Manufacturing Systems Line Balancing using Max-Plus Algebra

In today\u27s dynamic environment, particularly the manufacturing sector, the necessity of being agile, and flexible is far greater than before. Decision makers should be equipped with effective tools, methods, and information to respond to the market\u27s rapid changes. Modelling a manufacturing system provides unique insight into its behavior and allows simulating all crucial elements that have a role in the system performance. Max-Plus Algebra is a mathematical tool that can model a Discrete Event Dynamic System in the form of linear equations. Whereas Max-Plus Algebra was introduced after the 1980s, the number of studies regarding this tool and its applications is fewer than regarding Petri Nets, Automata, Markov process, Discrete Even Simulation and Queuing models. Consequently, Max-Plus Algebra needs to be applied and tested in many systems in order to explore hidden aspects of its function and capabilities. To work effectively; the production/assembly line should be balanced. Line balancing is one of the manufacturing functions that tries to divide work equally across the production flow. Car Headlight Manufacturing Line as a Discrete Manufacturing System is considered which is a combination of manufacturing and assembly lines composed of different stations. Seven system scenarios were modeled and analyzed using Max-Plus to balance the car headlights production line. Key Performance Indicators (KPIs) are used to compare the various scenarios including Cycle Time, Average Deliver Rate, Total Processing Lead Time, Stations\u27 Utilization Rate, Idle Time, Efficiency, and Financial Analysis. FlexSim simulation software is used to validate the Max-Plus models results and its advantages and drawbacks compared with Max-Plus Algebra. This study is a unique application of Max-Plus Algebra in line balancing of a manufacturing system. Moreover, the problem size of the considered model is at least twice (12 stations) that of previous studies. In the matter of complexity, seven different scenarios are developed through the combination of parallel stations and buffers. Due to that the last scenario is included four parallel stations plus two buffers Based on the findings, the superiority of scenario 7 compared to other scenarios is proved due to its lowest system delivering first output time (14 seconds), best average delivery rate (24.5 seconds), shortest cycle time (736 seconds), shortest total processing lead time (11,534 seconds), least percentage of idle time (12%), lowest unit cost ($6.9), and highest efficiency (88%). However, Scenario 4 has the best utilization rate at 75%

On Max-Plus Linear Dynamical System Theory: The Regulation Problem

A class of timed discrete event systems can be modeled by using Timed-Event Graphs, a class of timed Petri nets that can have its firing dynamic described by using an algebra called “Max-plus algebra”. For this kind of systems it may be desirable to enforce some timing constraints in steady state. In this paper, this problem is called a “max-plus regulation problem”. In this context we show a necessary condition for solving these regulation problems and in addition that this condition is sufficient for a large class of problems. The obtained controller is a simple linear static state feedback and can be computed using efficient pseudo-polynomial algorithms. Simulation results will illustrate the applicability of the proposed methodology

A Smart Products Lifecycle Management (sPLM) Framework - Modeling for Conceptualization, Interoperability, and Modularity

Autonomy and intelligence have been built into many of today’s mechatronic products, taking advantage of low-cost sensors and advanced data analytics technologies. Design of product intelligence (enabled by analytics capabilities) is no longer a trivial or additional option for the product development. The objective of this research is aimed at addressing the challenges raised by the new data-driven design paradigm for smart products development, in which the product itself and the smartness require to be carefully co-constructed. A smart product can be seen as specific compositions and configurations of its physical components to form the body, its analytics models to implement the intelligence, evolving along its lifecycle stages. Based on this view, the contribution of this research is to expand the “Product Lifecycle Management (PLM)” concept traditionally for physical products to data-based products. As a result, a Smart Products Lifecycle Management (sPLM) framework is conceptualized based on a high-dimensional Smart Product Hypercube (sPH) representation and decomposition. First, the sPLM addresses the interoperability issues by developing a Smart Component data model to uniformly represent and compose physical component models created by engineers and analytics models created by data scientists. Second, the sPLM implements an NPD3 process model that incorporates formal data analytics process into the new product development (NPD) process model, in order to support the transdisciplinary information flows and team interactions between engineers and data scientists. Third, the sPLM addresses the issues related to product definition, modular design, product configuration, and lifecycle management of analytics models, by adapting the theoretical frameworks and methods for traditional product design and development. An sPLM proof-of-concept platform had been implemented for validation of the concepts and methodologies developed throughout the research work. The sPLM platform provides a shared data repository to manage the product-, process-, and configuration-related knowledge for smart products development. It also provides a collaborative environment to facilitate transdisciplinary collaboration between product engineers and data scientists

Dynamic optimization of energy systems with thermal energy storage

textThermal energy storage (TES), the storage of heat or cooling, is a cost-effective energy storage technology that can greatly enhance the performance of the energy systems with which it interacts. TES acts as a buffer between transient supply and demand of energy. In solar thermal systems, TES enables the power output of the plant to be effectively regulated, despite fluctuating solar irradiance. In district energy systems, TES can be used to shift loads, allowing the system to avoid or take advantage of peak energy prices. The benefit of TES, however, can be significantly enhanced by dynamically optimizing the complete energy system. The ability of TES to shift loads gives the system newfound degrees of freedom which can be exploited to yield optimal performance. In the hybrid solar thermal/fossil fuel system explored in this work, the use of TES enables the system to extract nearly 50% more solar energy when the system is optimized. This requires relaxing some constraints, such as fixed temperature and power control, and dynamically optimizing the over a one-day time horizon. In a district cooling system, TES can help equipment to run more efficiently, by shifting cooling loads, not only between chillers, but temporally, allowing the system to take advantage of the most efficient times for running this equipment. This work also highlights the use of TES in a district energy system, where heat, cooling and electrical power are generated from central locations. Shifting the cooling load frees up electrical generation capacity, which is used to sell power to the grid at peak prices. The combination of optimization, TES, and participation in the electricity market yields a 16% cost savings. The problems encountered in this work require modeling a diverse range of systems including the TES, the solar power plant, boilers, gas and steam turbines, heat recovery equipment, chillers, and pumps. These problems also require novel solution methods that are efficient and effective at obtaining workable solutions. A simultaneous solution method is used for optimizing the solar power plant, while a static/dynamic decoupling method is used for the district energy system.Chemical Engineerin

Mobile Robotics

The book is a collection of ten scholarly articles and reports of experiences and perceptions concerning pedagogical practices with mobile robotics.“This work is funded by CIEd – Research Centre on Education, project UID/CED/01661/2019, Institute of Education, University of Minho, through national funds of FCT/MCTES-PT.