Knowledge-based Modelling of Additive Manufacturing for Sustainability Performance Analysis and Decision Making

Additiivista valmistusta on pidetty käyttökelpoisena monimutkaisissa geometrioissa, topologisesti optimoiduissa kappaleissa ja kappaleissa joita on muuten vaikea valmistaa perinteisillä valmistusprosesseilla. Eduista huolimatta, yksi additiivisen valmistuksen vallitsevista haasteista on ollut heikko kyky tuottaa toimivia osia kilpailukykyisillä tuotantomäärillä perinteisen valmistuksen kanssa. Mallintaminen ja simulointi ovat tehokkaita työkaluja, jotka voivat auttaa lyhentämään suunnittelun, rakentamisen ja testauksen sykliä mahdollistamalla erilaisten tuotesuunnitelmien ja prosessiskenaarioiden nopean analyysin. Perinteisten ja edistyneiden valmistusteknologioiden mahdollisuudet ja rajoitukset määrittelevät kuitenkin rajat uusille tuotekehityksille. Siksi on tärkeää, että suunnittelijoilla on käytettävissään menetelmät ja työkalut, joiden avulla he voivat mallintaa ja simuloida tuotteen suorituskykyä ja siihen liittyvän valmistusprosessin suorituskykyä, toimivien korkea arvoisten tuotteiden toteuttamiseksi. Motivaation tämän väitöstutkimuksen tekemiselle on, meneillään oleva kehitystyö uudenlaisen korkean lämpötilan suprajohtavan (high temperature superconducting (HTS)) magneettikokoonpanon kehittämisessä, joka toimii kryogeenisissä lämpötiloissa. Sen monimutkaisuus edellyttää monitieteisen asiantuntemuksen lähentymistä suunnittelun ja prototyyppien valmistuksen aikana. Tutkimus hyödyntää tietopohjaista mallinnusta valmistusprosessin analysoinnin ja päätöksenteon apuna HTS-magneettien mekaanisten komponenttien suunnittelussa. Tämän lisäksi, tutkimus etsii mahdollisuuksia additiivisen valmistuksen toteutettavuuteen HTS-magneettikokoonpanon tuotannossa. Kehitetty lähestymistapa käyttää fysikaalisiin kokeisiin perustuvaa tuote-prosessi-integroitua mallinnusta tuottamaan kvantitatiivista ja laadullista tietoa, joka määrittelee prosessi-rakenne-ominaisuus-suorituskyky-vuorovaikutuksia tietyille materiaali-prosessi-yhdistelmille. Tuloksina saadut vuorovaikutukset integroidaan kaaviopohjaiseen malliin, joka voi auttaa suunnittelutilan tutkimisessa ja täten auttaa varhaisessa suunnittelu- ja valmistuspäätöksenteossa. Tätä varten testikomponentit valmistetaan käyttämällä kahta metallin additiivista valmistus prosessia: lankakaarihitsaus additiivista valmistusta (wire arc additive manufacturing) ja selektiivistä lasersulatusta (selective laser melting). Rakenteellisissa sovelluksissa yleisesti käytetyistä metalliseoksista (ruostumaton teräs, pehmeä teräs, luja niukkaseosteinen teräs, alumiini ja kupariseokset) testataan niiden mekaaniset, lämpö- ja sähköiset ominaisuudet. Lisäksi tehdään metalliseosten mikrorakenteen karakterisointi, jotta voidaan ymmärtää paremmin valmistusprosessin parametrien vaikutusta materiaalin ominaisuuksiin. Integroitu mallinnustapa yhdistää kerätyn kokeellisen tiedon, olemassa olevat analyyttiset ja empiiriset vuorovaikutus suhteet, sekä muut tietopohjaiset mallit (esim. elementtimallit, koneoppimismallit) päätöksenteon tukijärjestelmän muodossa, joka mahdollistaa optimaalisen materiaalin, valmistustekniikan, prosessiparametrien ja muitten ohjausmuuttujien valinnan, lopullisen 3d-tulosteun komponentin halutun rakenteen, ominaisuuksien ja suorituskyvyn saavuttamiseksi. Valmistuspäätöksenteko tapahtuu todennäköisyysmallin, eli Bayesin verkkomallin toteuttamisen kautta, joka on vankka, modulaarinen ja sovellettavissa muihin valmistusjärjestelmiin ja tuotesuunnitelmiin. Väitöstyössä esitetyn mallin kyky parantaa additiivisien valmistusprosessien suorituskykyä ja laatua, täten edistää kestävän tuotannon tavoitteita.Additive manufacturing (AM) has been considered viable for complex geometries, topology optimized parts, and parts that are otherwise difficult to produce using conventional manufacturing processes. Despite the advantages, one of the prevalent challenges in AM has been the poor capability of producing functional parts at production volumes that are competitive with traditional manufacturing. Modelling and simulation are powerful tools that can help shorten the design-build-test cycle by enabling rapid analysis of various product designs and process scenarios. Nevertheless, the capabilities and limitations of traditional and advanced manufacturing technologies do define the bounds for new product development. Thus, it is important that the designers have access to methods and tools that enable them to model and simulate product performance and associated manufacturing process performance to realize functional high value products. The motivation for this dissertation research stems from ongoing development of a novel high temperature superconducting (HTS) magnet assembly, which operates in cryogenic environment. Its complexity requires the convergence of multidisciplinary expertise during design and prototyping. The research applies knowledge-based modelling to aid manufacturing process analysis and decision making in the design of mechanical components of the HTS magnet. Further, it explores the feasibility of using AM in the production of the HTS magnet assembly. The developed approach uses product-process integrated modelling based on physical experiments to generate quantitative and qualitative information that define process-structure-property-performance interactions for given material-process combinations. The resulting interactions are then integrated into a graph-based model that can aid in design space exploration to assist early design and manufacturing decision-making. To do so, test components are fabricated using two metal AM processes: wire and arc additive manufacturing and selective laser melting. Metal alloys (stainless steel, mild steel, high-strength low-alloyed steel, aluminium, and copper alloys) commonly used in structural applications are tested for their mechanical-, thermal-, and electrical properties. In addition, microstructural characterization of the alloys is performed to further understand the impact of manufacturing process parameters on material properties. The integrated modelling approach combines the collected experimental data, existing analytical and empirical relationships, and other data-driven models (e.g., finite element models, machine learning models) in the form of a decision support system that enables optimal selection of material, manufacturing technology, process parameters, and other control variables for attaining desired structure, property, and performance characteristics of the final printed component. The manufacturing decision making is performed through implementation of a probabilistic model i.e., a Bayesian network model, which is robust, modular, and can be adapted for other manufacturing systems and product designs. The ability of the model to improve throughput and quality of additive manufacturing processes will boost sustainable manufacturing goals

Trusted Artificial Intelligence in Manufacturing; Trusted Artificial Intelligence in Manufacturing

The successful deployment of AI solutions in manufacturing environments hinges on their security, safety and reliability which becomes more challenging in settings where multiple AI systems (e.g., industrial robots, robotic cells, Deep Neural Networks (DNNs)) interact as atomic systems and with humans. To guarantee the safe and reliable operation of AI systems in the shopfloor, there is a need to address many challenges in the scope of complex, heterogeneous, dynamic and unpredictable environments. Specifically, data reliability, human machine interaction, security, transparency and explainability challenges need to be addressed at the same time. Recent advances in AI research (e.g., in deep neural networks security and explainable AI (XAI) systems), coupled with novel research outcomes in the formal specification and verification of AI systems provide a sound basis for safe and reliable AI deployments in production lines. Moreover, the legal and regulatory dimension of safe and reliable AI solutions in production lines must be considered as well. To address some of the above listed challenges, fifteen European Organizations collaborate in the scope of the STAR project, a research initiative funded by the European Commission in the scope of its H2020 program (Grant Agreement Number: 956573). STAR researches, develops, and validates novel technologies that enable AI systems to acquire knowledge in order to take timely and safe decisions in dynamic and unpredictable environments. Moreover, the project researches and delivers approaches that enable AI systems to confront sophisticated adversaries and to remain robust against security attacks. This book is co-authored by the STAR consortium members and provides a review of technologies, techniques and systems for trusted, ethical, and secure AI in manufacturing. The different chapters of the book cover systems and technologies for industrial data reliability, responsible and transparent artificial intelligence systems, human centered manufacturing systems such as human-centred digital twins, cyber-defence in AI systems, simulated reality systems, human robot collaboration systems, as well as automated mobile robots for manufacturing environments. A variety of cutting-edge AI technologies are employed by these systems including deep neural networks, reinforcement learning systems, and explainable artificial intelligence systems. Furthermore, relevant standards and applicable regulations are discussed. Beyond reviewing state of the art standards and technologies, the book illustrates how the STAR research goes beyond the state of the art, towards enabling and showcasing human-centred technologies in production lines. Emphasis is put on dynamic human in the loop scenarios, where ethical, transparent, and trusted AI systems co-exist with human workers. The book is made available as an open access publication, which could make it broadly and freely available to the AI and smart manufacturing communities

Proceedings of the 2009 Joint Workshop of Fraunhofer IOSB and Institute for Anthropomatics, Vision and Fusion Laboratory

The joint workshop of the Fraunhofer Institute of Optronics, System Technologies and Image Exploitation IOSB, Karlsruhe, and the Vision and Fusion Laboratory (Institute for Anthropomatics, Karlsruhe Institute of Technology (KIT)), is organized annually since 2005 with the aim to report on the latest research and development findings of the doctoral students of both institutions. This book provides a collection of 16 technical reports on the research results presented on the 2009 workshop

Factories of the Future

Engineering; Industrial engineering; Production engineerin

Factories of the Future

Engineering; Industrial engineering; Production engineerin

NASA SBIR abstracts of 1992, phase 1 projects

The objectives of 346 projects placed under contract by the Small Business Innovation Research (SBIR) program of the National Aeronautics and Space Administration (NASA) are described. These projects were selected competitively from among proposals submitted to NASA in response to the 1992 SBIR Program Solicitation. The basic document consists of edited, non-proprietary abstracts of the winning proposals submitted by small businesses. The abstracts are presented under the 15 technical topics within which Phase 1 proposals were solicited. Each project was assigned a sequential identifying number from 001 to 346, in order of its appearance in the body of the report. Appendixes to provide additional information about the SBIR program and permit cross-reference of the 1992 Phase 1 projects by company name, location by state, principal investigator, NASA Field Center responsible for management of each project, and NASA contract number are included

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