Setup Optimization in High-Mix Surface Mount PCB Assembly

Siirretty Doriast

Joint Control of Manufacturing and Onsite Microgrid System Via Novel Neural-Network Integrated Reinforcement Learning Algorithms

Microgrid is a promising technology of distributed energy supply system, which consists of storage devices, generation capacities including renewable sources, and controllable loads. It has been widely investigated and applied for residential and commercial end-use customers as well as critical facilities. In this paper, we propose a joint state-based dynamic control model on microgrids and manufacturing systems where optimal controls for both sides are implemented to coordinate the energy demand and supply so that the overall production cost can be minimized considering the constraint of production target. Markov Decision Process (MDP) is used to formulate the decision-making procedure. The main computing challenge to solve the formulated MDP lies in the co-existence of both discrete and continuous parts of the high-dimensional state/action space that are intertwined with constraints. A novel reinforcement learning algorithm that leverages both Temporal Difference (TD) and Deterministic Policy Gradient (DPG) algorithms is proposed to address the computation challenge. Experiments for a manufacturing system with an onsite microgrid system with renewable sources have been implemented to justify the effectiveness of the proposed method

Design of a Multi-Mode Hybrid Micro-Gripper for Surface Mount Technology Component Assembly

In the last few decades, industrial sectors such as smart manufacturing and aerospace have rapidly developed, contributing to the increase in production of more complex electronic boards based on SMT (Surface Mount Technology). The assembly phases in manufacturing these electronic products require the availability of technological solutions able to deal with many heterogeneous products and components. The small batch production and pre-production are often executed manually or with semi-automated stations. The commercial automated machines currently available offer high performance, but they are highly rigid. Therefore, a great effort is needed to obtain machines and devices with improved reconfigurability and flexibility for minimizing the set-up time and processing the high heterogeneity of components. These high-level objectives can be achieved acting in different ways. Indeed, a work station can be seen as a set of devices able to interact and cooperate to perform a specific task. Therefore, the reconfigurability of a work station can be achieved through reconfigurable and flexible devices and their hardware and software integration and control For this reason, significant efforts should be focused on the conception and development of innovative devices to cope with the continuous downscaling and increasing variety of the products in this growing field. In this context, this paper presents the design and development of a multi-mode hybrid micro-gripper devoted to manipulate and assemble a wide range of micro- and meso-SMT components with different dimensions and proprieties. It exploits two different handling technologies: the vacuum and friction

Energy and Route Optimization of Moving Devices

This thesis highlights our efforts in energy and route optimization of moving devices. We have focused on three categories of such devices; industrial robots in a multi-robot environment, generic vehicles in a vehicle routing problem (VRP) context, automatedguided vehicles (AGVs) in a large-scale flexible manufacturing system (FMS). In the first category, the aim is to develop a non-intrusive energy optimization technique, based on a given set of paths and sequences of operations, such that the original cycle time is not exceeded. We develop an optimization procedure based on a mathematical programming model that aims to minimize the energy consumption and peak power. Our technique has several advantages. It is non-intrusive, i.e. it requires limited changes in the robot program and can be implemented easily. Moreover,it is model-free, in the sense that no particular, and perhaps secret, parameter or dynamic model is required. Furthermore, the optimization can be done offline, within seconds using a generic solver. Through careful experiments, we have shown that it is possible to reduce energy and peak-power up to about 30% and 50% respectively. The second category of moving devices comprises of generic vehicles in a VRP context. We have developed a hybrid optimization approach that integrates a distributed algorithm based on a gossip protocol with a column generation (CG) algorithm, which manages to solve the tested problems faster than the CG algorithm alone. The algorithm is developed for a VRP variation including time windows (VRPTW), which is meant to model the task of scheduling and routing of caregivers in the context of home healthcare routing and scheduling problems (HHRSPs). Moreover,the developed algorithm can easily be parallelized to further increase its efficiency. The last category deals with AGVs. The choice of AGVs was not arbitrary; by design, we decided to transfer our knowledge of energy optimization and routing algorithms to a class of moving devices in which both techniques are of interest. Initially, we improve an existing method of conflict-free AGV scheduling and routing, such that the new algorithm can manage larger problems. A heuristic version of the algorithm manages to solve the problem instances in a reasonable amount of time. Later, we develop strategies to reduce the energy consumption. The study is carried out using an AGV system installed at Volvo Cars. The results are promising; (1)the algorithm reduces performance measures such as makespan up to 50%, while reducing the total travelled distance of the vehicles about 14%, leading to an energy saving of roughly 14%, compared to the results obtained from the original traffic controller. (2) It is possible to reduce the cruise velocities such that more energy is saved, up to 20%, while the new makespan remains better than the original one

Applying Formal Methods to Networking: Theory, Techniques and Applications

Despite its great importance, modern network infrastructure is remarkable for the lack of rigor in its engineering. The Internet which began as a research experiment was never designed to handle the users and applications it hosts today. The lack of formalization of the Internet architecture meant limited abstractions and modularity, especially for the control and management planes, thus requiring for every new need a new protocol built from scratch. This led to an unwieldy ossified Internet architecture resistant to any attempts at formal verification, and an Internet culture where expediency and pragmatism are favored over formal correctness. Fortunately, recent work in the space of clean slate Internet design---especially, the software defined networking (SDN) paradigm---offers the Internet community another chance to develop the right kind of architecture and abstractions. This has also led to a great resurgence in interest of applying formal methods to specification, verification, and synthesis of networking protocols and applications. In this paper, we present a self-contained tutorial of the formidable amount of work that has been done in formal methods, and present a survey of its applications to networking.Comment: 30 pages, submitted to IEEE Communications Surveys and Tutorial

Digital twin concept applied to simulation and performance reporting for printed circuit board manufacturing

This industrial revolution, also known as Industry 4.0, is now taking place due to technol- ogy requirements. With an ever growing world population, new demands rise, henceforth better, more optimized, more customized, and faster product manufacturing must be achieved. A way to do this is by implementing Smart Manufacturing methods in indus- trial environments, which can be accomplished by using a Digital Twin solution. This dissertation focuses on expanding an already existing Digital Twin, developed by Visteon Corporation, which purpose is to modulate the productive capacity of Visteon’s PCB (Print Circuit Board) production lines. This extension consists of achieving one of the key advantages of using a Digital Twin solution, making predictions regarding a system’s real performance, that in this case, are the production lines. The extension further allows better planning for future changes.A atual revolução industrial, também conhecida como Indústria 4.0, está a ocorrer de- vido a necessidades tecnológicas. Com um aumento constante da população mundial, surgem novas exigências, por isso é necessário alcançar uma melhor, mais otimizada, mais customizada e mais rápida manufatura de produtos. Uma maneira de o fazer é implementando métodos de Smart Manufacturing em ambientes industriais, que pode ser alcançado através de uma solução de Digital Twin. O foco desta dissertação é expandir um Digital Twin já existente, que foi desenvolvido pela Visteon Corporation, cujo objetivo é modular a capacidade produtiva das linhas de produção de PCB (Print Circuit Board) da Visteon. Esta extensão tem como objetivo atingir uma das vantagens mais significativas do uso de uma solução de Digital Twin, fazer previsões da performance real de um sistema, que neste caso, são as linhas de produção. A extensão permite também fazer planeamentos mais rigorosos para o futuro

Combining business process and failure modelling to increase yield in electronics manufacturing

The prediction and capturing of defects in low-volume assembly of electronics is a technical challenge that is a prerequisite for design for manufacturing (DfM) and business process improvement (BPI) to increase first-time yields and reduce production costs. Failures at the component-level (component defects) and system-level (such as defects in design and manufacturing) have not been incorporated in combined prediction models. BPI efforts should have predictive capability while supporting flexible production and changes in business models. This research was aimed at the integration of enterprise modelling (EM) and failure models (FM) to support business decision making by predicting system-level defects. An enhanced business modelling approach which provides a set of accessible failure models at a given business process level is presented in this article. This model-driven approach allows the evaluation of product and process performance and hence feedback to design and manufacturing activities hence improving first-time yield and product quality. A case in low-volume, high-complexity electronics assembly industry shows how the approach leverages standard modelling techniques and facilitates the understanding of the causes of poor manufacturing performance using a set of surface mount technology (SMT) process failure models. A prototype application tool was developed and tested in a collaborator site to evaluate the integration of business process models with the execution entities, such as software tools, business database, and simulation engines. The proposed concept was tested for the defect data collection and prediction in the described case study