a new set of machining parameters. This paper presents an online tool condition monitoring approach based on Parsimonious Ensemble+, pENsemble+. The unique feature of pENsemble+ lies in its highly flexible principle where both ensemble structure and base-classifier structure can automatically grow and shrink on the fly based on the characteristics of data streams. Moreover, the online feature selection scenario is integrated to actively sample relevant input attributes. The paper presents advancement of a newly developed ensemble learning algorithm, pENsemble+, where online active learning scenario is incorporated to reduce operator labelling effort. The ensemble merging scenario is proposed which allows reduction of ensemble complexity while retaining its diversity. Experimental studies utilising real-world manufacturing data streams and comparisons with well known algorithms were carried out. Furthermore, the efficacy of pENsemble was examined using benchmark concept drift data streams. It has been found that pENsemble+ incurs low structural complexity and results in a significant reduction of operator labelling effort.Comment: this paper has been published by IEEE Transactions on Cybernetic

A multi-perspective dynamic feature concept in adaptive NC machining of complex freeform surfaces

This paper presents a new concept of feature for freeform surface machining that defines the changes in feature status during real manufacturing situations which have not been sufficiently addressed by current international standards and previous research in feature technology. These changes are multi-perspective, including (i) changes in depth-of-cut: the geometry of a feature in the depth-of-cut direction changes during different machining operations such as roughing, semi-finishing and finishing; (ii) changes across the surface: a surface may be divided into different machining regions (effectively sub-features) for the selection of appropriate manufacturing methods for each region such as different cutting tools, parameters, set-ups or machine tools; and (iii) changes in resources or manufacturing capabilities may require the re-planning of depth-of-cuts, division of machining regions and manufacturing operations (machines, tools, set-ups and parameters). Adding the above dynamic information to the part information models in current CAD systems (which only represent the final state of parts) would significantly improve the accuracy, efficiency and timeliness of manufacturing planning and optimisation, especially for the integrated NC machining planning for complex freeform surfaces. A case study in an aircraft manufacturing company will be included in this paper