A computer-based product classification and component detection for demanufacturing processes

This is an Author's Accepted Manuscript of an article published in International Journal of Computer Integrated Manufacturing, 24(10), 900-914, 2011 [copyright Taylor & Francis], available online at: http://www.tandfonline.com/10.1080/0951192X.2011.579169.The aim of this paper is to propose a novel computer-based product classification, component detection and tracking for demanufacturing and disassembly process. This is achieved by introducing a series of automated and sequential product scanning, component identification, image analysis and sorting – leading to the development of a bill of material (BOM). The produced BOM can then be associated with the relevant disassembly/demanufacture proviso. The proposed integrated image sorting and product classification (ISPC) approach can be considered as a step forward in automation of demanufacturing activities. The ISPC model proposed in this paper utilises and builds on the state-of-the-art technology and current body of research in computer-integrated demanufacturing and remanufacturing (CIDR). An appraisal of the latest research material and the factors that inhibit CIDR methods inpractice are presented. A novel solution for the integration of imaging and material identification techniques toovercome some of the existing shortcomings of automated recycling processes is proposed in this paper. The proposed product scanning and component detection ISPC software consists of four distinct models: the repertory database, the search engine, the product-attributes updater and the image sorting and classification algorithm. The software framework that integrates the four components is presented in this paper. Finally, an overall assessment of applying ISPC at various stages of CIDR processes concludes the article.University of Ibadan MacArthur Foundation Gran

Assembly and Disassembly Planning by using Fuzzy Logic & Genetic Algorithms

The authors propose the implementation of hybrid Fuzzy Logic-Genetic Algorithm (FL-GA) methodology to plan the automatic assembly and disassembly sequence of products. The GA-Fuzzy Logic approach is implemented onto two levels. The first level of hybridization consists of the development of a Fuzzy controller for the parameters of an assembly or disassembly planner based on GAs. This controller acts on mutation probability and crossover rate in order to adapt their values dynamically while the algorithm runs. The second level consists of the identification of theoptimal assembly or disassembly sequence by a Fuzzy function, in order to obtain a closer control of the technological knowledge of the assembly/disassembly process. Two case studies were analyzed in order to test the efficiency of the Fuzzy-GA methodologies

Modeling a complex production line using virtual cells

This chapter presents modeling and simulation of a complex multistage multiproduct production line with four closed loop networks configuration, which also act as a virtual cell. This allows for a greater understanding of the functions within the production line through the simplification of the production flow with the addition of buffers between the cells. Virtual cells are crucial in this instance due to the dynamic configuration, which could help production system designers in optimizing the complex configuration of production

Virtual bloXing - assembly rapid prototyping for near net shapes

Virtual reality (VR) provides another dimension to many engineering applications. Its immersive and interactive nature allows an intuitive approach to study both cognitive activities and performance evaluation. Market competitiveness means having products meet form, fit and function quickly. Rapid Prototyping and Manufacturing (RP&M) technologies are increasingly being applied to produce functional prototypes and the direct manufacturing of small components. Despite its flexibility, these systems have common drawbacks such as slow build rates, a limited number of build axes (typically one) and the need for post processing. This paper presents a Virtual Assembly Rapid Prototyping (VARP) project which involves evaluating cognitive activities in assembly tasks based on the adoption of immersive virtual reality along with a novel nonlayered rapid prototyping for near net shape (NNS) manufacturing of components. It is envisaged that this integrated project will facilitate a better understanding of design for manufacture and assembly by utilising equivalent scale digital and physical prototyping in one rapid prototyping system. The state of the art of the VARP project is also presented in this paper

Semi-automatic Design for Disassembly Strategy Planning: An Augmented Reality Approach

Abstract The mounting attention to environmental issues requires adopting better disassembly procedures at the product's End of Life. Planning and reckoning different disassembly strategies in the early stage of the design process can improve the development of sustainable products with an easy dismissing and recycling oriented approach. Nowadays many Computer Aided Process Planning software packages provide optimized assembly or disassembly sequences, but they are mainly based on a time and cost compression approach, neglecting the human factor. The environment we developed is based upon the integration of a CAD, an Augmented Reality tool, a Leap Motion Controller device, see-through glasses and an algorithm for disassembly strategies evaluation: this approach guarantees a more effective interaction with the 3D real and virtual assembly than an approach relying only on a CAD based disassembly sequence planning. In such a way, the operator may not test in a more natural and intuitive way automatic disassembly sequences, but he/she can also propose different strategies to improve the ergonomics. The methodology has been tested in a real case study to evaluate the strength points and criticalities of this approach

Virtual assembly rapid prototyping of near net shapes

Virtual reality (VR) provides another dimension to many engineering applications. Its immersive and interactive nature allows an intuitive approach to study both cognitive activities and performance evaluation. Market competitiveness means having products meet form, fit and function quickly. Rapid Prototyping and Manufacturing (RP&M) technologies are increasingly being applied to produce functional prototypes and the direct manufacturing of small components. Despite its flexibility, these systems have common drawbacks such as slow build rates, a limited number of build axes (typically one) and the need for post processing. This paper presents a Virtual Assembly Rapid Prototyping (VARP) project which involves evaluating cognitive activities in assembly tasks based on the adoption of immersive virtual reality along with a novel non-layered rapid prototyping for near net shape (NNS) manufacturing of components. It is envisaged that this integrated project will facilitate a better understanding of design for manufacture and assembly by utilising equivalent scale digital and physical prototyping in one rapid prototyping system. The state of the art of the VARP project is also presented in this paper

Modeling, design and scheduling of computer integrated manufacturing and demanufacturing systems

This doctoral dissertation work aims to provide a discrete-event system-based methodology for design, implementation, and operation of flexible and agile manufacturing and demanufacturing systems. After a review of the current academic and industrial activities in these fields, a Virtual Production Lines (VPLs) design methodology is proposed to facilitate a Manufacturing Execution System integrated with a shop floor system. A case study on a back-end semiconductor line is performed to demonstrate that the proposed methodology is effective to increase system throughput and decrease tardiness. An adaptive algorithm is proposed to deal with the machine failure and maintenance. To minimize the environmental impacts caused by end-of-life or faulty products, this research addresses the fundamental design and implementation issues of an integrated flexible demanufacturing system (IFDS). In virtue of the success of the VPL design and differences between disassembly and assembly, a systematic approach is developed for disassembly line design. This thesis presents a novel disassembly planning and demanufacturing scheduling method for such a system. Case studies on the disassembly of personal computers are performed illustrating how the proposed approaches work

Direct modeling techniques in the conceptual design stage in immersive environments for DfA&D

Due to the fast – growing competition of the mass – products markets, companies are looking for new technologies to maximize productivity and minimize time and costs. In the perspective of Computer Aided Process Planning (CAPP), companies want to optimize fixture design and assembly planning for different goals. To meet these demands, the designers' interest in Design for Assembly and Disassembly is growing considerably and is increasingly being integrated into the CAPP. The work described in this thesis aims to exploit immersive technologies to support the design of mating elements and assembly / disassembly, by developing a data exchange flow between the immersive environment and the modeling environment that provides the high – level modeling rules, both for modeling features and for assembly relationships. The main objective of the research is to develop the capability to model and execute simple coupling commands in a virtual environment by using fast direct modeling commands. With this tool the designer can model the coupling elements, position them and modify their layout. Thanks to the physical engine embedded in the scene editor software, it is possible to take into consideration physical laws such as gravity and collision between elements. A library of predefined assembly features has been developed through the use of an external modeling engine and put into communication with the immersive interaction environment. Subsequently, the research involved the study of immersive technologies for workforce development and training of workers. The research on immersive training involved industrial case studies, such as the projection of the disassembly sequence of an industrial product on a head mounted display, and less industrial case studies, such as the manual skills development of carpenters for AEC sectors and the surgeon training in the pre – operative planning in medical field