Product, process and resource model coupling for knowledge-driven assembly automation

: Accommodating frequent product changes in a short period of time is a challenging task due to limitations of the contemporary engineering approach to design, build and reconfigure automation systems. In particular, the growing quantity and diversity of manufacturing information, and the increasing need to exchange and reuse this information in an efficient way has become a bottleneck. To improve the engineering process, digital manufacturing and Product, Process and Resource (PPR) modelling are considered very promising to compress development time and engineering cost by enabling efficient design and reconfiguration of manufacturing resources. However, due to ineffective coupling of PPR data, design and reconfiguration of assembly systems are still challenging tasks due to the dependency on the knowledge and experience of engineers. This paper presents an approach for data models integration that can be employed for coupling the PPR domain models for matching the requirements of products for assembly automation. The approach presented in this paper can be used effectively to link data models from various engineering domains and engineering tools. For proof of concept, an example implementation of the approach for modelling and integration of PPR for a Festo test rig is presented as a case study

Extending product lifecycle management for manufacturing knowledge sharing

Product lifecycle management provides a framework for information sharing that promotes various types of decisionmaking procedures. For product lifecycle management to advance towards knowledge-driven decision support, then this demands more than simply exchanging information. There is, therefore, a need to formally capture best practice through-life engineering knowledge that can be fed back across the product lifecycle. This article investigates the interoperable manufacturing knowledge systems concept. Interoperable manufacturing knowledge systems use an expressive ontological approach that drives the improved configuration of product lifecycle management systems for manufacturing knowledge sharing. An ontology of relevant core product lifecycle concepts is identified from which viewpoint-specific domains, such as design and manufacture, can be formalised. Essential ontology-based mechanisms are accommodated to support the verification and sharing of manufacturing knowledge across domains. The work has been experimentally assessed using an aerospace compressor disc design and manufacture example. While it has been demonstrated that the approach supports the representation of disparate design and manufacture perspectives as well as manufacturing knowledge feedback in a timely manner, areas for improvement have also been identified for future work

An autonomous satellite architecture integrating deliberative reasoning and behavioural intelligence

This paper describes a method for the design of autonomous spacecraft, based upon behavioral approaches to intelligent robotics. First, a number of previous spacecraft automation projects are reviewed. A methodology for the design of autonomous spacecraft is then presented, drawing upon both the European Space Agency technological center (ESTEC) automation and robotics methodology and the subsumption architecture for autonomous robots. A layered competency model for autonomous orbital spacecraft is proposed. A simple example of low level competencies and their interaction is presented in order to illustrate the methodology. Finally, the general principles adopted for the control hardware design of the AUSTRALIS-1 spacecraft are described. This system will provide an orbital experimental platform for spacecraft autonomy studies, supporting the exploration of different logical control models, different computational metaphors within the behavioral control framework, and different mappings from the logical control model to its physical implementation

An application of physical flexibility and software reconfigurability for the automation of battery module assembly

Batteries are a strategic technology to decarbonize conventional automotive powertrains and enable energy policy turnaround from fossil fuels to renewable energy. The demand for battery packs is rising, but they remain unable to compete with conventional technologies, primarily due to higher costs. Major sources of cost remain in manufacturing and assembly. These costs can be attributed to a need for high product quality, material handling complexity, uncertain and fluctuating production volumes, and an unpredictable breadth of product variants. This research paper applies the paradigms of flexibility from a mechanical engineering perspective, and reconfigurability from a software perspective to form a holistic, integrated manufacturing solution to better realize product variants. This allows manufacturers to de-risk investment as there is increased confidence that a facility can meet new requirements with reduced effort, and also shows how part of the vision of Industry 4.0 associated with the integration and exploitation of data can be fulfilled. A functional decomposition of battery packs is used to develop a foundational understanding of how changes in customer requirements can result in physical product changes. A Product, Process, and Resource (PPR) methodology is employed to link physical product characteristics to physical and logical characteristics of resources. This mapping is leveraged to enable the design of a gripper with focused flexibility by the Institute for Machine Tools and Industrial Management (iwb) at the Technical University of Munich, as it is acknowledged that mechanical changes are challenging to realize within industrial manufacturing facilities. Reconfigurability is realised through exploitation of data integration across the PPR domains, through the extension of the capabilities of a non-commercial virtual engineering toolset developed by the Automation Systems Group at the University of Warwick. The work shows an “end-to-end” approach that practically demonstrates the application of the flexibility and reconfigurability paradigms within an industrial engineering context

Ontology-Based Data Integration in Multi-Disciplinary Engineering Environments: A Review

Today's industrial production plants are complex mechatronic systems. In the course of the production plant lifecycle, engineers from a variety of disciplines (e.g., mechanics, electronics, automation) need to collaborate in multi-disciplinary settings that are characterized by heterogeneity in terminology, methods, and tools. This collaboration yields a variety of engineering artifacts that need to be linked and integrated, which on the technical level is reflected in the need to integrate heterogeneous data. Semantic Web technologies, in particular ontologybased data integration (OBDI), are promising to tackle this challenge that has attracted strong interest from the engineering research community. This interest has resulted in a growing body of literature that is dispersed across the Semantic Web and Automation System Engineering research communities and has not been systematically reviewed so far. We address this gap with a survey reflecting on OBDI applications in the context of Multi-Disciplinary Engineering Environment (MDEE). To this end, we analyze and compare 23 OBDI applications from both the Semantic Web and the Automation System Engineering research communities. Based on this analysis, we (i) categorize OBDI variants used in MDEE, (ii) identify key problem context characteristics, (iii) compare strengths and limitations of OBDI variants as a function of problem context, and (iv) provide recommendation guidelines for the selection of OBDI variants and technologies for OBDI in MDEE

An Application of Physical Flexibility and Software Reconfigurability for the Automation of Battery Module Assembly

Batteries are a strategic technology to decarbonize conventional automotive powertrains and enable energy policy turnaround from fossil fuels to renewable energy. The demand for battery packs is rising, but they remain unable to compete with conventional technologies, primarily due to higher costs. Major sources of cost remain in manufacturing and assembly. These costs can be attributed to a need for high product quality, material handling complexity, uncertain and fluctuating production volumes, and an unpredictable breadth of product variants. This research paper applies the paradigms of flexibility from a mechanical engineering perspective, and reconfigurability from a software perspective to form a holistic, integrated manufacturing solution to better realize product variants. This allows manufacturers to de-risk investment as there is increased confidence that a facility can meet new requirements with reduced effort, and also shows how part of the vision of Industry 4.0 associated with the integration and exploitation of data can be fulfilled. A functional decomposition of battery packs is used to develop a foundational understanding of how changes in customer requirements can result in physical product changes. A Product, Process, and Resource (PPR) methodology is employed to link physical product characteristics to physical and logical characteristics of resources. This mapping is leveraged to enable the design of a gripper with focused flexibility by the Institute for Machine Tools and Industrial Management (iwb) at the Technical University of Munich, as it is acknowledged that mechanical changes are challenging to realize within industrial manufacturing facilities. Reconfigurability is realised through exploitation of data integration across the PPR domains, through the extension of the capabilities of a non-commercial virtual engineering toolset developed by the Automation Systems Group at the University of Warwick. The work shows an “end-to-end” approach that practically demonstrates the application of the flexibility and reconfigurability paradigms within an industrial engineering context

A Framework for Automatically Realizing Assembly Sequence Changes in a Virtual Manufacturing Environment

© 2016 The Authors. Global market pressures and the rapid evolution of technologies and materials force manufacturers to constantly design, develop and produce new and varied products to maintain a competitive edge. Although virtual design and engineering tools have been key to supporting this fast rate of change, there remains a lack of seamless integration between and within tools across the domains of product, process, and resource design-especially to accommodate change. This research examines how changes to designs within these three domains can be captured and evaluated within a component based engineering tool (vueOne, developed by the Automation Systems Group at the University of Warwick). This paper describes how and where data within these tools can be mapped to quickly evaluate change (where typically a tedious process of data entry is required) decreasing lead times and cost and increasing productivity. The approach is tested on a sub-assembly of a hydrogen fuel cell, where an assembly system is modelled and changes are made to the sequence which is translated through to control logic. Although full implementation has not yet been realized, the concept has the potential to radically change the way changes are made and the approach can be extended to supporting other change types provided the appropriate rules and mapping