Design of an electrochemical micromachining machine

Electrochemical micromachining (μECM) is a non-conventional machining process based on the phenomenon of electrolysis. μECM became an attractive area of research due to the fact that this process does not create any defective layer after machining and that there is a growing demand for better surface integrity on different micro applications including microfluidics systems, stress-free drilled holes in automotive and aerospace manufacturing with complex shapes, etc. This work presents the design of a next generation μECM machine for the automotive, aerospace, medical and metrology sectors. It has three axes of motion (X, Y, Z) and a spindle allowing the tool-electrode to rotate during machining. The linear slides for each axis use air bearings with linear DC brushless motors and 2-nm resolution encoders for ultra precise motion. The control system is based on the Power PMAC motion controller from Delta Tau. The electrolyte tank is located at the rear of the machine and allows the electrolyte to be changed quickly. This machine features two process control algorithms: fuzzy logic control and adaptive feed rate. A self-developed pulse generator has been mounted and interfaced with the machine and a wire ECM grinding device has been added. The pulse generator has the possibility to reverse the pulse polarity for on-line tool fabrication.The research reported in this paper is supported by the European Commission within the project “Minimizing Defects in Micro-Manufacturing Applications (MIDEMMA)” (FP7-2011-NMPICT- FoF-285614)

OPEN ARCHITECTURE PLATFORMS FOR THE CONTROL OF ROBOTIC SYSTEMS AND A PROPOSED REFERENCE ARCHITECTURE MODEL

This paper presents advantages of using open architecture for the real-time control of robot manipulators, parallel kinematics machine tools and other multi-axis machining systems. In order to increase their competitiveness, companies need to follow the global economy requirements. The constant incorporation of new technologies into existing controllers and reduction in the development time and costs are the main objectives. An open architecture control (OAC) concept appears as a solution to deal with these requirements. This article explains the rationale for the development of OAC systems, presents the major international activities which propose various approaches to OACs and a series of controllers that have been developed using this design philosophy at the Lola Institute

OPEN ARCHITECTURE PLATFORMS FOR THE CONTROL OF ROBOTIC SYSTEMS AND A PROPOSED REFERENCE ARCHITECTURE MODEL

This paper presents advantages of using open architecture for the real-time control of robot manipulators, parallel kinematics machine tools and other multi-axis machining systems. In order to increase their competitiveness, companies need to follow the global economy requirements. The constant incorporation of new technologies into existing controllers and reduction in the development time and costs are the main objectives. An open architecture control (OAC) concept appears as a solution to deal with these requirements. This article explains the rationale for the development of OAC systems, presents the major international activities which propose various approaches to OACs and a series of controllers that have been developed using this design philosophy at the Lola Institute

Investigation into inspection system utilisation for advanced manufacturing systems.

Masters Degree. University of KwaZulu-Natal, Durban.Varied inspection is an aperiodic inspection utilisation methodology that was developed for advanced manufacturing systems. The inspection scheme was created as a solution to improve manufacturing performance where inspection hinders production, such as cases where inspection time is significantly larger than machining time. Frequent inspection impedes production cycles which result in undesirable blocking, starving, low machine utilisation, increased lead time and work-in-process. The aim of the inspection strategy was to aid manufacturing metrics by adjusting inspection utilisation through multiple control methods. The novelty of the research lies in using an inspection strategy for improved manufacturing performance. Quality control was traditionally viewed as an unintegrated aspect of production. As such, quality control was only used as a tool for ensuring certain standards of products, rather than being used as a tool to aid production. The problem was solved by using the amount of inspection performed as a variable, and changing that variable based on the needs of the manufacturing process. “Inspection intensity” was defined as the amount of inspection performed on a part stream and was based on inputs such as part quality, required production rates, work-in-process requirements among other factors. Varied inspection was executed using a two-level control architecture of fuzzy controllers. Lower level controllers performed varied inspection while an upper level supervisory controller measured overall system performance and made adjustments to lower level controllers to meet system requirements. The research was constrained to simulation results to test the effects of varied inspection on different manufacturing models. Simulation software was used to model advanced manufacturing systems to test the effects of varied inspection against traditional quality control schemes. Matlab’s SimEvents® was used for discrete-event simulation and Fuzzy Logic Toolbox® was used for the controller design. Through simulation, varied inspection was used to meet production needs such as reduced manufacturing lead time, reduced work-in-process, reduced starvation and blockage, and reduced appraisal costs. Machine utilisation was increased. The contribution of the research was that quality control could be used to aid manufacturing systems instead of slowing it down. Varied inspection can be used as a flexible form of inspection. The research can be used as a control methodology to improve the usage of inspection systems to enhance manufacturing performance

AN ON-LINE INTELLIGENT ADAPTIVE CONTROLLER FOR MANUFACTURING OPERATIONS BASED ON AN OPEN ARCHITECTURE

In the development of the unattended and self-adjust machining system, where the human operator must be replaced by a Computer Numerical Control, the control system should properly process information with its varying environment in an intelligent way. The intelligent CNC must be able to recognize, in real time, major problems of operation connected to the machining process like chipping problems or tool breakage. To do that, the CNC intelligent system must be able to receive, process, and analyze inputs from multiple types of external sensor attached to it. This approach can only be possible on the base of an Open Architecture. The author of this paper proposes the use of fuzzy logic to develop an intelligent adaptive controller for manufacturing operations based on an open architecture that must be able to face problems of control, monitoring and fault diagnosis in real time

CPS Platform Approach to Industrial Robots: State of the Practice, Potentials, Future Research Directions

Approaches, such as Cloud Robotics, Robot-as-a-Service, merged Internet of Things and robotics, and Cyber-Physical Systems (CPS) in production, show that the industrial robotics domain experiences a paradigm shift that increasingly links robots in real-life factories with virtual reality. However, despite the growing body of research to date, though insightful, the paradigm shift to CPS in industrial robotics remains an under-researched area. Findings from the present paper make several contributions to the current state of research: We provide a potentially reusable framework of analysis and apply this framework in order to reveal whether and to what extent the industrial robotics branch implements abilities and characteristics of CPS. We examine the top five industrial robot manufacturers ABB, Fanuc, Kawasaki, Kuka, and Yaskawa and identify considerable, current implementations. However, concerning one of three perspectives—the perspective on CPS as industry platform constructs, takes the industrial robotics branch only certain small steps towards CPS platforms. We discuss them and outline a set of business model patterns that can transform product innovations, enabled by abilities and characteristics of CPS, into business model innovations in the industrial robot domain. In order to enable the industry to exploit the full potential of industrial robots understood as CPS, we question the right degree of openness in the context of industry platform constructs. Our methodological approach combines conceptual with empirical research

LinuxCNC – Napredni sustav CNC upravljanja: primjena i kritički osvrt

Ovaj rad prikazuje osvrt na implementaciju upravljačkog sustava otvorene arhitekture, tzv. Enhanced Machine Controller-a (EMC2), koji je primijenjen na glodalici kao ispitnom postavu. Razvoj ispitnog postava motiviran je edukacijskim i istraživačkim potrebama, osobito u području razvoja i analize algoritama za nadzor i upravljanje procesima obrade odvajanjem. EMC2 sustav je razmatran s obzirom na kompatibilne hardverske komponente i mogućnosti prilagodbe specifičnostima obradnog stroja, kao i mogućnostima za industrijsku primjenu. U radu su također prikazane tehničke karakteristike ispitnog postava i upravljačkog sustava

Five-Axis Machine Tool Condition Monitoring Using dSPACE Real-Time System

This paper presents the design, development and SIMULINK implementation of the lumped parameter model of C-axis drive from GEISS five-axis CNC machine tool. The simulated results compare well with the experimental data measured from the actual machine. Also the paper describes the steps for data acquisition using ControlDesk and hardware-in-the-loop implementation of the drive models in dSPACE real-time system. The main components of the HIL system are: the drive model simulation and input – output (I/O) modules for receiving the real controller outputs. The paper explains how the experimental data obtained from the data acquisition process using dSPACE real-time system can be used for the development of machine tool diagnosis and prognosis systems that facilitate the improvement of maintenance activities

A flexible manufacturing system for lawnmower cutting cylinders

The thesis is concerned with the conception and design of a FLEXIBLE MANUFACTURING SYSTEM (FMS) for the automation of the manufacture of lawnmower cutting cylinders at Suffolk Lawnmowers Ltd. A review of FMS definitions, planning methods and current systems is carried out for the development of a suitable FMS configuration for the final stages of manufacture of grass cutting cylinders having 21 different design specifications. This involves examination of the capabilities of robotics and microcontrollers to automate the technologies used in cylinder production. The company's current manual batch production system is analysed to determine the suitable form and requirements of the FMS. This includes analyses of annual volumes, throughputs, batch sizes, product and process mixes. Long term objectives to automate the system are identified from which short term objectives are derived. The FMS recommended for immediate development encompasses the short term objectives for the welding, hardening, grinding and transfer processes of 8 cutting cylinder specifications. It is shown that the MIG (Argon/C02) are welding, progressive flame hardening and wide-face cylindrical grinding processes can be developed successfully to automate cylinder production. The recommended system integrates these processes into an FMS through the'automatic handling of cylinders (through three process routes) by a robotic manipulator utilising a double gripper. 'A robotic welding station, manually loaded, is also recommended. ' The system is controlled overall by a 32K microcontroller with the process machines individually controlled by programmahle logic controllers with up to 6K of memory each. The economic appraisal of the FMS indicates a 4.4 year payback based on direct labour and material cost savings. The company's application for grant aid to implement the FMS design has led to an offer of a Department of Industry grant to cover 50% of all capital and revenue costs. The grant of £166,943 reduces the payback period to 2.3 years