Constraint-Aware, Scalable, and Efficient Algorithms for Multi-Chip Power Module Layout Optimization

Moving towards an electrified world requires ultra high-density power converters. Electric vehicles, electrified aerospace, data centers, etc. are just a few fields among wide application areas of power electronic systems, where high-density power converters are essential. As a critical part of these power converters, power semiconductor modules and their layout optimization has been identified as a crucial step in achieving the maximum performance and density for wide bandgap technologies (i.e., GaN and SiC). New packaging technologies are also introduced to produce reliable and efficient multichip power module (MCPM) designs to push the current limits. The complexity of the emerging MCPM layouts is surpassing the capability of a manual, iterative design process to produce an optimum design with agile development requirements. An electronic design automation tool called PowerSynth has been introduced with ongoing research toward enhanced capabilities to speed up the optimized MCPM layout design process. This dissertation presents the PowerSynth progression timeline with the methodology updates and corresponding critical results compared to v1.1. The first released version (v1.1) of PowerSynth demonstrated the benefits of layout abstraction, and reduced-order modeling techniques to perform rapid optimization of the MCPM module compared to the traditional, manual, and iterative design approach. However, that version is limited by several key factors: layout representation technique, layout generation algorithms, iterative design-rule-checking (DRC), optimization algorithm candidates, etc. To address these limitations, and enhance PowerSynth’s capabilities, constraint-aware, scalable, and efficient algorithms have been developed and implemented. PowerSynth layout engine has evolved from v1.3 to v2.0 throughout the last five years to incorporate the algorithm updates and generate all 2D/2.5D/3D Manhattan layout solutions. These fundamental changes in the layout generation methodology have also called for updates in the performance modeling techniques and enabled exploring different optimization algorithms. The latest PowerSynth 2 architecture has been implemented to enable electro-thermo-mechanical and reliability optimization on 2D/2.5D/3D MCPM layouts, and set up a path toward cabinet-level optimization. PowerSynth v2.0 computer-aided design (CAD) flow has been hardware-validated through manufacturing and testing of an optimized novel 3D MCPM layout. The flow has shown significant speedup compared to the manual design flow with a comparable optimization result

Challenges and Status on Design and Computation for Emerging Additive Manufacturing Technologies

The revolution of additive manufacturing (AM) has led to many opportunities in fabricating complex and novel products. The increase of printable materials and the emergence of novel fabrication processes continuously expand the possibility of engineering systems in which product components are no longer limited to be single material, single scale, or single function. In fact, a paradigm shift is taking place in industry from geometry-centered usage to supporting functional demands. Consequently, engineers are expected to resolve a wide range of complex and difficult problems related to functional design. Although a higher degree of design freedom beyond geometry has been enabled by AM, there are only very few computational design approaches in this new AM-enabled domain to design objects with tailored properties and functions. The objectives of this review paper are to provide an overview of recent additive manufacturing developments and current computer-aided design methodologies that can be applied to multimaterial, multiscale, multiform, and multifunctional AM technologies. The difficulties encountered in the computational design approaches are summarized and the future development needs are emphasized. In the paper, some present applications and future trends related to additive manufacturing technologies are also discussed

Smart Manufacturing

This book is a collection of 11 articles that are published in the corresponding Machines Special Issue “Smart Manufacturing”. It represents the quality, breadth and depth of the most updated study in smart manufacturing (SM); in particular, digital technologies are deployed to enhance system smartness by (1) empowering physical resources in production, (2) utilizing virtual and dynamic assets over the Internet to expand system capabilities, (3) supporting data-driven decision-making activities at various domains and levels of businesses, or (4) reconfiguring systems to adapt to changes and uncertainties. System smartness can be evaluated by one or a combination of performance metrics such as degree of automation, cost-effectiveness, leanness, robustness, flexibility, adaptability, sustainability, and resilience. This book features, firstly, the concepts digital triad (DT-II) and Internet of digital triad things (IoDTT), proposed to deal with the complexity, dynamics, and scalability of complex systems simultaneously. This book also features a comprehensive survey of the applications of digital technologies in space instruments; a systematic literature search method is used to investigate the impact of product design and innovation on the development of space instruments. In addition, the survey provides important information and critical considerations for using cutting edge digital technologies in designing and manufacturing space instruments

Digital fabrication of custom interactive objects with rich materials

As ubiquitous computing is becoming reality, people interact with an increasing number of computer interfaces embedded in physical objects. Today, interaction with those objects largely relies on integrated touchscreens. In contrast, humans are capable of rich interaction with physical objects and their materials through sensory feedback and dexterous manipulation skills. However, developing physical user interfaces that offer versatile interaction and leverage these capabilities is challenging. It requires novel technologies for prototyping interfaces with custom interactivity that support rich materials of everyday objects. Moreover, such technologies need to be accessible to empower a wide audience of researchers, makers, and users. This thesis investigates digital fabrication as a key technology to address these challenges. It contributes four novel design and fabrication approaches for interactive objects with rich materials. The contributions enable easy, accessible, and versatile design and fabrication of interactive objects with custom stretchability, input and output on complex geometries and diverse materials, tactile output on 3D-object geometries, and capabilities of changing their shape and material properties. Together, the contributions of this thesis advance the fields of digital fabrication, rapid prototyping, and ubiquitous computing towards the bigger goal of exploring interactive objects with rich materials as a new generation of physical interfaces.Computer werden zunehmend in Geräten integriert, mit welchen Menschen im Alltag interagieren. Heutzutage basiert diese Interaktion weitgehend auf Touchscreens. Im Kontrast dazu steht die reichhaltige Interaktion mit physischen Objekten und Materialien durch sensorisches Feedback und geschickte Manipulation. Interfaces zu entwerfen, die diese Fähigkeiten nutzen, ist allerdings problematisch. Hierfür sind Technologien zum Prototyping neuer Interfaces mit benutzerdefinierter Interaktivität und Kompatibilität mit vielfältigen Materialien erforderlich. Zudem sollten solche Technologien zugänglich sein, um ein breites Publikum zu erreichen. Diese Dissertation erforscht die digitale Fabrikation als Schlüsseltechnologie, um diese Probleme zu adressieren. Sie trägt vier neue Design- und Fabrikationsansätze für das Prototyping interaktiver Objekte mit reichhaltigen Materialien bei. Diese ermöglichen einfaches, zugängliches und vielseitiges Design und Fabrikation von interaktiven Objekten mit individueller Dehnbarkeit, Ein- und Ausgabe auf komplexen Geometrien und vielfältigen Materialien, taktiler Ausgabe auf 3D-Objektgeometrien und der Fähigkeit ihre Form und Materialeigenschaften zu ändern. Insgesamt trägt diese Dissertation zum Fortschritt der Bereiche der digitalen Fabrikation, des Rapid Prototyping und des Ubiquitous Computing in Richtung des größeren Ziels, der Exploration interaktiver Objekte mit reichhaltigen Materialien als eine neue Generation von physischen Interfaces, bei

ReSCon '09, Research Student Conference: Book of Abstracts

The second SED Research Student Conference (ReSCon2009) was hosted over three days, 22-24 June 2009, in the Lecture Centre at Brunel University. The conference consisted of technical presentations, a poster session and social events. The abstracts and presentations were the result of ongoing research by postgraduate research students from the School of Engineering and Design at Brunel University. The conference is held annually, and ReSCon plays a key role in contributing to research and innovations within the School

MakerFluidics: low cost microfluidics for synthetic biology

Recent advancements in multilayer, multicellular, genetic logic circuits often rely on manual intervention throughout the computation cycle and orthogonal signals for each chemical “wire”. These constraints can prevent genetic circuits from scaling. Microfluidic devices can be used to mitigate these constraints. However, continuous-flow microfluidics are largely designed through artisanal processes involving hand-drawing features and accomplishing design rule checks visually: processes that are also inextensible. Additionally, continuous-flow microfluidic routing is only a consideration during chip design and, once built, the routing structure becomes “frozen in silicon,” or for many microfluidic chips “frozen in polydimethylsiloxane (PDMS)”; any changes to fluid routing often require an entirely new device and control infrastructure. The cost of fabricating and controlling a new device is high in terms of time and money; attempts to reduce one cost measure are, generally, paid through increases in the other. This work has three main thrusts: to create a microfluidic fabrication framework, called MakerFluidics, that lowers the barrier to entry for designing and fabricating microfluidics in a manner amenable to automation; to prove this methodology can design, fabricate, and control complex and novel microfluidic devices; and to demonstrate the methodology can be used to solve biologically-relevant problems. Utilizing accessible technologies, rapid prototyping, and scalable design practices, the MakerFluidics framework has demonstrated its ability to design, fabricate and control novel, complex and scalable microfludic devices. This was proven through the development of a reconfigurable, continuous-flow routing fabric driven by a modular, scalable primitive called a transposer. In addition to creating complex microfluidic networks, MakerFluidics was deployed in support of cutting-edge, application-focused research at the Charles Stark Draper Laboratory. Informed by a design of experiments approach using the parametric rapid prototyping capabilities made possible by MakerFluidics, a plastic blood--bacteria separation device was optimized, demonstrating that the new device geometry can separate bacteria from blood while operating at 275% greater flow rate as well as reduce the power requirement by 82% for equivalent separation performance when compared to the state of the art. Ultimately, MakerFluidics demonstrated the ability to design, fabricate, and control complex and practical microfluidic devices while lowering the barrier to entry to continuous-flow microfluidics, thus democratizing cutting edge technology beyond a handful of well-resourced and specialized labs

Ono: an open platform for social robotics

In recent times, the focal point of research in robotics has shifted from industrial ro- bots toward robots that interact with humans in an intuitive and safe manner. This evolution has resulted in the subfield of social robotics, which pertains to robots that function in a human environment and that can communicate with humans in an int- uitive way, e.g. with facial expressions. Social robots have the potential to impact many different aspects of our lives, but one particularly promising application is the use of robots in therapy, such as the treatment of children with autism. Unfortunately, many of the existing social robots are neither suited for practical use in therapy nor for large scale studies, mainly because they are expensive, one-of-a-kind robots that are hard to modify to suit a specific need. We created Ono, a social robotics platform, to tackle these issues. Ono is composed entirely from off-the-shelf components and cheap materials, and can be built at a local FabLab at the fraction of the cost of other robots. Ono is also entirely open source and the modular design further encourages modification and reuse of parts of the platform

A petri-net based methodology for modeling, simulation, and control of flexible manufacturing systems

Global competition has made it necessary for manufacturers to introduce such advanced technologies as flexible and agile manufacturing, intelligent automation, and computer-integrated manufacturing. However, the application extent of these technologies varies from industry to industry and has met various degrees of success. One critical barrier leading to successful implementation of advanced manufacturing systems is the ever-increasing complexity in their modeling, analysis, simulation, and control. The purpose of this work is to introduce a set of Petri net-based tools and methods to address a variety of problems associated with the design and implementation of flexible manufacturing systems (FMSs). More specifically, this work proposes Petri nets as an integrated tool for modeling, simulation, and control of flexible manufacturing systems (FMSs). The contributions of this work are multifold. First, it demonstrates a new application of PNs for simulation by evaluating the performance of pull and push diagrams in manufacturing systems. Second, it introduces a class of PNs, Augmented-timed Petri nets (ATPNs) in order to increase the power of PNs to simulate and control flexible systems with breakdowns. Third, it proposes a new class of PNs called Realtime Petri nets (RTPNs) for discrete event control of FMS s. The detailed comparison between RTPNs and traditional discrete event methods such as ladder logic diagrams is presented to answer the basic question \u27Why is a PN better tool than ladder logic diagram?\u27 and to justify the PN method. Also, a conversion procedure that automatically generates PN models from a given class of logic control specifications is presented. Finally, a methodology that uses PNs for the development of object-oriented control software is proposed. The present work extends the PN state-of-the-art in two ways. First, it offers a wide scope for engineers and managers who are responsible for the design and the implementation of modem manufacturing systems to evaluate Petri nets for applications in their work. Second, it further develops Petri net-based methods for discrete event control of manufacturing systems