Design and development of a hybrid control system for flexible manufacturing : a thesis presented in partial fulfilment of the requirements for the degree of Master of Technology in Manufacturing and Industrial Technology at Massey University

Irregular Pagination MisnumberedFlexible Manufacturing Systems (FMS) appeared upon the manufacturing scene in the early 1970s, installations presently number in the thousands. However, many current installations in fact lack flexibility, do not operate in real-time and are prohibitively expensive. Therefore there are obvious benefits to be gained from making improvements to existing flexible manufacturing systems. Research conducted for this thesis focused on two major areas. The implementation of the FMS control system on a SCADA package and the development of an auction based scheduling system. This entailed the development of a hybrid control model composed of three distinct layers; factory, cell and intelligent entity. Key portions of both the factory and cell controllers were then implemented so as to create a minimal system. This has been completed to the point where the auction algorithm has been implemented and tested in an appropriate framework. In achieving the goals mentioned above a number of novel design concepts have been utilised. There are two which are most important, these are the use of low cost modules for the construction of a flexible co-operative manufacturing system, and the ability of this system to operate in a physically distributed area via a Local Area Network. Meaning it is inherently adaptable and resistant to failure. These novel design concepts were ingrained throughout the entire three layered control model. It is felt that this research has succeeded in demonstrating the possibility of implementing a FMS control system on a low cost SCADA package using low cost software and computing elements. The ability of the distributed, auction-based approach to operate successfully within this system, has also been demonstrated through simulation

Versatile and on-demand biologics co-production in yeast

Current limitations to on-demand drug manufacturing can be addressed by technologies that streamline manufacturing processes. Combining the production of two or more drugs into a single batch could not only be useful for research, clinical studies, and urgent therapies but also effective when combination therapies are needed or where resources are scarce. Here we propose strategies to concurrently produce multiple biologics from yeast in single batches by multiplexing strain development, cell culture, separation, and purification. We demonstrate proof-of-concept for three biologics co-production strategies: (i) inducible expression of multiple biologics and control over the ratio between biologic drugs produced together; (ii) consolidated bioprocessing; and (iii) co-expression and co-purification of a mixture of two monoclonal antibodies. We then use these basic strategies to produce drug mixtures as well as to separate drugs. These strategies offer a diverse array of options for on-demand, flexible, low-cost, and decentralized biomanufacturing applications without the need for specialized equipment

Silicon web process development

Silicon dendritic web, a single crystal ribbon shaped during growth by crystallographic forces and surface tension (rather than dies), is a highly promising base material for efficient low cost solar cells. The form of the product smooth, flexible strips 100 to 200 microns thick, conserves expensive silicon and facilitates automation of crystal growth and the subsequent manufacturing of solar cells. These characteristics, coupled with the highest demonstrated ribbon solar cell efficiency-15.5%-make silicon web a leading candidate to achieve, or better, the 1986 Low Cost Solar Array (LSA) Project cost objective of 50 cents per peak watt of photovoltaic output power. The main objective of the Web Program, technology development to significantly increase web output rate, and to show the feasibility for simultaneous melt replenishment and growth, have largely been accomplished. Recently, web output rates of 23.6 sq cm/min, nearly three times the 8 sq cm/min maximum rate of a year ago, were achieved. Webs 4 cm wide or greater were grown on a number of occassions

Emerging technologies for low‐cost, rapid vaccine manufacture

To stop the spread of future epidemics and meet infant vaccination demands in low- and middle-income countries, flexible, rapid and low-cost vaccine development and manufacturing technologies are required. Vaccine development platform technologies that can produce a wide range of vaccines are emerging, including: a) humanized, high-yield yeast recombinant protein vaccines; b) insect cell-baculovirus ADDomer vaccines; c) Generalized Modules for Membrane Antigens (GMMA) vaccines; d) RNA vaccines. Herein, existing and future platforms are assessed in terms of addressing challenges of scale, cost, and responsiveness. To assess the risk and feasibility of the four emerging platforms, the following six metrics are applied: 1) technology readiness; 2) technological complexity; 3) ease of scale-up; 4) flexibility for the manufacturing of a wide range of vaccines; 5) thermostability of the vaccine product at tropical ambient temperatures; and 6) speed of response from threat identification to vaccine deployment. The assessment indicated that technologies in the order of increasing feasibility and decreasing risk are the yeast platform, ADDomer platform, followed by RNA and GMMA platforms. The comparative strengths and weaknesses of each technology are discussed in detail, illustrating the associated development and manufacturing needs and priorities

The Factory of the Future

A brief history of aircraft production techniques is given. A flexible machining cell is then described. It is a computer controlled system capable of performing 4-axis machining part cleaning, dimensional inspection and materials handling functions in an unmanned environment. The cell was designed to: allow processing of similar and dissimilar parts in random order without disrupting production; allow serial (one-shipset-at-a-time) manufacturing; reduce work-in-process inventory; maximize machine utilization through remote set-up; maximize throughput and minimize labor

Communication and control in small batch part manufacturing

This paper reports on the development of a real-time control network as an integrated part of a shop floor control system for small batch part manufacturing. The shop floor control system is called the production control system (PCS). The PCS aims at an improved control of small batch part manufacturing systems, enabling both a more flexible use of resources and a decrease in the economical batch size. For this, the PCS integrates various control functions such as scheduling, dispatching, workstation control and monitoring, whilst being connected on-line to the production equipment on the shop floor. The PCS can be applied irrespective of the level of automation on the shop floor. The control network is an essential part of the PCS, as it provides a real-time connection between the different modules (computers) of the PCS, which are geographically distributed over the shop floor. An overview of the requirements of such a control network is given. The description of the design includes the services developed, the protocols used and the physical layout of the network. A prototype of the PCS, including the control network, has been installed and tested in a pilot plant. The control network has proven that it can supply a manufacturing environment, consisting of equipment from different vendors with different levels of automation, with a reliable, low cost, real-time communication facility

An improved cell controller for the aerospace manufacturing

The aerospace manufacturing industry is unique in that production typically focuses on high variety and quality but low volume. Existing flexible manufacturing cells are limited to certain types of machines, robots and cells which makes it difficult to introduce any changes. In this paper idea of treating machines, robots, any hardware and software as resource has been introduced. It describes the development of the Flexa Cell Coordinator (FCC), a system that is providing a solution to manage cells and their resources in a new flexible manner. It can control, organise and coordinate between cells and resources and is capable of controlling remote cells because of its distributed nature. It also provides connectivity with company systems e.g., Enterprise Resource Planner (ERP). It is extendable and capable of adding multiple cells inside the system. In FCC resources (e.g., tracker) can also be shared between cells. The paper presents its development and results of initial successful testing

Emerging Next Generation Solar Cells Route to High Efficiency and Low Cost

Generation of clean energy is one of the main challenges of the 21st century. Solar energy is the most abundantly available renewable energy source which would be supplying more than 50 of the global electricity demand in 2100. Solar cells are used to convert light energy into electrical energy directly with an appeal that it does not generate any harmful bi products, like greenhouse gasses. The manufacturing of solar cells is actually based on the types of semiconducting or non semiconducting materials used and commercial maturity. From the very beginning of the terrestrial use of Solar Cells, efficiency and costs are the main focusing areas of research. The definition of so called emerging technologies sometimes described as including any technology capable of overcoming the Shockley-Queisser limit of power conversion efficiency 33.7 percent for a single junction device. In this paper, few promising materials for solar cells are discussed including their structural morphology, electrical and optical properties. The excellent state of the art technology, advantages and potential research issues yet to be explored are also pointed out. Md. Samiul Islam Sadek | Dr. M Junaebur Rashid | Dr. Zahid Hasan Mahmood "Emerging Next Generation Solar Cells: Route to High Efficiency and Low Cost" Published in International Journal of Trend in Scientific Research and Development (ijtsrd), ISSN: 2456-6470, Volume-1 | Issue-4 , June 201

Enhanced cell controller for aerospace manufacturing

Aerospace manufacturing industry is unique in that production typically focuses on high variety and quality but extremely low volume. Manufacturing processes are also sometimes unique and not repeatable and, hence, costly. Production is getting more expensive with the introduction of industrial robots and their cells. This paper describes the development of the Flexa Cell Coordinator (FCC), a system that is providing a solution to manage resources at assembly cell level. It can control, organise and coordinate between the resources and is capable of controlling remote cells and resources because of its distributed nature. It also gives insight of a system to the higher management via its rich reporting facility and connectivity with company systems e.g., Enterprise Resource Planner (ERP). It is able to control various kinds of cells and resources (network based) which are not limited to robots and machines. It is extendable and capable of adding multiple numbers of cells inside the system. It also provides the facility of scheduling the task to avoid the deadlocking in the process. In FCC resources (e.g., tracker) can also be shared between cells

Sliver Solar Cells

Sliver solar cells are thin, mono-crystalline silicon solar cells, fabricated using micro-machining techniques combined with standard solar cell fabrication technology. Sliver solar modules can be efficient, low cost, bifacial, transparent, flexible, shadow-tolerant, and lightweight. Sliver modules require only 5 to 10% of the pure silicon and less than 5% of the wafer starts per MWp of factory output when compared with conventional photovoltaic modules. At ANU, we have produced 20% efficient Sliver solar cells using a robust, optimised cell fabrication process described in this paper. We have devised a rapid, reliable and simple method for extracting Sliver cells from a Sliver wafer, and methods for assembling modularised Sliver cell sub-modules. The method for forming these Sliver sub-modules, along with a low-cost method for rapidly forming reliable electrical interconnections, are presented. Using the sub-module approach, we describe low-cost methods for assembling and encapsulating Sliver cells into a range of module designs