Development of a reconfigurable assembly system with an integrated information management system

Thesis (M. Tech. (Engineering Electrical)) -- Central University of Technology, Free State, [2014]This dissertation evaluates the software and hardware components used to develop a Reconfigurable Assembly System with an Integrated Information Management System. The assembly system consists of a modular Cartesian robot and vision system. The research focuses on the reconfigurability, modularity, scalability and flexibility that can be achieved in terms of the software and hardware components used within the system. The assembly system can be divided into high-level control and low-level control components. All information related to the product, Cartesian positioning and processes to follow resides in the Information Management System. The Information Management System is the high-level component and consists of a database, web services and low-levelcontrol drivers. The high-level system responds to the data received from the low-level systems and determines the next process to take place. The low-level systems consist of the PLC (Programmable Logic Controller) and the vision system. The PLC controls the Cartesian robot’s motor controllers and handles all events raised by field devices (e g. sensors or push buttons). The vision system contains a number of pre-loaded inspections used to identify barcodes and parts, obtain positioning data and verify the products’ build quality. The Cartesian robot’s positioning data and the vision system’s inspections are controlled by the Information Management System. The results showed that the high-level control software components are able to add more modularity and reconfigurability to the system, as it can easily adapt to changes in the product. The high-level control components also have the ability to be reconfigured while the assembly system is online without affecting the assembly system. The low-level control system is better suited to handling the control of motor controllers, field devices and vision inspections over an industrial network

Assembly-setup verification and quality control using machine vision within a reconfigurable assembly system

Thesis (M. Tech. (Engineering: Electrical)) -- Central University of technology, Free State, [2014]The project is aimed at exploring the application of Machine Vision in a Reconfigurable Manufacturing System (RMS) Environment. The Machine Vision System interfaces with the RMS to verify the reconfiguration and positioning of devices within the assembly system, and inspects the product for defects that infringe on the quality of that product. The vision system interfaces to the Multi-agent System (MAS), which is in charge of scheduling and allocating resources of the RMS, in order to communicate and exchange data regarding the quality of the product. The vision system is comprised of a Compact Vision System (CVS) device with fire-wire cameras to aid in the image acquisition, inspection and verification process. Various hardware and software manufacturers offer a platform to implement this with a multiple array of vision equipment and software packages. The most appropriate devices and software platform were identified for the implementation of the project. An investigation into illumination was also undertaken in order to determine whether external lighting sources would be required at the point of inspection. Integration into the assembly system involved the establishment communication between the vision system and assembly system controller

Reconfigurable and transportable container-integrated production system

In this paper, the concept and the prototype realization of a novel reconfigurable small-footprint manufacturing system in a transportable container is presented. The containerized format enables transportation of the system to provide on-site manufacturing, enabling the benefits of localized service delivery without duplication of equipment at multiple locations. Three industrial product use cases with varying manufacturing and performance requirements were analyzed. All of the use cases demanded highly customized products with high quality in low production volumes. Based on their requirements, a general system specification was derived and used to develop a concept for the container-integrated factory. A reconfigurable, modular manufacturing system is integral to the overall container concept. Production equipment was integrated in the form of interchangeable process modules, which can be quickly connected by standard utility supply and control interfaces. A modular and self-configuring control system provides assisted production workflow programming, while a modular process chain combining Additive Manufacturing, milling, precision assembly and cleaning processes has been developed. A prototype of the container-integrated factory with reconfigurable process modules and control system has been established, with full functionality and feasibility of the system demonstrated

Flexible Automation and Intelligent Manufacturing: The Human-Data-Technology Nexus

This is an open access book. It gathers the first volume of the proceedings of the 31st edition of the International Conference on Flexible Automation and Intelligent Manufacturing, FAIM 2022, held on June 19 – 23, 2022, in Detroit, Michigan, USA. Covering four thematic areas including Manufacturing Processes, Machine Tools, Manufacturing Systems, and Enabling Technologies, it reports on advanced manufacturing processes, and innovative materials for 3D printing, applications of machine learning, artificial intelligence and mixed reality in various production sectors, as well as important issues in human-robot collaboration, including methods for improving safety. Contributions also cover strategies to improve quality control, supply chain management and training in the manufacturing industry, and methods supporting circular supply chain and sustainable manufacturing. All in all, this book provides academicians, engineers and professionals with extensive information on both scientific and industrial advances in the converging fields of manufacturing, production, and automation

Multiple vision inspections from a single control system using vision assistant software

Published ArticleThe development of a Machine Vision system involved the selection of various components that will work together in order to solve a vision problem. The vision system was tasked with verifying reconfiguration and the position of devices within the assembly system, as well as inspecting the product for defects that infringe on its quality. The aim in this article is to discuss the control and setup of the multiple vision inspections that the vision system had to perform in order to solve the assembly systems verification and quality assurance problem

An early-stage decision-support framework for the implementation of intelligent automation

The constant pressure on manufacturing companies to improve productivity, reduce the lead time and progress in quality requires new technological developments and adoption.The rapid development of smart technology and robotics and autonomous systems (RAS) technology has a profound impact on manufacturing automation and might determine winners and losers of the next generation’s manufacturing competition. Simultaneously, recent smart technology developments in the areas enable an automation response to new production paradigms such as mass customisation and product-lifecycle considerations in the context of Industry 4.0. New paradigms, like mass customisation, increased both the complexity of the tasks and the risk due to smart technology integration. From a manufacturing automation perspective, intelligent automation has been identified as a possible response to arising demands. The presented research aims to support the industrial uptake of intelligent automation into manufacturing businesses by quantifying risks at the early design stage and business case development. An early-stage decision-support framework for the implementation of intelligent automation in manufacturing businesses is presented in this thesis.The framework is informed by an extensive literature review, updated and verified with surveys and workshops to add to the knowledge base due to the rapid development of the associated technologies. A paradigm shift from cost to a risk-modelling perspective is proposed to provide a more flexible and generic approach applicable throughout the current technology landscape. The proposed probabilistic decision-support framework consists of three parts:• A clustering algorithm to identify the manufacturing functions in manual processes from task analysis to mitigate early-stage design uncertainties• A Bayesian Belief Network (BBN) informed by an expert elicitation via the DELPHI method, where the identified functions become the unit of analysis.• A Markov-Chain Monte-Carlo method modelling the effects of uncertainties on the critical success factors to address issues of factor interdependencies after expert elicitation.Based on the overall decision framework a toolbox was developed in Microsoft Excel. Five different case studies are used to test and validate the framework. Evaluation of the results derived from the toolbox from the industrial feedback suggests a positive validation for commercial use. The main contributions to knowledge in the presented thesis arise from the following four points:• Early-stage decision-support framework for business case evaluation of intelligent automation.• Translating manual tasks to automation function via a novel clustering approach• Application of a Markov-Chain Monte-Carlo Method to simulate correlation between decision criteria• Causal relationship among Critical Success Factors has been established from business and technical perspectives.The implications on practise might be promising. The feedback arising from the created tool was promising from the industry, and a practical realisation of the decision-support tool seems to be desired from an industrial point of view.With respect to further work, the decision-support tool might have established a ground to analyse a human task automatically for automation purposes. The established clustering mechanisms and the related attributes could be connected to sensorial data and analyse a manufacturing task autonomously without the subjective input of task analysis experts. To enable such an autonomous process, however, the psychophysiological understanding must be increased in the future.</div

A gabor filter-based protocol for automated image-based building detection

Detecting buildings from high-resolution satellite imagery is beneficial in mapping, environmental preparation, disaster management, military planning, urban planning and research purposes. Differentiating buildings from the images is possible however, it may be a time-consuming or complicated process. Therefore, the high-resolution imagery from satellites needs to be automated to detect the buildings. Additionally, buildings exhibit several different characteristics, and their appearance in these images is unplanned. Moreover, buildings in the metropolitan environment are typically crowded and complicated. Therefore, it is challenging to identify the building and hard tolocate them. To resolve this situation, a novel probabilistic method has been suggested using local features and probabilistic approaches. A local feature extraction technique was implemented, which was used to calculate the probability density function. The locations in the image were represented as joint probability distributions and were used to estimate their probability distribution function (pdf). The density of building locations in the image was extracted. Kernel density distribution was also used to find the density flow for different metropolitan cities such as Sydney (Australia), Tokyo (Japan), and Mumbai (India), which is useful for distribution intensity and pattern of facility point f interest (POI). The purpose system can detect buildings/rooftops and to test our system, we choose some crops with panchromatic high-resolution satellite images from Australia and our results looks promising with high efficiency and minimal computational time for feature extraction. We were able to detect buildings with shadows and building without shadows in 0.4468 (seconds) and 0.5126 (seconds) respectively