An experience of modularity through design

We aim to utilise the experiences of a marine industry-based design team to determine the need for research into a modular design methodology in an industrial environment. In order to achieve this we couple the outcome of a current design project with the findings of a recent literature survey with the objectives of firstly, clarifying why a methodology is required and, secondly, defining the key elements which the methodology would have to realise or address. The potential benefits of modularity have long been recognised in the shipbuilding industry. Many shipbuilders adopt a 'module' approach to ship construction whereby the ship structure is separated into a number of large structural 'blocks' to ease manufacture and manoeuvrability during construction. However, as understanding of the capabilities of modularity as a design tool develops there is increased interest in capitalising on the differing life phase benefits of modularity such as reduced design costs and time, increased ease of maintenance, upgrade, re-use, redesign and standardisation across individual products and product families. This is especially pertinent in naval shipbuilding where the maintenance of a class of ship requires that all previously designed ships in that class must be of similar outfitting and must be able to interface with the new ship, in terms of propulsion, weapons, communications and electronics, and thus often require some form of retrofit. Therefore, many shipbuilders are moving from viewing modularity as a purely 'manufacturing' principle to a design centred principle. However, as noted by Chang and Ward 'none of the design theories or tools in the mechanical world serves as an articulate procedure for designers to follow in practising modular design'. Thus, despite the identification of a need to introduce modular principles at an earlier stage than detail design and construction, there is little aid in the form of tools, techniques and methodologies for designers in practice

Developing and applying an integrated modular design methodology within a SME

Modularity within a product can bring advantages to the design process by facilitating enhanced design reuse, reduced lead times, decreased cost and higher levels of quality. While the benefits of modularity are becoming increasingly better known, at present it is usually left to the designers themselves to introduce modularity into products. Studies into modularity have shown that byimplementing 'formal' methods, further benefits can be made in terms of time, cost, quality and performance. Current approaches that have been proposed for the formal development of modular design methodologies fail to accurately represent knowledge that is inherently produced during design projects and fail to consider design from the different viewpoints of the development process. This work, built on previous work on modularity and design for reuse, aims to develop an integrated design methodology that will optimise the modules created through the design process and allow for modularity to be 'built-in' to product development from the initial stages. The methodology andassociated tools have been developed to provide an easy-to-use approach to modularity that has support for design rationales and company knowledge that aid in effective design decision making. The methodology, named GeMoCURE, provides an integrated total solution to modular design based on reuse of proven physical and knowledge modules. Its incremental nature allows for the optimalstructure to be maintained as the design progresses. A special focus has been on the application of this approach for Small to Medium Enterprises (SMEs), which are typically challenged by a lack of design human resources and expertise

LAS BATALLAS FESTIVAS DE ESPANA

Serving individual customer needs at reasonable prices can be a profitable target market in high-wage countries. The dilemma between scale and scope-oriented production is one major research topic within the Cluster of Excellence "Integrative Production Technology for High-Wage Countries" at the RWTH Aachen University. One main objective of this project is to bridge the existing gap between individual manufacturing and mass production. Modularization is a widely accepted approach in tool-based manufacturing processes. In this paper, we propose a flexible design methodology for modular tools and dies. The methodology will assist the design engineer in setting up a series of modularized tools in a conceptually closed manner. The described methodology covers modularization in a broad sense, i.e. it includes hardware modularization as well as modularization of the construction process. The methodology consists of three phases: initiation, analysis and design phase

MEADE: A Modular, Extensible, Adaptable Design Environment for ASIC and FPGA Development

We present MEADE, a Modular, Extensible, Adaptable Design Environment. MEADE has been developed to answer the need for an adaptive design framework for encapsulation of Computer Aided Design (CAD) tools and management of the massive amounts of data associated with the design process. Other frameworks have existed but lacked the critical open source requirement that enables rapid adaptation to a rapidly advancing design methodology. While the initial application and development of MEADE is targeted toward ASIC and FPGA design, the MEADE engine can be easily adapted to abstract any procedural application. MEADE allows the definition of procedures, which are defined as some sequence or flow of actions, which can be performed by potentially multiple different agents. With this system, design methodology management is specified in the procedures. Tool interoperability is handled by the action definitions. The unique agents perform tool interchangeability (the use of “best-inclass” tools). All details of procedure implementation are extended outside of the MEADE microkernel to the individual agent modules (Source code control, code builds, multi-user simulations, etc.). With an open, extensible system, the design community will be able to integrate specific design flows and account for sitespecific variances. Additionally, new CAD tools can be rapidly integrated into a design flow for effective evaluation. It is believed that the simple modular interface and open-source philosophy will enable MEADE to succeed where other CAD frameworks have failed

STRICT: a language and tool set for the design of very large scale integrated circuits

PhD ThesisAn essential requirement for the design of large VLSI circuits is a design methodology which would allow the designer to overcome the complexity and correctness issues associated with the building of such circuits. We propose that many of the problems of the design of large circuits can be solved by using a formal design notation based upon the functional programming paradigm, that embodies design concepts that have been used extensively as the framework for software construction. The design notation should permit parallel, sequential, and recursive decompositions of a design into smaller components, and it should allow large circuits to be constructed from simpler circuits that can be embedded in a design in a modular fashion. Consistency checking should be provided as early as possible in a design. Such a methodology would structure the design of a circuit in much the same way that procedures, classes, and control structures may be used to structure large software systems. However, such a design notation must be supported by tools which automatically check the consistency of the design, if the methodology is to be practical. In principle, the methodology should impose constraints upon circuit design to reduce errors and provide' correctness by construction' . It should be possible to generate efficient and correct circuits, by providing a route to a large variety of design tools commonly found in design systems: simulators, automatic placement and routing tools, module generators, schematic capture tools, and formal verification and synthesis tools

Model and Algorithm for Designing of Block-Modular Cutting Tools

Рассмотрены методология, модели и алгоритмы создания комплекта блочно-модульных режущих инструментов для вспомогательных и ремонтных производств. Приведены графы формирования блочно-модульных режущих инструментов различного назначения. Получены обобщенные формулы, описывающие любой тип режущего инструмента. Представленный теоретический подход по проектированию режущих инструментов на основе теории множеств проиллюстрирован технологическими схемами сборки блока резцового, фрезы торцовой и расточной головки.= The methodology, models and algorithms for creating a set of block-modular cutting tools for auxiliary and repair industries are considered. Graphs of the formation of block-modular cutting tools for various purposes are given. Generalized formulas describing any type of cutting tool are obtained. The presented theoretical approach on design of cutting tools on the basis of set theory is illustrated by technological schemes of the incisive block, end mill and boring head assembly

Process Improvement at Source International

The objective of this Major Qualifying Project was to help Source International to optimize their manufacturing process for the Modular product line while reducing costs, non-value added time, and employee motion within their work area. The methods used to accomplish this included axiomatic design matrix, Lean Methodologies comprised of value stream map, spaghetti diagram, DMAIC, 5S methodology, 7 Wastes, and Arena® Simulation. The team’s recommendations included implementing these Lean Methodologies tools in order to improve the Modular product line. In conclusion, the application of Lean Analytic tools would yield substantial savings in time and money, and increasing efficiency of the manufacturing process that Source International uses

Requirements for implementing real-time control functional modules on a hierarchical parallel pipelined system

Analysis of a robot control system leads to a broad range of processing requirements. One fundamental requirement of a robot control system is the necessity of a microcomputer system in order to provide sufficient processing capability.The use of multiple processors in a parallel architecture is beneficial for a number of reasons, including better cost performance, modular growth, increased reliability through replication, and flexibility for testing alternate control strategies via different partitioning. A survey of the progression from low level control synchronizing primitives to higher level communication tools is presented. The system communication and control mechanisms of existing robot control systems are compared to the hierarchical control model. The impact of this design methodology on the current robot control systems is explored

Fully Automated Radiation Hardened by Design Circuit Construction

abstract: A fully automated logic design methodology for radiation hardened by design (RHBD) high speed logic using fine grained triple modular redundancy (TMR) is presented. The hardening techniques used in the cell library are described and evaluated, with a focus on both layout techniques that mitigate total ionizing dose (TID) and latchup issues and flip-flop designs that mitigate single event transient (SET) and single event upset (SEU) issues. The base TMR self-correcting master-slave flip-flop is described and compared to more traditional hardening techniques. Additional refinements are presented, including testability features that disable the self-correction to allow detection of manufacturing defects. The circuit approach is validated for hardness using both heavy ion and proton broad beam testing. For synthesis and auto place and route, the methodology and circuits leverage commercial logic design automation tools. These tools are glued together with custom CAD tools designed to enable easy conversion of standard single redundant hardware description language (HDL) files into hardened TMR circuitry. The flow allows hardening of any synthesizable logic at clock frequencies comparable to unhardened designs and supports standard low-power techniques, e.g. clock gating and supply voltage scaling.Dissertation/ThesisPh.D. Electrical Engineering 201

Graphical modelling of modular machines

This research is aimed at advancing machine design through specifying and implementing (in "proof of concept" form) a set of tools which graphically model modular machines. The tools allow mechanical building elements (or machine modules) to be selected and configured together in a highly flexible manner so that operation of the chosen configuration can be simulated and performance properties evaluated. Implementation of the tools has involved an extension in capability of a proprietary robot simulation system. This research has resulted in a general approach to graphically modelling manufacturing machines built from modular elements. A focus of study has been on a decomposition of machine functionality leading to the establishment of a library of modular machine primitives. This provides a useful source of commonly required machine building elements for use by machine designers. Study has also focussed on the generation of machine configuration tools which facilitate the construction of a simulation model and ultimately the physical machine itself. Simulation aspects of machine control are also considered which depict methods of manipulating a machine model in the simulation phase. In addition methods of achieving machine programming have been considered which specify the machine and its operational tasks. Means of adopting common information data structures are also considered which can facilitate interfacing with other systems, including the physical machine system constructed as an issue of the simulation phase. Each of these study areas is addressed in its own context, but collectively they provide a means of creating a complete modular machine design environment which can provide significant assistance to machine designers. Part of the methodology employed in the study is based on the use of the discrete event simulation technique. To easily and effectively describe a modular machine and its activity in a simulation model, a hierarchical ring and tree data structure has been designed and implemented. The modularity and reconfigurability are accommodated by the data structure, and homogeneous transformations are adopted to determine the spatial location and orientation of each of the machine elements. A three-level machine task programming approach is used to describe the machine's activities. A common data format method is used to interface the machine design environment with the physical machine and other building blocks of manufacturing systems (such as CAD systems) where systems integration approaches can lead to enhanced product realisation. The study concludes that a modular machine design environment can be created by employing the graphical simulation approach together with a set of comprehensive configuration. tools. A generic framework has been derived which outlines the way in which machine design environments can be constructed and suggestions are made as to how the proof of concept design environment implemented in this study can be advanced