Hybrid Manufacturing System Modeling and Development

2012 ◽  
Author(s):  
Jacquelyn K. S. Nagel ◽  
Frank W. Liou
Keyword(s):  
Hybrid System ◽  
Manufacturing Process ◽  
Manufacturing Systems ◽  
Manufacturing System ◽  
System Modeling ◽  
Production Costs ◽  
Production Model ◽  
Hybrid Manufacturing ◽  
Lamp System ◽  
Metallic Parts

Reliable and economical fabrication of metallic parts with complicated geometries is of considerable interest for the aerospace, medical, automotive, tooling and consumer products industries. In an effort to shorten the time-to-market, decrease the manufacturing process chain, and cut production costs of products produced by these industries, research has focused on the integration of multiple unit manufacturing processes into one machine. The end goal is to reduce production space, time, and manpower requirements. Our research into hybrid manufacturing systems has lead to the integration of additive and subtractive processes within a single machine footprint such that both processes are leveraged during fabrication. The laser aided manufacturing process (LAMP) system provides a rapid prototyping and rapid manufacturing infrastructure for research and education. The LAMP system creates fully dense, metallic parts and provides all the advantages of commercial laser metal deposition (LMD) systems. This hybrid system is a very competitive and economical approach to fabricating metallic structures. Hybrid manufacturing systems facilitate a sustainable and intelligent production model and offer flexibility of infrastructure to adapt with emergent technology, customization, and changing market needs. This paper summarizes the salient research activities and the findings of those activities related to the modeling and development of the hybrid manufacturing system. Our qualitative and quantitative modeling efforts, as well as the resultant system architecture are described. The approach and strategies utilized in this research coalesce to facilitate an interdisciplinary approach to the development a hybrid manufacturing system to produce metal parts that are not only functional but also processed to the final desired surface-finished and tolerance. Furthermore, the approach to hybrid system modeling and development can assist in general with integrated manufacturing systems.

scholarly journals Flexible Productive Systems Modeling and Control Tools: Literature Review

2020 ◽  
pp. 91-98
Author(s):  
URC Mazzoni ◽  
OL Asato ◽  
FY Nakamoto
Keyword(s):  
Control System ◽  
Control Systems ◽  
Manufacturing Systems ◽  
New Technologies ◽  
System Modeling ◽  
Production Costs ◽  
Modeling Tools ◽  
Modeling And Control ◽  
Productive Systems ◽  
And Control

The challenges imposed on Manufacturing Systems (MS), given the demands of a dynamic and competitive market, instigates the development of new technologies to promote the reduction of production costs, increase productivity and ensure the level of quality established by the company. Such technologies applied in MS create demands for new paradigms for the design of control systems, mainly about the integration of automated systems, such as multifunction machines, flexible machining centers, intelligent robotic conveyor systems, and the integration of information systems, production planning and management, and manufacturing execution. The main purpose of control system modeling is to represent a real system using conceptual models to visualize, predict and simulate the desired dynamic behavior of the system. This article presents some modeling tools for control systems capable of adequately representing a manufacturing system with all its requirements and intrinsic characteristics, supported by formal methods for structured modeling of the control system.

Material distribution method in discrete manufacturing systems and a case study from engine builders

2020 ◽  
Vol 234 (14) ◽  
pp. 1720-1728
Author(s):  
Li Li ◽  
Yujin Chen ◽  
Debin Lai ◽  
Bo Li ◽  
Xiangqing Wei
Keyword(s):  
Manufacturing Systems ◽  
Manufacturing System ◽  
Assembly Line ◽  
System Modeling ◽  
Active Material ◽  
Configuration Model ◽  
Material Distribution ◽  
Distribution Method ◽  
Research Perspective ◽  
Discrete Manufacturing

In a discrete manufacturing enterprise, it is difficult to satisfy the fast matching and accurate supply of production materials or the demand of modern dynamic production systems using passive material supply. With a focus on engine builders, this study explores the active material configuration and systematic material distribution approaches. Due to the material characteristics and the granularity of logistics demand, the material distribution is arranged in reverse chronological order, and the corresponding mathematical modeling of the distributing period is proposed to achieve lean manufacturing. To ensure exact material distribution time, the allocation material configuration model that works best for the dynamic manufacturing system is presented by means of system modeling. Next, a production material distribution method for the general assembly line and the sub-assembly line with a closely related production sequence is proposed to achieve the exact match of manufacturing and material resources through the analysis of data fusion and logistics resource matching. Finally, a simulation is conducted using production data gathered from engine builders. The results indicate the effectiveness of the proposed active material configuration method. The outcome of this study can be used as a guide for the time planning of material flow in a dynamic manufacturing system and can provide a new research perspective on production logistics or distribution in a production line.

Designing a Modular Rapid Manufacturing Process

2010 ◽  
Vol 132 (6) ◽  
Author(s):  
Jacquelyn K. S. Nagel ◽  
Frank W. Liou
Keyword(s):  
Manufacturing Process ◽  
Design Methodology ◽  
Manufacturing Systems ◽  
Manufacturing System ◽  
Modular Design ◽  
Process Integration ◽  
Process Analysis ◽  
Integrated System ◽  
Rapid Manufacturing ◽  
Potential Cost

Freeform fabrication and additive fabrication technologies have been combined with subtractive processes to achieve a variety of fully integrated rapid manufacturing systems. The combination of separate fabrication techniques into one rapid manufacturing system results in unit manufacturing process integration, sometimes known as a hybrid system. However, the design methods or approaches required to construct these integrated systems are vaguely described or not mentioned at all. The final product from any integrated system is affected not only by the unit manufacturing processes themselves, but also by the extent the individual units are assimilated into an integrated process. A wide variety of integrated and hybrid manufacturing systems and current manufacturing design methodologies are described in this paper, along with their similarities and differences. Through our extensive review, it was discovered that there are five key elements to a reliable integrated rapid manufacturing system: process planning software, motion system, control system, unit manufacturing process, and a finishing process. By studying the manner in which all other systems have been integrated, a table of successful integrated manufacturing system element combinations has been complied, documenting each of the key element choices, resulting in a variety of modular designs. This paper further discusses the importance of the five elements in manufacturing system integration, and how an integrated system is the way to move forward in the manufacturing domain. To that end, a rapid manufacturing system design methodology was developed that explores designs via process analysis to discover integration potential. Cost-benefit analysis is then used to assess the performance of the new system. This analysis determines if all needs have been met, while staying within the constraints of time and resources. Additionally, a table of common issues and obstacles encountered during manufacturing system development has been compiled to assist in the design and development of future rapid manufacturing systems. To illustrate the design methodology, our modular design experience with a laser aided manufacturing process is presented. Unit manufacturing process integration has increased the productivity and capabilities of our system, which reduced resource volume and increased productivity.

scholarly journals Increasing the Environmental Sustainability of an Over-Injection Line for the Automotive Component Industry

2021 ◽  
Vol 13 (22) ◽  
pp. 12692
Author(s):  
Alexandre L. N. Vieira ◽  
Raul D. S. G. Campilho ◽  
Francisco J. G. Silva ◽  
Luís P. Ferreira
Keyword(s):  
Environmental Sustainability ◽  
Manufacturing Systems ◽  
Production Costs ◽  
Energetic Efficiency ◽  
Production Lines ◽  
Automated Production ◽  
Injection Line ◽  
Metallic Parts ◽  
The Cost ◽  
Automotive Component Industry

Thermoplastic injection is currently employed in different industrial fields. This process has significantly evolved over the years, and injection machine manufacturers are continuously forced to innovate, to improve the energetic efficiency, aiming to reduce costs, improve competitiveness, and promote environmental sustainability. This work focuses on the development of a novel, profitable, and environmentally friendly plastic over-injection equipment of small metallic parts for the automotive industry, to be applied in a bowden cable production line, to cover the zamak terminations with plastic, or produce terminations entirely made of plastic. The work is based on an over-sized existing solution. The operating parameters required for the work are quantified, and all machine parts are designed separately to achieve the required functionality. Known approaches are finally used to perform the cost analysis, calculate the return on investment (ROI), and energetic efficiency, to substantiate the replacement of the current solution. The new equipment was able to increase the energetic efficiency of the current assembly line while keeping the required injection rates. An efficient and sustainable solution was presented, with a ROI of 1.2 years over the current solution. The proposed design is also applicable to different automated production lines that require this technology. Nowadays, this concept can be extended to all fields of industry that employ injection molding in their processes, enabling to integrate new manufacturing systems, and increasing energetic efficiency while reducing production costs.

scholarly journals A Multi-State Model for Reliability Analysis of Metal Sheet Manufacturing Process Using Artificial Neural Network Technique

2020 ◽  
Vol 28 (4) ◽  
Author(s):  
Anil Chandra ◽  
Surbhi Gupta ◽  
Chandra Kant Jaggi
Keyword(s):  
Neural Network ◽  
Artificial Neural Network ◽  
Reliability Analysis ◽  
Manufacturing Process ◽  
Manufacturing Systems ◽  
Manufacturing System ◽  
Metal Sheet ◽  
Time Period ◽  
Artificial Neural ◽  
Over Time

A manufacturing system is governed by its various processes upon which its efficiency is dependent. Since failure results in considerable losses, many manufacturing systems have certain redundancies for some processes. These redundancies cause the system to work under different efficiency states called multi-state elements. In this paper, various processes of metal sheet manufacturing unit have been categorized as subsystems to determine the multi-state probabilities of its different efficiency states. Artificial Neural Network Technique (ANN) has been used to estimate the change in these multi-state probabilities over time. The ANN has also been used to estimate variation in upstate and downstate probabilities of the system for a particular-time period. The results have been used to determine variation in profit over time for the system.

Effective Applications of Optimization Methods in the Manufacturing Environment in Turkey

2016 ◽  
pp. 319-335 ◽  
Author(s):  
Omer Faruk Yilmaz ◽  
Hikmet Erbiyik
Keyword(s):  
Manufacturing Systems ◽  
Manufacturing System ◽  
Optimization Methods ◽  
Hybrid Manufacturing ◽  
Manufacturing Environment ◽  
Literature Research ◽  
The Real ◽  
Extant Literature ◽  
Functional Layout ◽  
Manufacturing Environments

In today's manufacturing environment both used equipment and worker resources have become more crucial. Both resource must be used in an effective and appropriate way. Therefore, studies in conjuction with manufacturing environment are actualized under dual resource constrained (DRC). In the extant literature, DRC manufacturing environments place importance on certain dimensions which are surveyed in detail in this study. This literature research is conducted for manufacturing environments where worker planning and product scheduling topics are studied frequently. Our observations reveal that the systems of single conducted do not reflect the real manufacturing environment; hence, hybrid manufacturing systems which consist of functional layout and cells are investigated. The efficiency of hybrid manufacturing systems in the DRC environment are revealed by searching through literature. Therefore, the more effective way of usage of optimization methods are proposed by examining the studies regarding hybrid manufacturing system in terms of usage of optimization methods.

scholarly journals Distributed Control of a Manufacturing System with One-Dimensional Cellular Automata

Complexity ◽  
2018 ◽  
Vol 2018 ◽  
pp. 1-15
Author(s):  
Irving Barragan-Vite ◽  
Juan C. Seck-Tuoh-Mora ◽  
Norberto Hernandez-Romero ◽  
Joselito Medina-Marin ◽  
Eva S. Hernandez-Gress
Keyword(s):  
Cellular Automata ◽  
Cellular Automaton ◽  
Distributed Control ◽  
Manufacturing Process ◽  
Manufacturing Systems ◽  
Manufacturing System ◽  
Complex Dynamics ◽  
Initial Conditions ◽  
Global Dynamics ◽  
One Dimensional

We present a distributed control modeling approach for an automated manufacturing system based on the dynamics of one-dimensional cellular automata. This is inspired by the fact that both cellular automata and manufacturing systems are discrete dynamical systems where local interactions given among their elements (resources) can lead to complex dynamics, despite the simple rules governing such interactions. The cellular automaton model developed in this study focuses on two states of the resources of a manufacturing system, namely, busy or idle. However, the interaction among the resources such as whether they are shared at different stages of the manufacturing process determines the global dynamics of the system. A procedure is shown to obtain the local evolution rule of the automaton based on the relationships among the resources and the material flow through the manufacturing process. The resulting distributed control of the manufacturing system appears to be heterarchical, and the evolution of the cellular automaton exhibits a Class II behavior for some given disordered initial conditions.

scholarly journals Scalability analysis of selected structures of a reconfigurable manufacturing system taking into account a reduction in machine tools reliability

2021 ◽  
Vol 23 (2) ◽  
pp. 242-252
Author(s):  
Arkadiusz Gola ◽  
Zbigniew Pastuszak ◽  
Marcin Relich ◽  
Łukasz Sobaszek ◽  
Eryk Szwarc
Keyword(s):  
Manufacturing Process ◽  
Machine Tools ◽  
Manufacturing Systems ◽  
Manufacturing System ◽  
Production Capacity ◽  
Cost Effective ◽  
Simulation Software ◽  
Reconfigurable Manufacturing ◽  
Product Demand ◽  
The Impact

Scalability is a key feature of reconfigurable manufacturing systems (RMS). It enables fast and cost-effective adaptation of their structure to sudden changes in product demand. In principle, it allows to adjust a system's production capacity to match the existing orders. However, scalability can also act as a "safety buffer" to ensure a required minimum level of productivity, even when there is a decline in the reliability of the machines that are part of the machine tool subsystem of a manufacturing system. In this article, we analysed selected functional structures of an RMS under design to see whether they could be expanded should the reliability of machine tools decrease making it impossible to achieve a defined level of productivity. We also investigated the impact of the expansion of the system on its reliability. To identify bottlenecks in the manufacturing process, we ran computer simulations in which the course of the manufacturing process was modelled and simulated for 2-, 3-, 4- and 5-stage RMS structures using Tecnomatix Plant Simulation software.

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