Develop an autonomous product-based reconfigurable manufacturing system

With the ever-emerging market including mass customization and product variety, reconfigurable manufacturing systems (RMS) have been presented as the solution. A manufacturing system that combines the benefits of the two classic manufacturing systems to increase responsiveness and reduce production time and costs. To cope with the lack of physical systems, an RMS system have been built at UiT Narvik. Today, both reconfiguration and deciding layout must be executed manually by a human. A task that is both incredibly time consuming and far from optimal. A method of automating the layout generation and thus the manufacturing system is presented in this thesis. To the author’s knowledge such experiment has not been performed previously. Layouts is generated with a NSGA-II algorithm in Python by minimizing objectives from a developed mathematical model. The results have been tested with a MiR-100 mobile robot placing five modules in two different layouts. The results have been compared with a digital visualization for validation. In addition to the visualization, videos of the physical system's automated layout generation are presented. The results concludes that the method both generates feasible layouts as well as enhancing the automation of the system

Reconfigurable Surfaces Employing Linear-Rotational and Bistable-Translational (LRBT) Joints

Reconfigurable surfaces are useful in many applications. This paper proposes a type of reconfigurable surfaces that consist of rigid elements (tiles) connected by novel compliant joints. Depending on the actuation, these novel connecting joints can either operate as torsional hinges, which create isometric transformation (like origami folding) between connected tiles, or bistable translational springs, which accommodate metric-changing transformation between connected tiles. A specific example of a reconfigurable surface with square tile shape that can morph into flat, cylindrical (in two different directions), and spherical configurations with simple actuation is given

Reconfigurable Surfaces Employing Linear-Rotational and Bistable-Translational (LRBT) Joints

Reconfigurable surfaces are useful in many applications. This paper proposes a type of reconfigurable surfaces that consist of rigid elements (tiles) connected by novel compliant joints. Depending on the actuation, these novel connecting joints can either operate as torsional hinges, which create isometric transformation (like origami folding) between connected tiles, or bistable translational springs, which accommodate metric-changing transformation between connected tiles. A specific example of a reconfigurable surface with square tile shape that can morph into flat, cylindrical (in two different directions), and spherical configurations with simple actuation is given

TRANSFORMING A CIRCULAR ECONOMY INTO A HELICAL ECONOMY FOR ADVANCING SUSTAINABLE MANUFACTURING

The U.N. projects the world population to reach nearly 10 billion people by 2050, which will cause demand for manufactured goods to reach unforeseen levels. In order for us to produce the goods to support an equitable future, the methods in which we manufacture those goods must radically change. The emerging Circular Economy (CE) concept for production systems has promised to drastically increase economic/business value by significantly reducing the world’s resource consumption and negative environmental impacts. However, CE is inherently limited because of its emphasis on recycling and reuse of materials. CE does not address the holistic changes needed across all of the fundamental elements of manufacturing: products, processes, and systems. Therefore, a paradigm shift is required for moving from sustainment to sustainability to “produce more with less” through smart, innovative and transformative convergent manufacturing approaches rooted in redesigning next generation manufacturing infrastructure. This PhD research proposes the Helical Economy (HE) concept as a novel extension to CE. The proposed HE concepts shift the CE’s status quo paradigm away from post-use recovery for recycling and reuse and towards redesigning manufacturing infrastructure at product, process, and system levels, while leveraging IoT-enabled data infrastructures and an upskilled workforce. This research starts with the conceptual overview and a framework for implementing HE in the discrete product manufacturing domain by establishing the future state vision of the Helical Economy Manufacturing Method (HEMM). The work then analyzes two components of the framework in detail: designing next-generation products and next-generation IoT-enabled data infrastructures. The major research problems that need to be solved in these subcomponents are identified in order to make near-term progress towards the HEMM. The work then proceeds with the development and discussion of initial methods for addressing these challenges. Each method is demonstrated using an illustrative industry example. Collectively, this initial work establishes the foundational body of knowledge for the HE and the HEMM, provides implementation methods at the product and IoT-enabled data infrastructure levels, and it shows a great potential for HE’s ability to create and maximize sustainable value, optimize resource consumption, and ensure continued technological progress with significant economic growth and innovation. This research work then presents an outlook on the future work needed, as well as calls for industry to support the continued refinement and development of the HEMM through relevant prototype development and subsequent applications

Autonomous Task-Based Evolutionary Design of Modular Robots

In an attempt to solve the problem of finding a set of multiple unique modular robotic designs that can be constructed using a given repertoire of modules to perform a specific task, a novel synthesis framework is introduced based on design optimization concepts and evolutionary algorithms to search for the optimal design. Designing modular robotic systems faces two main challenges: the lack of basic rules of thumb and design bias introduced by human designers. The space of possible designs cannot be easily grasped by human designers especially for new tasks or tasks that are not fully understood by designers. Therefore, evolutionary computation is employed to design modular robots autonomously. Evolutionary algorithms can efficiently handle problems with discrete search spaces and solutions of variable sizes as these algorithms offer feasible robustness to local minima in the search space; and they can be parallelized easily to reducing system runtime. Moreover, they do not have to make assumptions about the solution form. This dissertation proposes a novel autonomous system for task-based modular robotic design based on evolutionary algorithms to search for the optimal design. The introduced system offers a flexible synthesis algorithm that can accommodate to different task-based design needs and can be applied to different modular shapes to produce homogenous modular robots. The proposed system uses a new representation for modular robotic assembly configuration based on graph theory and Assembly Incidence Matrix (AIM), in order to enable efficient and extendible task-based design of modular robots that can take input modules of different geometries and Degrees Of Freedom (DOFs). Robotic simulation is a powerful tool for saving time and money when designing robots as it provides an accurate method of assessing robotic adequacy to accomplish a specific task. Furthermore, it is difficult to predict robotic performance without simulation. Thus, simulation is used in this research to evaluate the robotic designs by measuring the fitness of the evolved robots, while incorporating the environmental features and robotic hardware constraints. Results are illustrated for a number of benchmark problems. The results presented a significant advance in robotic design automation state of the art

A novel design process of low cost 3D printed ambidextrous finger designed for an ambidextrous robotic hand

This paper presents the novel mechanical design of an ambidextrous finger specifically designed for an ambidextrous anthropomorphic robotic hand actuated by pneumatic artificial muscles. The ambidextrous nature of design allows fingers to perform both left and right hand movements. The aim of our design is to reduce the number of actuators, increase the range of movements with best possible range ideally greater than a common human finger. Four prototypes are discussed in this paper; first prototype is focused on the choice of material and to consider the possible ways to reduce friction. Second prototype is designed to investigate the tendons routing configurations. Aim of third and fourth prototype is to improve the overall performance and to maximize the grasping force. Finally, a unified design (Final design) is presented in great detail. Comparison of all prototypes is done from different angles to evaluate the best design. The kinematic features of intermediate mode have been analysed to optimize both the flexibility and the robustness of the system, as well as to minimize the number of pneumatic muscles. The final design of an ambidextrous finger has developed, tested and 3D printed

Toward Biologically-Inspired Self-Healing, Resilient Architectures for Digital Instrumentation and Control Systems and Embedded Devices

Digital Instrumentation and Control (I&C) systems in safety-related applications of next generation industrial automation systems require high levels of resilience against different fault classes. One of the more essential concepts for achieving this goal is the notion of resilient and survivable digital I&C systems. In recent years, self-healing concepts based on biological physiology have received attention for the design of robust digital systems. However, many of these approaches have not been architected from the outset with safety in mind, nor have they been targeted for the automation community where a significant need exists. This dissertation presents a new self-healing digital I&C architecture called BioSymPLe, inspired from the way nature responds, defends and heals: the stem cells in the immune system of living organisms, the life cycle of the living cell, and the pathway from Deoxyribonucleic acid (DNA) to protein. The BioSymPLe architecture is integrating biological concepts, fault tolerance techniques, and operational schematics for the international standard IEC 61131-3 to facilitate adoption in the automation industry. BioSymPLe is organized into three hierarchical levels: the local function migration layer from the top side, the critical service layer in the middle, and the global function migration layer from the bottom side. The local layer is used to monitor the correct execution of functions at the cellular level and to activate healing mechanisms at the critical service level. The critical layer is allocating a group of functional B cells which represent the building block that executes the intended functionality of critical application based on the expression for DNA genetic codes stored inside each cell. The global layer uses a concept of embryonic stem cells by differentiating these type of cells to repair the faulty T cells and supervising all repair mechanisms. Finally, two industrial applications have been mapped on the proposed architecture, which are capable of tolerating a significant number of faults (transient, permanent, and hardware common cause failures CCFs) that can stem from environmental disturbances and we believe the nexus of its concepts can positively impact the next generation of critical systems in the automation industry

The pursuit of responsiveness in production environments: from flexibility to reconfigurability

Many production plants are pursuing responsiveness (i.e., timely purposeful change guided by external demands) as one of their main performance priorities and are looking for ways for their responsiveness to be improved. One of the ways that they are currently trying to do this is through the flexibility provided by production practices. On the other hand, other systems are also being now developed based on reconfigurability (such as reconfigurable manufacturing systems (RMSs)) which can enhance a company’s technological ability to respond to market requirements by reconfiguring its products and processes. This paper analyses how current production programmes can be a prior step to achieving reconfigurability. The analysis uses a holistic framework that considers a number of linkages or combinations of practices (technology, JIT, TQ, HR, TPM and production strategy) and how these enhance performance in terms of cost, quality and responsiveness. The framework is tested with data collected from a survey of 314 plants worldwide using a series of canonical correlation analyses. The results confirm not only the importance of practice linkages that do not only include technology as the launch pad for reconfigurability, but also that in their pursuit of responsiveness it is vital for plants to implement practices in the technology programme as well as to link them to organisational programmes. The framework presents a contribution to both theory and practice. It offers novel insights into the programme and production practices involved in transitioning from flexibility to reconfigurability in the pursuit of responsiveness and provides a basis for future research.Ministerio de Ciencia e Innovación DPI-2009-11148Junta de Andalucía P08-SEJ-0384