Aggregate process planning and manufacturing assessment for concurrent engineering

The introduction of concurrent engineering has led to a need to perform product development tasks with reduced information detail. Decisions taken during the early design stages will have the greatest influence on the cost of manufacture. The manufacturing requirements for alternative design options should therefore be considered at this time. Existing tools for product manufacture assessment are either too detailed, requiring the results of detailed design information, or too abstract, unable to consider small changes in design configuration. There is a need for an intermediate level of assessment which will make use of additional design detail where available, whilst allowing assessment of early designs. This thesis develops the concept of aggregate process planning as a methodology for supporting concurrent engineering. A methodology for performing aggregate process planning of early product designs is presented. Process and resources alternatives are identified for each feature of the component and production plans are generated from these options. Alternative production plans are assessed in terms of cost, quality and production time. A computer based system (CESS, Concurrent Engineering Support System) has been developed to implement the proposed methodology. The system employs object oriented modelling techniques to represent designs, manufacturing resources and process planning knowledge. A product model suitable for the representation of component designs at varying levels of detail is presented. An aggregate process planning functionality has been developed to allow the generation of sets of alternative plans for a component in a given factory. Manufacturing cost is calculated from the cost of processing, set-ups, transport, material and quality. Processing times are calculated using process specific methods which are based on standard cutting data. Process quality cost is estimated from a statistical analysis of historical SPC data stored for similar operations performed in the factory, where available. The aggregate process planning functionality has been tested with example component designs drawn from industry

Developing an Intelligent Education System for Design and Manufacturability Evaluation

This paper addresses the concept and development of an intelligent education system  in concurrent engineering environment based on object oriented technique for conventional processes such as drilling, reaming, boring, slot drilling, end milling, tapping, etc. and unconventional processes such as electrochemical machining (ECM), electro-discharge machining (EDM), electrochemical spark machining (ECSM), ultrasonic machining (USM) and wire-electro-erosion-dissolution machining (Wire-EEDM) for manufacturability evaluation and generation of alternative processes for improving product design. A feature based approach for acquiring design specification is used. Then the system automatically generates all possible alternative processes and estimates machining (cutting) cycle time, and cost, penetration rate, and efficiency for each process.  The system works as a process of iterative redesign which suggests a way of using process information to find ways of reducing the cost of each design feature. It also estimates the optimum operation parameters for each process which balances between quality and manufacturing efficiency and to give designers immediate feedback about parameters such as the machining cycle time, cost and quality, efficiency and so on for optimization and give some advice to manufacturing engineers related to feed, speed, penetration rate, machining cycle time and cost saving

Review of research in feature-based design

Research in feature-based design is reviewed. Feature-based design is regarded as a key factor towards CAD/CAPP integration from a process planning point of view. From a design point of view, feature-based design offers possibilities for supporting the design process better than current CAD systems do. The evolution of feature definitions is briefly discussed. Features and their role in the design process and as representatives of design-objects and design-object knowledge are discussed. The main research issues related to feature-based design are outlined. These are: feature representation, features and tolerances, feature validation, multiple viewpoints towards features, features and standardization, and features and languages. An overview of some academic feature-based design systems is provided. Future research issues in feature-based design are outlined. The conclusion is that feature-based design is still in its infancy, and that more research is needed for a better support of the design process and better integration with manufacturing, although major advances have already been made

A CSP-Based Trajectory for Designing Formally Verified Embedded Control Software

This paper presents in a nutshell a procedure for producing formally verified concurrent software. The design paradigm provides means for translating block-diagrammed models of systems from various problem domains in a graphical notation for process-oriented architectures. Briefly presented CASE tool allows code generation both for formal analysis of the models of software and code generation in a target implementation language. For formal analysis a highquality commercial formal checker is used

An Object-Oriented Model for Extensible Concurrent Systems: the Composition-Filters Approach

Applying the object-oriented paradigm for the development of large and complex software systems offers several advantages, of which increased extensibility and reusability are the most prominent ones. The object-oriented model is also quite suitable for modeling concurrent systems. However, it appears that extensibility and reusability of concurrent applications is far from trivial. The problems that arise, the so-called inheritance anomalies are analyzed and presented in this paper. A set of requirements for extensible concurrent languages is formulated. As a solution to the identified problems, an extension to the object-oriented model is presented; composition filters. Composition filters capture messages and can express certain constraints and operations on these messages, for example buffering. In this paper we explain the composition filters approach, demonstrate its expressive power through a number of examples and show that composition filters do not suffer from the inheritance anomalies and fulfill the requirements that were established

Building Blocks for Control System Software

Software implementation of control laws for industrial systems seem straightforward, but is not. The computer code stemming from the control laws is mostly not more than 10 to 30% of the total. A building-block approach for embedded control system development is advocated to enable a fast and efficient software design process.\ud We have developed the CTJ library, Communicating Threads for Java¿,\ud resulting in fundamental elements for creating building blocks to implement communication using channels. Due to the simulate-ability, our building block method is suitable for a concurrent engineering design approach. Furthermore, via a stepwise refinement process, using verification by simulation, the implementation trajectory can be done efficiently