World Academy of Science, Engineering and Technology

Authors: A. Shirzadeh Chaleshtari, Sh. Shadrokh

Abstract:

Renewable and non-renewable resource constraints have been vast studied in theoretical fields of project scheduling problems. However, although cumulative resources are widespread in practical cases, the literature on project scheduling problems subject to these resources is scant. So in order to study this type of resources more, in this paper we use the framework of a resource constrained project scheduling problem (RCPSP) with finish-start precedence relations between activities and subject to the cumulative resources in addition to the renewable resources. We develop a branch and bound algorithm for this problem customizing precedence tree algorithm of RCPSP. We perform extensive experimental analysis on the algorithm to check its effectiveness and performance for solving different instances of the problem in question.

Keywords: Resource constrained project scheduling problem, cumulative resources, branch and bound algorithm, precedence tree.

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Authors: S.B. Ahmadi, Z. Moradpour, Gh. Liaghat

Abstract:

In this article the accumulated results out of the effects and length of the manufacture and production projects in the university and research standard have been settled with the usefulness definition of the process of project management for the accessibility to the proportional pattern in the “time and action" stages. Studies show that many problems confronted by the researchers in these projects are connected to the non-profiting of: 1) autonomous timing for gathering the educational theme, 2) autonomous timing for planning and pattern, presenting before the construction, and 3) autonomous timing for manufacture and sample presentation from the output. The result of this study indicates the division of every manufacture and production projects into three smaller autonomous projects from its kind, budget and autonomous expenditure, shape and order of the stages for the management of these kinds of projects. In this case study real result are compared with theoretical results.

Keywords: Project management, Manufacturing, production.

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Authors: Kezia Amanda Kurniadi, Emre Islamoglu, Kwangyeol Ryu

Abstract:

As there has been a recognizable transition in automotive industry from mass production to mass customization, automobile manufacturers and their suppliers have been seeking ways for more flexible and efficient processes. Eventually, modular production is currently being applied to manage the changing orders of the industry. In this paper, two different modular assembly line concepts were studied: conveyor line and box assembly line. Mathematical model for two assembly line concepts were developed and their production line efficiency were compared as a performance measure to improve their assembly line balancing.

Keywords: Line Efficiency, Box assembly line, Conventional conveyor line

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Authors: Myo Min Aung, Yoon Seok Chang, Woo Ram Kim

Abstract:

This paper presents a cold chain monitoring system which focuses on assessment of quality and dynamic pricing information about food in cold chain. Cold chain is composed of many actors and stages; however it can be seen as a single entity since a breakdown in temperature control at any stage can impact the final quality of the product. In a cold chain, the shelf life, quality, and safety of perishable food throughout the supply chain is greatly impacted by environmental factors especially temperature. In this paper, a prototype application is implemented to retrieve timetemperature history, the current quality and the dynamic price setting according to changing quality impacted by temperature fluctuations in real-time.

Keywords: Cold chain, monitoring, quality, temperature, traceability.

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Authors: Bita Tadayon, Nasser Salmasi

Abstract:

This research deals with a flexible flowshop scheduling problem with arrival and delivery of jobs in groups and processing them individually. Due to the special characteristics of each job, only a subset of machines in each stage is eligible to process that job. The objective function deals with minimization of sum of the completion time of groups on one hand and minimization of sum of the differences between completion time of jobs and delivery time of the group containing that job (waiting period) on the other hand. The problem can be stated as FFc / rj , Mj / irreg which has many applications in production and service industries. A mathematical model is proposed, the problem is proved to be NPcomplete, and an effective heuristic method is presented to schedule the jobs efficiently. This algorithm can then be used within the body of any metaheuristic algorithm for solving the problem.

Keywords: flexible flowshop scheduling, group processing, machine eligibility constraint, mathematical modeling.

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Authors: R. Bhuvenesh, M.H. Norizaman, M.S. Abdul Manan

Abstract:

Industrial surveys shows that manufacturing companies define the qualities of thermal removing process based on the dimension and physical appearance of the cutting material surface. Therefore, the roughness of the surface area of the material cut by the plasma arc cutting process and the rate of the removed material by the manual plasma arc cutting machine was importantly considered. Plasma arc cutter Selco Genesis 90 was used to cut Standard AISI 1017 Steel of 200 mm x100 mm x 6 mm manually based on the selected parameters setting. The material removal rate (MRR) was measured by determining the weight of the specimens before and after the cutting process. The surface roughness (SR) analysis was conducted using Mitutoyo CS-3100 to determine the average roughness value (Ra). Taguchi method was utilized to achieve optimum condition for both outputs studied. The microstructure analysis in the region of the cutting surface is performed using SEM. The results reveal that the SR values are inversely proportional to the MRR values. The quality of the surface roughness depends on the dross peak that occurred after the cutting process.

Keywords: Material removal rate, plasma arc cutting, surface roughness, Taguchi method

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Authors: Zakari Yaou, Lirong Cui

Abstract:

In a product development process, understanding the functional behavior of the system, the role of components in achieving functions and failure modes if components/subsystem fails its required function will help develop appropriate design validation and verification program for reliability assessment. The integration of these three issues will help design and reliability engineers in identifying weak spots in design and planning future actions and testing program. This case study demonstrate the advantage of unascertained theory described in the subjective cognition uncertainty, and then applies blind number (BN) theory in describing the uncertainty of the mechanical system failure process and the same time used the same theory in bringing out another mechanical reliability system model. The practical calculations shows the BN Model embodied the characters of simply, small account of calculation but betterforecasting capability, which had the value of macroscopic discussion to some extent.

Keywords: Mechanical structure Design, time-dependent stochastic process, unascertained information, blind number theory.

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Authors: Hun Go, Ji-Su Kim, Dong-Ho Lee

Abstract:

This study considers the problem of determining operation and maintenance schedules for a containership equipped with components during its sailing according to a pre-determined navigation schedule. The operation schedule, which specifies work time of each component, determines the due-date of each maintenance activity, and the maintenance schedule specifies the actual start time of each maintenance activity. The main constraints are component requirements, workforce availability, working time limitation, and inter-maintenance time. To represent the problem mathematically, a mixed integer programming model is developed. Then, due to the problem complexity, we suggest a heuristic for the objective of minimizing the sum of earliness and tardiness between the due-date and the starting time of each maintenance activity. Computational experiments were done on various test instances and the results are reported.

Keywords: Containerships, operation and preventive maintenance schedules, integer programming, heuristic

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Authors: Seungkyum Kim, Yongtae Park

Abstract:

Recently, business environment and customer needs have become rapidly changing, hence it is very difficult to fulfill sophisticated customer needs by product or service innovation only. In practice, to cope with this problem, various manufacturing companies have developed services to combine with their products. Along with this, many academic studies on PSS (Product Service System) which is the integrated system of products and services have been conducted from the viewpoint of manufacturers. On the other hand, service providers are also attempting to develop service-supporting products to increase their service competitiveness and provide differentiated value. However, there is a lack of research based on the service-centric point of view. Accordingly, this paper proposes a concept generation method for service-supporting product development from the service-centric point of view. This method is designed to be executed in five consecutive steps: situation analysis, problem definition, problem resolution, solution evaluation, and concept generation. In the proposed approach, some tools of TRIZ (Theory of Solving Inventive Problem) such as ISQ (Innovative Situation Questionnaire) and 40 inventive principles are employed in order to define problems of the current services and solve them by generating service-supporting product concepts. This research contributes to the development of service-supporting products and service-centric PSSs.

Keywords: TRIZ, PSS (Product Service System), service-supporting product, concept generation

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Authors: Mohsen Ebrahimi

Abstract:

In this paper, Steam Assisted Gravity Drainage (SAGD) is introduced and its advantages over ordinary steam injection is demonstrated. A simple simulation model is built and three scenarios of natural production, ordinary steam injection, and SAGD are compared in terms of their cumulative oil production and cumulative oil steam ratio. The results show that SAGD can significantly enhance oil production in quite a short period of time. However, since the distance between injection and production wells is short, the oil to steam ratio decreases gradually through time.

Keywords: Thermal recovery, Steam injection, SAGD, Enhanced oil recovery

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Authors: Serap Akcan, Ali Kokangul

Abstract:

We consider a single-echelon, single-item inventory system where both demand and lead-time are stochastic. Continuous review policy is used to control the inventory system. The objective is to calculate the reorder point level under stochastic parameters. A case study is presented in Neonatal Intensive Care Unit.

Keywords: Inventory control system, reorder point level, stochastic demand, stochastic lead time

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Authors: D.Katherasan, Madana Sashikant, S.Sandeep Bhat, P.Sathiya

Abstract:

Bead-on-plate welds were carried out on AISI 316L (N) austenitic stainless steel (ASS) using flux cored arc welding (FCAW) process. The bead on plates weld was conducted as per L25 orthogonal array. In this paper, the weld bead geometry such as depth of penetration (DOP), bead width (BW) and weld reinforcement (R) of AISI 316L (N) ASS are investigated. Taguchi approach is used as statistical design of experiment (DOE) technique for optimizing the selected welding input parameters. Grey relational analysis and desirability approach are applied to optimize the input parameters considering multiple output variables simultaneously. Confirmation experiment has also been conducted to validate the optimized parameters.

Keywords: bead-on-plate welding, bead profiles, desirability approach, grey relational analysis

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Authors: A. Nourmohammadzadeh, R. Tavakkoli- Moghaddam

Abstract:

As the air traffic increases at a hub airport, some flights cannot land or depart at their preferred target time. This event happens because the airport runways become occupied to near their capacity. It results in extra costs for both passengers and airlines because of the loss of connecting flights or more waiting, more fuel consumption, rescheduling crew members, etc. Hence, devising an appropriate scheduling method that determines a suitable runway and time for each flight in order to efficiently use the hub capacity and minimize the related costs is of great importance. In this paper, we present a mixed-integer zero-one model for scheduling a set of mixed landing and departing flights (despite of most previous studies considered only landings). According to the fact that the flight cost is strongly affected by the level of airline, we consider different airline categories in our model. This model presents a single objective minimizing the total sum of three terms, namely 1) the weighted deviation from targets, 2) the scheduled time of the last flight (i.e., makespan), and 3) the unbalancing the workload on runways. We solve 10 simulated instances of different sizes up to 30 flights and 4 runways. Optimal solutions are obtained in a reasonable time, which are satisfactory in comparison with the traditional rule, namely First- Come-First-Serve (FCFS) that is far apart from optimality in most cases.

Keywords: Arrival and departure scheduling, Airline level, Mixed-integer model

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Authors: Maissom Qanber Abbasi, Philip Lew, Irfan Rafique, Zhang Li

Abstract:

Perceptions of quality from both designers and users perspective have now stretched beyond the traditional usability, incorporating abstract and subjective concepts. This has led to a shift in human computer interaction research communities- focus; a shift that focuses on achieving user experience (UX) by not only fulfilling conventional usability needs but also those that go beyond them. The term UX, although widely spread and given significant importance, lacks consensus in its unified definition. In this paper, we survey various UX definitions and modeling frameworks and examine them as the foundation for proposing a UX evolution lifecycle framework for understanding UX in detail. In the proposed framework we identify the building blocks of UX and discuss how UX evolves in various phases. The framework can be used as a tool to understand experience requirements and evaluate them, resulting in better UX design and hence improved user satisfaction.

Keywords: Usability, user experience lifecycle, user satisfaction

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Authors: Mehdi Seifbarghy, Keyvan Roshan

Abstract:

Main goal of preventive healthcare problems are at decreasing the likelihood and severity of potentially life-threatening illnesses by protection and early detection. The levels of establishment and staffing costs along with summation of the travel and waiting time that clients spent are considered as objectives functions of the proposed nonlinear integer programming model. In this paper, we have proposed a bi-objective mathematical model for designing a network of preventive healthcare facilities so as to minimize aforementioned objectives, simultaneously. Moreover, each facility acts as M/M/1 queuing system. The number of facilities to be established, the location of each facility, and the level of technology for each facility to be chosen are provided as the main determinants of a healthcare facility network. Finally, to demonstrate performance of the proposed model, four multi-objective decision making techniques are presented to solve the model.

Keywords: Preventive healthcare problems, Non-linear integer programming models, Multi-objective decision making techniques

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Authors: Rungchat Chompu-Inwai, Akararit Charoenkasemsuk

Abstract:

The use of electronic sensors in the electronics industry has become increasingly popular over the past few years, and it has become a high competition product. The frequency adjustment process is regarded as one of the most important process in the electronic sensor manufacturing process. Due to inaccuracies in the frequency adjustment process, up to 80% waste can be caused due to rework processes; therefore, this study aims to provide a preliminary understanding of the role of parameters used in the frequency adjustment process, and also make suggestions in order to further improve performance. Four parameters are considered in this study: air pressure, dispensing time, vacuum force, and the distance between the needle tip and the product. A full factorial design for experiment 2k was considered to determine those parameters that significantly affect the accuracy of the frequency adjustment process, where a deviation in the frequency after adjustment and the target frequency is expected to be 0 kHz. The experiment was conducted on two levels, using two replications and with five center-points added. In total, 37 experiments were carried out. The results reveal that air pressure and dispensing time significantly affect the frequency adjustment process. The mathematical relationship between these two parameters was formulated, and the optimal parameters for air pressure and dispensing time were found to be 0.45 MPa and 458 ms, respectively. The optimal parameters were examined by carrying out a confirmation experiment in which an average deviation of 0.082 kHz was achieved.

Keywords: Design of Experiment, Electronic Sensor, Frequency Adjustment, Parametric Analysis

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Authors: M. S. Abdelwahed, M. A. El-Baz, T. T. El-Midany

Abstract:

this paper aims to provide an approach to predict the performance of the product produced after multi-stages of manufacturing processes, as well as the assembly. Such approach aims to control and subsequently identify the relationship between the process inputs and outputs so that a process engineer can more accurately predict how the process output shall perform based on the system inputs. The approach is guided by a six-sigma methodology to obtain improved performance. In this paper a case study of the manufacture of a hermetic reciprocating compressor is presented. The application of artificial neural networks (ANNs) technique is introduced to improve performance prediction within this manufacturing environment. The results demonstrate that the approach predicts accurately and effectively.

Keywords: Artificial neural networks, Reciprocating compressor manufacturing, Performance prediction, Quality improvement

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Authors: Liv Gingnell, Evelina Ericsson, Joakim Lilliesköld, Robert Langerström

Abstract:

In recent years, an increased competition and lower profit margins have necessitated a focus on improving the performance of the product development process, an area that traditionally have been excluded from detailed steering and evaluation. A systematic improvement requires a good understanding of the current performance, wherefore the interest for product development performance measurement has increased dramatically. This paper presents a case study that evaluates the performance of the product development performance measurement system used in a Swedish company that is a part of a global corporate group. The study is based on internal documentation and eighteen in-depth interviews with stakeholders involved in the product development process. The results from the case study includes a description of what metrics that are in use, how these are employed, and its affect on the quality of the performance measurement system. Especially, the importance of having a well-defined process proved to have a major impact on the quality of the performance measurement system in this particular case.

Keywords: Outcome metric, Performance driver, Performance measurement, Product development process.

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Authors: Mohsen Ebrahimi, Milad M. Rabieh

Abstract:

In this paper, two very different optimization algorithms, Genetic and DIRECT algorithms, are used to history match a bottomhole pressure response for a reservoir with wellbore storage and skin with the best possible analytical model. No initial guesses are available for reservoir parameters. The results show that the matching process is much faster and more accurate for DIRECT method in comparison with Genetic algorithm. It is furthermore concluded that the DIRECT algorithm does not need any initial guesses, whereas Genetic algorithm needs to be tuned according to initial guesses.

Keywords: DIRECT algorithm, Genetic algorithm, Analytical modeling, History match

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Authors: Seyed Habib A. Rahmati

Abstract:

During last decades, developing multi-objective evolutionary algorithms for optimization problems has found considerable attention. Flexible job shop scheduling problem, as an important scheduling optimization problem, has found this attention too. However, most of the multi-objective algorithms that are developed for this problem use nonprofessional approaches. In another words, most of them combine their objectives and then solve multi-objective problem through single objective approaches. Of course, except some scarce researches that uses Pareto-based algorithms. Therefore, in this paper, a new Pareto-based algorithm called controlled elitism non-dominated sorting genetic algorithm (CENSGA) is proposed for the multi-objective FJSP (MOFJSP). Our considered objectives are makespan, critical machine work load, and total work load of machines. The proposed algorithm is also compared with one the best Pareto-based algorithms of the literature on some multi-objective criteria, statistically.

Keywords: Scheduling, Flexible job shop scheduling problem, controlled elitism non-dominated sorting genetic algorithm

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Authors: Tim Giesen, Christian Fischmann, Fabian Böttinger, Alexander Ehm, Alexander Verl

Abstract:

In a state-of-the-art industrial production line of photovoltaic products the handling and automation processes are of particular importance and implication. While processing a fully functional crystalline solar cell an as-cut photovoltaic wafer is subject to numerous repeated handling steps. With respect to stronger requirements in productivity and decreasing rejections due to defects the mechanical stress on the thin wafers has to be reduced to a minimum as the fragility increases by decreasing wafer thicknesses. In relation to the increasing wafer fragility, researches at the Fraunhofer Institutes IPA and CSP showed a negative correlation between multiple handling processes and the wafer integrity. Recent work therefore focused on the analysis and optimization of the dry wafer stack separation process with compressed air. The achievement of a wafer sensitive process capability and a high production throughput rate is the basic motivation in this research.

Keywords: Automation, Photovoltaic Manufacturing, Thin Wafer, Material Handling

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Authors: Ayse Gecer, Nihal Erginel

Abstract:

Quality control is the crucial step for ISO 9001 Quality System Management Standard for companies. While measuring the quality level of both raw material and semi product/product, the calibration of the measuring device is an essential requirement. Calibration suppliers are in the service sector and therefore the calibration supplier selection is becoming a worthy topic for improving service quality. This study presents the results of a questionnaire about the selection criteria of a calibration supplier. The questionnaire was applied to 103 companies and the results are discussed in this paper. The analysis was made with MINITAB 14.0 statistical programs. “Competence of documentations" and “technical capability" are defined as the prerequisites because of the ISO/IEC17025:2005 standard. Also “warranties and complaint policy", “communication", “service features", “quality" and “performance history" are defined as very important criteria for calibration supplier selection.

Keywords: Calibration, criteria of calibration supplier selection, calibration supplier selection, questionnaire

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Authors: Somsri Binraman, Boonliang Kaewnapan, Krittika Tanprasert

Abstract:

In the package design industry, there are a lot of tacit knowledge resided within each designer. The objectives are to capture them and compile it to be used as a teaching resource and to create a video clip of package design process as well as to evaluate its quality and learning effectiveness. Interview were used as a technique for capturing knowledge in brand design concept, differentiation, recognition, rank of recognition factor, consumer survey, knowledge about marketing, research, graphic design, the effect of color, and law and regulation. Video clip about package design were created. The clip consisted of both the speech and clip of actual process. The quality of the video in term of media was ranked as good while the content was ranked as excellent. The students- score on post-test was significantly greater than that of pretest (p>0.001).

Keywords: Tacit knowledge, interview, video, packaging, design.

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Authors: M. Torabizadeh, M. Khatami Rad, A. Noshadi

Abstract:

In order to achieve competitive advantage and better performance of firm, supply chain management (SCM) strategy should support and drive forward business strategy. It means that supply chain should be aligned with business strategy, at the same time supply chain (SC) managers need to use appropriate information system (IS) solution to support their strategy, which would lead to stay competitive. There are different kinds of IS strategies which enable managers to meet the SC requirement by selecting the best IS strategy. Therefore, it is important to align IS strategies and practices with SC strategies and practices, which could help us to plan for an IS application that supports and enhances a SCMS. In this study, aligning IS with SC in strategy level is considered. The main aim of this paper is to align the various IS strategies with SCM strategies and demonstrate their impact on SC and firm performance.

Keywords: Information system strategy, alignment, firm performance, supply chain strategy.

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Authors: Ellysa Nursanti, Anas Ma'ruf, Tota Simatupang, Bermawi P. Iskandar

Abstract:

This study proposes a hybrid minimal repair policy which combines periodic maintenance policy with age-based maintenance policy for a serial production system. Parameters of such policy are defined as
and  which indicate as hybrid minimal repair time and planned preventive maintenance time respectively  . Under this hybrid policy, the system is repaired minimally if it fails during ,
. A perfect repair is conducted on the first failure after
at any machines. At the same time, we take opportunity to advance the preventive maintenance of other machines simultaneously. If the system is still operating properly up to , then the preventive maintenance is carried out as its predetermined schedule. For a given , we obtain the optimal value
which minimizes the expected cost per time unit. Numerical example is presented to illustrate the properties of the optimal solution.

Keywords: Hybrid minimal repair, opportunistic maintenance, preventive maintenance, series system

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Authors: Raid A. Al-Aomar

Abstract:

This paper presents an application of 5S lean technology to a production facility. Due to increased demand, high product variety, and a push production system, the plant has suffered from excessive wastes, unorganized workstations, and unhealthy work environment. This has translated into increased production cost, frequent delays, and low workers morale. Under such conditions, it has become difficult, if not impossible, to implement effective continuous improvement studies. Hence, the lean project is aimed at diagnosing the production process, streamlining the workflow, removing/reducing process waste, cleaning the production environment, improving plant layout, and organizing workstations. 5S lean technology is utilized for achieving project objectives. The work was a combination of both culture changes and tangible/physical changes on the shop floor. The project has drastically changed the plant and developed the infrastructure for a successful implementation of continuous improvement as well as other best practices and quality initiatives.

Keywords: 5S Technique, Continuous Improvement, Kaizen, Lean Technology, Work Methods, Work Standards

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Authors: Yongyoon Suh, Chulhyun Kim, Moon-soo Kim

Abstract:

As the trend of manufacturing is being dominated depending on services, products and processes are more and more related with sophisticated services. Thus, this research starts with the discussion about integration of the product, process, and service in the innovation process. In particular, this paper sets out some foundations for a theory of service innovation in the field of manufacturing, and proposes the dynamic model of service innovation related to product and process. Two dynamic models of service innovation are suggested to investigate major tendencies and dynamic variations during the innovation cycle: co-innovation and sequential innovation. To structure dynamic models of product, process, and service innovation, the innovation stages in which two models are mainly achieved are identified. The research would encourage manufacturers to formulate strategy and planning for service development with product and process.

Keywords: dynamic model, service innovation, service innovation models, innovation cycle, manufacturing industry.

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Authors: Ahmad Majdi Bin Abdul-Rani, Mesfin Gizaw, Yusri Yusof

Abstract:

Researches related to standard product model and development of neutral manufacturing interfaces for numerical control machines becomes a significant topic since the last 25 years. In this paper, a detail description of STEP implementation on turnmill manufacturing has been discussed. It shows requirements of information contents from ISO14649 data model. It covers to describe the design of STEP-NC framework applicable to turn-mill manufacturing. In the framework, EXPRESS-G and UML modeling tools are used to depict the information contents of the system and established the bases of information model requirement. A product and manufacturing data model applicable for STEP compliant manufacturing. The next generation turn-mill operations requirements have been represented by a UML diagram. An object oriented classes of ISO1449 has been developed on Visual Basic dot NET platform for binding the static information model represented by the UML diagram. An architect of the proposed system implementation has been given on the bases of the design and manufacturing module of STEP-NC interface established. Finally, a part 21 file process plan generated for an illustration of turn-mill components.

Keywords: CAPP, ISO14649, Product modeling, STEP-NC

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Authors: J. Chatthong, W. Boonchouytan, R. Burapa

Abstract:

The purpose of study was to design and construction the semi-automatic sliced ginger machine for reduce production times in sheet and slice ginger procedure furthermore, reduced amount of labor of slides and cutting method. Take consider into clean and safety of workers and consumers. The principle of machines, used 1 horsepower motor, rotation speed of sliced blade 967 rpm, the diameter of sliced dish 310 mm, consists of 2 blades for sheet cutting ginger and the power from motor which transfer to rotate the sliced blade roller, rotation speed 440 rpm. The slice cutter roller was sliced ginger from sheet ginger to line ginger. The conveyer could adjustment level of motors, used to the beginning area that sheet ginger was transference to the roller for sheet and sliced cutting in next process. The cover of sliced cutting had channel for 1 tuber of ginger. The semi-automatic sliced ginger machine could produced sheet ginger 81.8 kg/h (6.2 times of labor) and line ginger 17.9 kg/h (2.5 times of labor) compare with, labor work could produced sheet ginger 13.2 kg/h and line ginger 7.1 kg/h, and when timekeeper, the total times of semi auto machine 30.86 kg/h and labor 4.6 kg/h, there for the semi auto machine was 6.7 times of labor. The semiautomatic sliced ginger machine convenient, easy for use and maintain, in addition to reduce fatigue of body and seriousness from works; must be used high skill, and protection accident in slicing procedure. Beside, machine could used with other vegetables for example potato, carrot .etc

Keywords: Sliced Machine, Sliced Ginger, Line Ginger

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Authors: Johan Wall, Johan Fredin, Anders Jönsson, Göran Broman

Abstract:

Designing modern machine tools is a complex task. A simulation tool to aid the design work, a virtual machine, has therefore been developed in earlier work. The virtual machine considers the interaction between the mechanics of the machine (including structural flexibility) and the control system. This paper exemplifies the usefulness of the virtual machine as a tool for product development. An optimisation study is conducted aiming at improving the existing design of a machine tool regarding weight and manufacturing accuracy at maintained manufacturing speed. The problem can be categorised as constrained multidisciplinary multiobjective multivariable optimisation. Parameters of the control and geometric quantities of the machine are used as design variables. This results in a mix of continuous and discrete variables and an optimisation approach using a genetic algorithm is therefore deployed. The accuracy objective is evaluated according to international standards. The complete systems model shows nondeterministic behaviour. A strategy to handle this based on statistical analysis is suggested. The weight of the main moving parts is reduced by more than 30 per cent and the manufacturing accuracy is improvement by more than 60 per cent compared to the original design, with no reduction in manufacturing speed. It is also shown that interaction effects exist between the mechanics and the control, i.e. this improvement would most likely not been possible with a conventional sequential design approach within the same time, cost and general resource frame. This indicates the potential of the virtual machine concept for contributing to improved efficiency of both complex products and the development process for such products. Companies incorporating such advanced simulation tools in their product development could thus improve its own competitiveness as well as contribute to improved resource efficiency of society at large.

Keywords: Machine tools, Mechatronics, Non-deterministic, Optimisation, Product development, Virtual machine

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