An integrated framework for developing generic modular reconfigurable platforms for micro manufacturing and its implementation

This thesis was submitted for the degree of Doctor of Philosophy and awarded by Brunel University.The continuing trends of miniaturisation, mass customisation, globalisation and wide use of the Internet have great impacts upon manufacturing in the 21st century. Micro manufacturing will play an increasingly important role in bridging the gap between the traditional precision manufacturing and the emerging technologies like MEMS/NEMS. The key requirements for micro manufacturing in this context are hybrid manufacturing capability, modularity, reconfigurability, adaptability and energy/resource efficiency. The existing design approaches tend to have narrow scope and are largely limited to individual manufacturing processes and applications. The above requirements demand a fundamentally new approach to the future applications of micro manufacturing so as to obtain producibility, predictability and productivity covering the full process chains and value chains. A novel generic modular reconfigurable platform (GMRP) is proposed in such a context. The proposed GMRP is able to offer hybrid manufacturing capabilities, modularity, reconfigurablity and adaptivity as both an individual machine tool and a micro manufacturing system, and provides a cost effective solution to high value micro manufacturing in an agile, responsive and mass customisation manner. An integrated framework has been developed to assist the design of GMRPs due to their complexity. The framework incorporates theoretical GMRP model, design support system and extension interfaces. The GMRP model covers various relevant micro manufacturing processes and machine tool elements. The design support system includes a user-friendly interface, a design engine for design process and design evaluation, together with scalable design knowledge base and database. The functionalities of the framework can also be extended through the design support system interface, the GMRP interface and the application interface, i.e. linking to external hardware and/or software modules. The design support system provides a number of tools for the analysis and evaluation of the design solutions. The kinematic simulation of machine tools can be performed using the Virtual Reality toolbox in Matlab. A module has also been developed for the multiscale modelling, simulation and results analysis in Matlab. A number of different cutting parameters can be studied and the machining performance can be subsequently evaluated using this module. The mathematical models for a non-traditional micro manufacturing process, micro EDM, have been developed with the simulation performed using FEA. Various design theories and methodologies have been studied, and the axiomatic design theory has been selected because of its great power and simplicity. It has been applied in the conceptual design of GMRP and its design support system. The implementation of the design support system is carried out using Matlab, Java and XML technologies. The proposed GMRP and framework have been evaluated through case studies and experimental results

Modular Self-Reconfigurable Robot Systems

The field of modular self-reconfigurable robotic systems addresses the design, fabrication, motion planning, and control of autonomous kinematic machines with variable morphology. Modular self-reconfigurable systems have the promise of making significant technological advances to the field of robotics in general. Their promise of high versatility, high value, and high robustness may lead to a radical change in automation. Currently, a number of researchers have been addressing many of the challenges. While some progress has been made, it is clear that many challenges still exist. By illustrating several of the outstanding issues as grand challenges that have been collaboratively written by a large number of researchers in this field, this article has shown several of the key directions for the future of this growing fiel

Low-power Programmable Processor for Fast Fourier Transform Based on Transport Triggered Architecture

This paper describes a low-power processor tailored for fast Fourier transform computations where transport triggering template is exploited. The processor is software-programmable while retaining an energy-efficiency comparable to existing fixed-function implementations. The power savings are achieved by compressing the computation kernel into one instruction word. The word is stored in an instruction loop buffer, which is more power-efficient than regular instruction memory storage. The processor supports all power-of-two FFT sizes from 64 to 16384 and given 1 mJ of energy, it can compute 20916 transforms of size 1024.Comment: 5 pages, 4 figures, 1 table, ICASSP 2019 conferenc

Cycle-accurate evaluation of reconfigurable photonic networks-on-chip

There is little doubt that the most important limiting factors of the performance of next-generation Chip Multiprocessors (CMPs) will be the power efficiency and the available communication speed between cores. Photonic Networks-on-Chip (NoCs) have been suggested as a viable route to relieve the off- and on-chip interconnection bottleneck. Low-loss integrated optical waveguides can transport very high-speed data signals over longer distances as compared to on-chip electrical signaling. In addition, with the development of silicon microrings, photonic switches can be integrated to route signals in a data-transparent way. Although several photonic NoC proposals exist, their use is often limited to the communication of large data messages due to a relatively long set-up time of the photonic channels. In this work, we evaluate a reconfigurable photonic NoC in which the topology is adapted automatically (on a microsecond scale) to the evolving traffic situation by use of silicon microrings. To evaluate this system's performance, the proposed architecture has been implemented in a detailed full-system cycle-accurate simulator which is capable of generating realistic workloads and traffic patterns. In addition, a model was developed to estimate the power consumption of the full interconnection network which was compared with other photonic and electrical NoC solutions. We find that our proposed network architecture significantly lowers the average memory access latency (35% reduction) while only generating a modest increase in power consumption (20%), compared to a conventional concentrated mesh electrical signaling approach. When comparing our solution to high-speed circuit-switched photonic NoCs, long photonic channel set-up times can be tolerated which makes our approach directly applicable to current shared-memory CMPs

A Vision-based Scheme for Kinematic Model Construction of Re-configurable Modular Robots

Re-configurable modular robotic (RMR) systems are advantageous for their reconfigurability and versatility. A new modular robot can be built for a specific task by using modules as building blocks. However, constructing a kinematic model for a newly conceived robot requires significant work. Due to the finite size of module-types, models of all module-types can be built individually and stored in a database beforehand. With this priori knowledge, the model construction process can be automated by detecting the modules and their corresponding interconnections. Previous literature proposed theoretical frameworks for constructing kinematic models of modular robots, assuming that such information was known a priori. While well-devised mechanisms and built-in sensors can be employed to detect these parameters automatically, they significantly complicate the module design and thus are expensive. In this paper, we propose a vision-based method to identify kinematic chains and automatically construct robot models for modular robots. Each module is affixed with augmented reality (AR) tags that are encoded with unique IDs. An image of a modular robot is taken and the detected modules are recognized by querying a database that maintains all module information. The poses of detected modules are used to compute: (i) the connection between modules and (ii) joint angles of joint-modules. Finally, the robot serial-link chain is identified and the kinematic model constructed and visualized. Our experimental results validate the effectiveness of our approach. While implementation with only our RMR is shown, our method can be applied to other RMRs where self-identification is not possible

Generic Design Methodology for Smart Manufacturing Systems From a Practical Perspective. Part II—Systematic Designs of Smart Manufacturing Systems

In a traditional system paradigm, an enterprise reference model provides the guide for practitioners to select manufacturing elements, configure elements into a manufacturing system, and model system options for evaluation and comparison of system solutions against given performance metrics. However, a smart manufacturing system aims to reconfigure different systems in achieving high-level smartness in its system lifecycle; moreover, each smart system is customized in terms of the constraints of manufacturing resources and the prioritized performance metrics to achieve system smartness. Few works were found on the development of systematic methodologies for the design of smart manufacturing systems. The novel contributions of the presented work are at two aspects: (1) unified definitions of digital functional elements and manufacturing systems have been proposed; they are generalized to have all digitized characteristics and they are customizable to any manufacturing system with specified manufacturing resources and goals of smartness and (2) a systematic design methodology has been proposed; it can serve as the guide for designs of smart manufacturing systems in specified applications. The presented work consists of two separated parts. In the first part of paper, a simplified definition of smart manufacturing (SM) is proposed to unify the diversified expectations and a newly developed concept digital triad (DT-II) is adopted to define a generic reference model to represent essential features of smart manufacturing systems. In the second part of the paper, the axiomatic design theory (ADT) is adopted and expanded as the generic design methodology for design, analysis, and assessment of smart manufacturing systems. Three case studies are reviewed to illustrate the applications of the proposed methodology, and the future research directions towards smart manufacturing are discussed as a summary in the second part

Enabling collaboration in virtual reality navigators

In this paper we characterize a feature superset for Collaborative Virtual Reality Environments (CVRE), and derive a component framework to transform stand-alone VR navigators into full-fledged multithreaded collaborative environments. The contributions of our approach rely on a cost-effective and extensible technique for loading software components into separate POSIX threads for rendering, user interaction and network communications, and adding a top layer for managing session collaboration. The framework recasts a VR navigator under a distributed peer-to-peer topology for scene and object sharing, using callback hooks for broadcasting remote events and multicamera perspective sharing with avatar interaction. We validate the framework by applying it to our own ALICE VR Navigator. Experimental results show that our approach has good performance in the collaborative inspection of complex models.Postprint (published version