Design of generic modular reconfigurable platforms (GMRPS) for a product-oriented micro manufacturing system

With the proposition of the concept of product-service systems, many manufacturers are focusing on selling services or functionality rather than products. Industrial production is shifting production models from mass production to mass customization and highly personalized needs. As a result, there is a tendency for manufacturing system suppliers to develop product-oriented systems to responsively cope with the dynamic fast moving competitive market. The key features of such a manufacturing system are the reconfigurability and adaptability, which can enable the system respond to the changeable needs of customers quickly and adaptively. Therefore, one of the challenges for the micro manufacturing system provider has been the design of a reconfigurable machine platform which will provide the functionalities and flexibility required by the product-oriented systems. In this paper, a new micro manufacturing platform, i.e. a generic modular reconfigurable platform (GMRP) is proposed in order to provide an effective means for fabrication of high quality micro products at low cost in a responsive manner. The GMRP-based system aims to be a product-oriented reconfigurable, highly responsive manufacturing system particularly for high value nano/micro manufacturing purposes. To reuse components and decrease material consumption, GMRP is characterized by hybrid micro manufacturing processes, modularity of key components, and reconfigurability of machine platforms and key components. Furthermore, a practical methodology for the design of reconfigurable machine platforms is discussed against the requirements from product-driven micro manufacturing and its extension for adaptive production

Automatic generation of human machine interface screens from component-based reconfigurable virtual manufacturing cell

Increasing complexity and decreasing time-tomarket require changes in the traditional way of building automation systems. The paper describes a novel approach to automatically generate the Human Machine Interface (HMI) screens for component-based manufacturing cells based on their corresponding virtual models. Manufacturing cells are first prototyped and commissioned within a virtual engineering environment to validate and optimise the control behaviour. A framework for reusing the embedded control information in the virtual models to automatically generate the HMI screens is proposed. Finally, for proof of concept, the proposed solution is implemented and tested on a test rig

Realising the open virtual commissioning of modular automation systems

To address the challenges in the automotive industry posed by the need to rapidly manufacture more product variants, and the resultant need for more adaptable production systems, radical changes are now required in the way in which such systems are developed and implemented. In this context, two enabling approaches for achieving more agile manufacturing, namely modular automation systems and virtual commissioning, are briefly reviewed in this contribution. Ongoing research conducted at Loughborough University which aims to provide a modular approach to automation systems design coupled with a virtual engineering toolset for the (re)configuration of such manufacturing automation systems is reported. The problems faced in the virtual commissioning of modular automation systems are outlined. AutomationML - an emerging neutral data format which has potential to address integration problems is discussed. The paper proposes and illustrates a collaborative framework in which AutomationML is adopted for the data exchange and data representation of related models to enable efficient open virtual prototype construction and virtual commissioning of modular automation systems. A case study is provided to show how to create the data model based on AutomationML for describing a modular automation system

Agent and cyber-physical system based self-organizing and self-adaptive intelligent shopfloor

The increasing demand of customized production results in huge challenges to the traditional manufacturing systems. In order to allocate resources timely according to the production requirements and to reduce disturbances, a framework for the future intelligent shopfloor is proposed in this paper. The framework consists of three primary models, namely the model of smart machine agent, the self-organizing model, and the self-adaptive model. A cyber-physical system for manufacturing shopfloor based on the multiagent technology is developed to realize the above-mentioned function models. Gray relational analysis and the hierarchy conflict resolution methods were applied to achieve the self-organizing and self-adaptive capabilities, thereby improving the reconfigurability and responsiveness of the shopfloor. A prototype system is developed, which has the adequate flexibility and robustness to configure resources and to deal with disturbances effectively. This research provides a feasible method for designing an autonomous factory with exception-handling capabilities

Reconfigurability Function Deployment in Software Development

In the forthcoming highly dynamic and complex business environment high-speed and cost-effective development of software applications for targeting a precise, unique and momentary set of requirements (no more-no less) associated to a customized business case will bring sig-nificant benefits both for producers and users. This requires a life cycle change-oriented ap-proach in software development. In this respect, designing software with intrinsic evolutionary resources for reconfiguration represents the sound approach. A methodology for concurrent deployment of reconfigurability characteristics in software applications is introduced in this paper. Its potential is exemplified in a case study dealing with web-based software tools to support systematic product innovation projects.Reconfigurability, Software Development, Innovation, TRIZ, RAD

Special Session on Industry 4.0

No abstract available

Virtual manufacturing: prediction of work piece geometric quality by considering machine and set-up

Lien vers la version éditeur: http://www.tandfonline.com/doi/full/10.1080/0951192X.2011.569952#.U4yZIHeqP3UIn the context of concurrent engineering, the design of the parts, the production planning and the manufacturing facility must be considered simultaneously. The design and development cycle can thus be reduced as manufacturing constraints are taken into account as early as possible. Thus, the design phase takes into account the manufacturing constraints as the customer requirements; more these constraints must not restrict the creativity of design. Also to facilitate the choice of the most suitable system for a specific process, Virtual Manufacturing is supplemented with developments of numerical computations (Altintas et al. 2005, Bianchi et al. 1996) in order to compare at low cost several solutions developed with several hypothesis without manufacturing of prototypes. In this context, the authors want to predict the work piece geometric more accurately by considering machine defects and work piece set-up, through the use of process simulation. A particular case study based on a 3 axis milling machine will be used here to illustrate the authors’ point of view. This study focuses on the following geometric defects: machine geometric errors, work piece positioning errors due to fixture system and part accuracy

Enhanced integrated modelling approach to reconfiguring manufacturing enterprises

Dynamism and uncertainty are real challenges for present day manufacturing enterprises (MEs). Reasons include: an increasing demand for customisation, reduced time to market, shortened product life cycles and globalisation. MEs can reduce competitive pressure by becoming reconfigurable and change-capable. However, modern manufacturing philosophies, including agile and lean, must complement the application of reconfigurable manufacturing paradigms. Choosing and applying the best philosophies and techniques is very difficult as most MEs deploy complex and unique configurations of processes and resource systems, and seek economies of scope and scale in respect of changing and distinctive product flows. It follows that systematic methods of achieving model driven reconfiguration and interoperation of component based manufacturing systems are required to design, engineer and change future MEs. This thesis, titled Enhanced Integrated Modelling Approach to Reconfiguring Manufacturing Enterprises , introduces the development and prototyping a model-driven environment for the design, engineering, optimisation and control of the reconfiguration of MEs with an embedded capability to handle various types of change. The thesis describes a novel systematic approach, namely enhanced integrated modelling approach (EIMA), in which coherent sets of integrated models are created that facilitates the engineering of MEs especially their production planning and control (PPC) systems. The developed environment supports the engineering of common types of strategic, tactical and operational processes found in many MEs. The EIMA is centred on the ISO standardised CIMOSA process modelling approach. Early study led to the development of simulation models during which various CIMOSA shortcomings were observed, especially in its support for aspects of ME dynamism. A need was raised to structure and create semantically enriched models hence forming an enhanced integrated modelling environment. The thesis also presents three industrial case examples: (1) Ford Motor Company; (2) Bradgate Furniture Manufacturing Company; and (3) ACM Bearings Company. In order to understand the system prior to realisation of any PPC strategy, multiple process segments of any target organisation need to be modelled. Coherent multi-perspective case study models are presented that have facilitated process reengineering and associated resource system configuration. Such models have a capability to enable PPC decision making processes in support of the reconfiguration of MEs. During these case studies, capabilities of a number of software tools were exploited such as Arena®, Simul8®, Plant Simulation®, MS Visio®, and MS Excel®. Case study results demonstrated effectiveness of the concepts related to the EIMA. The research has resulted in new contributions to knowledge in terms of new understandings, concepts and methods in following ways: (1) a structured model driven integrated approach to the design, optimisation and control of future reconfiguration of MEs. The EIMA is an enriched and generic process modelling approach with capability to represent both static and dynamic aspects of an ME; and (2) example application cases showing benefits in terms of reduction in lead time, cost and resource load and in terms of improved responsiveness of processes and resource systems with a special focus on PPC; (3) identification and industrial application of a new key performance indicator (KPI) known as P3C the measuring and monitoring of which can aid in enhancing reconfigurability and responsiveness of MEs; and (4) an enriched modelling concept framework (E-MUNE) to capture requirements of static and dynamic aspects of MEs where the conceptual framework has the capability to be extended and modified according to the requirements. The thesis outlines key areas outlining a need for future research into integrated modelling approaches, interoperation and updating mechanisms of partial models in support of the reconfiguration of MEs