Search results for: Manufacturing Control

Authors: T. Yuri M. Zagloel, Inaki M. Hakim, A. M. Syarafi

Abstract:

Manufacturing process has been considered as one of the most important activity in business process. It correlates with productivity and quality of the product so industries could fulfill customer’s demand. With the increasing demand from customer, industries must improve their manufacturing ability such as shorten lead-time and reduce wastes on their process. Lean manufacturing has been considered as one of the tools to waste elimination in manufacturing or service industry. Workforce development is one practice in lean manufacturing that can reduce waste generated from operator such as waste of unnecessary motion. Anthropometric approach is proposed to determine the recommended measurement in operator’s work area. The method will get some dimensions from Indonesia people that related to piston workstation. The result from this research can be obtained new design for the work area considering ergonomic aspect.

Keywords: Adjustable, anthropometric, ergonomic, waste.

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Authors: Meftah O. Bashir, Fatma A. Karkory

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Rapid prototyping is a new group of manufacturing processes, which allows fabrication of physical of any complexity using a layer by layer deposition technique directly from a computer system. The rapid prototyping process greatly reduces the time and cost necessary to bring a new product to market. The prototypes made by these systems are used in a range of industrial application including design evaluation, verification, testing, and as patterns for casting processes. These processes employ a variety of materials and mechanisms to build up the layers to build the part. The present work was to build a FDM prototyping machine that could control the X-Y motion and material deposition, to generate two-dimensional and three-dimensional complex shapes. This study focused on the deposition of wax material. This work was to find out the properties of the wax materials used in this work in order to enable better control of the FDM process. This study will look at the integration of a computer controlled electro-mechanical system with the traditional FDM additive prototyping process. The characteristics of the wax were also analysed in order to optimise the model production process. These included wax phase change temperature, wax viscosity and wax droplet shape during processing.

Keywords: Rapid prototyping, wax, manufacturing processes, additive prototyping.

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Authors: J. C. T. Benavente, J. C. E. Ferreira

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The rapid development of manufacturing and information systems has caused significant changes in manufacturing environments in recent decades. Mass production has given way to flexible manufacturing systems, in which an important characteristic is customized or "on demand" production. In this scenario, the seamless and without gaps information flow becomes a key factor for success of enterprises. In this paper we present a framework to support the mapping of features into machining workingsteps compliant with the ISO 14649 standard (known as STEP-NC). The system determines how the features can be made with the available manufacturing resources. Examples of the mapping method are presented for features such as a pocket with a general surface.

Keywords: Features, ISO 14649 standard, STEP-NC, mapping, machining workingsteps.

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Authors: M. Senthil Arumugam, M.V.C. Rao

Abstract:

This paper presents a novel two-phase hybrid optimization algorithm with hybrid genetic operators to solve the optimal control problem of a single stage hybrid manufacturing system. The proposed hybrid real coded genetic algorithm (HRCGA) is developed in such a way that a simple real coded GA acts as a base level search, which makes a quick decision to direct the search towards the optimal region, and a local search method is next employed to do fine tuning. The hybrid genetic operators involved in the proposed algorithm improve both the quality of the solution and convergence speed. The phase–1 uses conventional real coded genetic algorithm (RCGA), while optimisation by direct search and systematic reduction of the size of search region is employed in the phase – 2. A typical numerical example of an optimal control problem with the number of jobs varying from 10 to 50 is included to illustrate the efficacy of the proposed algorithm. Several statistical analyses are done to compare the validity of the proposed algorithm with the conventional RCGA and PSO techniques. Hypothesis t – test and analysis of variance (ANOVA) test are also carried out to validate the effectiveness of the proposed algorithm. The results clearly demonstrate that the proposed algorithm not only improves the quality but also is more efficient in converging to the optimal value faster. They can outperform the conventional real coded GA (RCGA) and the efficient particle swarm optimisation (PSO) algorithm in quality of the optimal solution and also in terms of convergence to the actual optimum value.

Keywords: Hybrid systems, optimal control, real coded genetic algorithm (RCGA), Particle swarm optimization (PSO), Hybrid real coded GA (HRCGA), and Hybrid genetic operators.

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Authors: Khaing Yadana Swe, Lillie Dewan

Abstract:

At present, the cascade PID control is widely used to control the superheating temperature (main steam temperature). As Main Steam Temperature has the characteristics of large inertia, large time-delay and time varying, etc., conventional PID control strategy cannot achieve good control performance. In order to overcome the bad performance and deficiencies of main steam temperature control system, Model Free Adaptive Control (MFAC) - P cascade control system is proposed in this paper. By substituting MFAC in PID of the main control loop of the main steam temperature control, it can overcome time delays, non-linearity, disturbance and time variation.

Keywords: Model free Adaptive Control, Cascade Control, Adaptive Control, PID.

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Authors: N. Pekin Alakoç, A. Apaydın

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Quality control charts indicate out of control conditions if any nonrandom pattern of the points is observed or any point is plotted beyond the control limits. Nonrandom patterns of Shewhart control charts are tested with sensitizing rules. When the processes are defined with fuzzy set theory, traditional sensitizing rules are insufficient for defining all out of control conditions. This is due to the fact that fuzzy numbers increase the number of out of control conditions. The purpose of the study is to develop a set of fuzzy sensitizing rules, which increase the flexibility and sensitivity of fuzzy control charts. Fuzzy sensitizing rules simplify the identification of out of control situations that results in a decrease in the calculation time and number of evaluations in fuzzy control chart approach.

Keywords: Fuzzy set theory, Quality control charts, Run Rules, Unnatural patterns.

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Authors: A. Abbasi Moshaii, M. Soltan Rezaee, M. Mohammadi Moghaddam

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Control of some mechanisms is hard because of their complex dynamic equations. If part of the complexity is resulting from uncertainties, an efficient way for solving that is robust control. By this way, the control procedure could be simple and fast and finally, a simple controller can be designed. One kind of these mechanisms is 3-RRR which is a parallel mechanism and has three revolute joints. This paper aims to robust control a 3-RRR planner mechanism and it presents that this could be used for other mechanisms. So, a significant problem in mechanisms control could be solved. The relevant diagrams are drawn and they show the correctness of control process.

Keywords: 3-RRR, dynamic equations, mechanisms control, structural uncertainty.

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Authors: R. Meier, M. Pander

Abstract:

In accordance with the industry 4.0 concept, manufacturing process steps as well as the materials themselves are going to be more and more digitalized within the next years. The “digital twin” representing the simulated and measured dataset of the (semi-finished) product can be used to control and optimize the individual processing steps and help to reduce costs and expenditure of time in product development, manufacturing, and recycling. In the present work, two material characterization methods based on Lamb waves were evaluated and compared. For demonstration purpose, both methods were shown at a standard industrial product - copper ribbons, often used in photovoltaic modules as well as in high-current microelectronic devices. By numerical approximation of the Rayleigh-Lamb dispersion model on measured phase velocities second order elastic constants (Young’s modulus, Poisson’s ratio) were determined. Furthermore, the effective third order elastic constants were evaluated by applying elastic, “non-destructive”, mechanical stress on the samples. In this way, small microstructural variations due to mechanical preconditioning could be detected for the first time. Both methods were compared with respect to precision and inline application capabilities. Microstructure of the samples was systematically varied by mechanical loading and annealing. Changes in the elastic ultrasound transport properties were correlated with results from microstructural analysis and mechanical testing. In summary, monitoring the elastic material properties of plate-like structures using Lamb waves is valuable for inline and non-destructive material characterization and manufacturing process control. Second order elastic constants analysis is robust over wide environmental and sample conditions, whereas the effective third order elastic constants highly increase the sensitivity with respect to small microstructural changes. Both Lamb wave based characterization methods are fitting perfectly into the industry 4.0 concept.

Keywords: Lamb waves, industry 4.0, process control, elasticity, acoustoelasticity.

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Authors: A. K. Kamath, N. M. Singh, R. Pasumarthy

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This paper investigates the control of a bouncing ball using Model Predictive Control. Bouncing ball is a benchmark problem for various rhythmic tasks such as juggling, walking, hopping and running. Humans develop intentions which may be perceived as our reference trajectory and tries to track it. The human brain optimizes the control effort needed to track its reference; this forms the central theme for control of bouncing ball in our investigations.

Keywords: Bouncing Ball, impact dynamics, intermittent control, model predictive control.

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Authors: N. Javadian, J. Rezaeian, Y. Maali

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In this paper a multi-objective nonlinear programming model of cellular manufacturing system is presented which minimize the intercell movements and maximize the sum of reliability of cells. We present a genetic approach for finding efficient solutions to the problem of cell formation for products having multiple routings. These methods find the non-dominated solutions and according to decision makers prefer, the best solution will be chosen.

Keywords: Cellular Manufacturing, Genetic Algorithm, Multiobjective, Life-Cycle.

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Authors: Yong-can Cao, Wei-dong Zhang

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To deal with random delays in Networked Control System (NCS), Modified Fuzzy PID Controller is introduced in this paper to implement real-time control adaptively. Via adjusting the control signal dynamically, the system performance is improved. In this paper, the design process and the ultimate simulation results are represented. Finally, examples and corresponding comparisons prove the significance of this method.

Keywords: Fuzzy Control, Networked Control System, PID, Random Delays

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Authors: M. Reza Bagerzadeh Karimi, M. Mahdi Bagerzadeh Karimi

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In the present paper, active control system is used in different heights of the building and the most effective part was studied where the active control system is applied. The mathematical model of the building is established in MATLAB and in order to active control the system FLC method was used. Three different locations of the building are chosen to apply active control system, namely at the lowest story, the middle height of the building, and at the highest point of the building with TMD system. The equation of motion was written for high rise building and it was solved by statespace method. Also passive control was used with Tuned Mass Damper (TMD) at the top floor of the building to show the robustness of FLC method when compared with passive control system.

Keywords: Fuzzy Logic Controller (FLC), Tuned Mass Damper(TMD), Active control, passive control

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Authors: H. Zare Amadabadi, S. Soltani Gerdefaramarzi

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In recent years, strategic alliances have taken increasing importance as a means to control competitive forces and to enter into new markets. Joint ventures are one of the most frequently used contractual forms in strategic alliances. There are various motivations for cooperation between two or more firms e.g., accessing to technical know-how, accessing to financial resources and managing risks. The firms must know about these motivations to encourage for establishing joint venture. So, it is important for managers to understand about these motives. On the other hand, the cooperation section is one of the most effective parts in each country. In this way, our study identifies goals of joint venture between cooperative manufacturing firms, and prioritizes those using TOPSIS1. The results show that the most important of joint venture goals are: accessing to managerial know-how, sharing total capital investment.

Keywords: Cooperative, Joint Venture, TOPSIS

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Authors: Marco Ryll, Svetan Ratchev

Abstract:

This paper discusses the applicability of the Data Distribution Service (DDS) for the development of automated and modular manufacturing systems which require a flexible and robust communication infrastructure. DDS is an emergent standard for datacentric publish/subscribe middleware systems that provides an infrastructure for platform-independent many-to-many communication. It particularly addresses the needs of real-time systems that require deterministic data transfer, have low memory footprints and high robustness requirements. After an overview of the standard, several aspects of DDS are related to current challenges for the development of modern manufacturing systems with distributed architectures. Finally, an example application is presented based on a modular active fixturing system to illustrate the described aspects.

Keywords: Flexible Manufacturing, Publish/Subscribe, Plug & Produce.

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Authors: D. R. Delgado Sobrino, P. Košťál, J. Oravcová

Abstract:

Lately, significant work in the area of Intelligent Manufacturing has become public and mainly applied within the frame of industrial purposes. Special efforts have been made in the implementation of new technologies, management and control systems, among many others which have all evolved the field. Aware of all this and due to the scope of new projects and the need of turning the existing flexible ideas into more autonomous and intelligent ones, i.e.: Intelligent Manufacturing, the present paper emerges with the main aim of contributing to the design and analysis of the material flow in either systems, cells or work stations under this new “intelligent" denomination. For this, besides offering a conceptual basis in some of the key points to be taken into account and some general principles to consider in the design and analysis of the material flow, also some tips on how to define other possible alternative material flow scenarios and a classification of the states a system, cell or workstation are offered as well. All this is done with the intentions of relating it with the use of simulation tools, for which these have been briefly addressed with a special focus on the Witness simulation package. For a better comprehension, the previous elements are supported by a detailed layout, other figures and a few expressions which could help obtaining necessary data. Such data and others will be used in the future, when simulating the scenarios in the search of the best material flow configurations.

Keywords: Flexible/Intelligent Manufacturing System/Cell (F/IMS/C), material flow/design/configuration (MF/D/C), workstation.

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Authors: Neha Khanduja

Abstract:

This paper presents a comparative analysis of continuously stirred tank reactor (CSTR) control based on adaptive control and optimal tuning of PID control based on particle swarm optimization. In the design of adaptive control, Model reference adaptive control (MRAC) scheme is used, in which the adaptation law have been developed by MIT rule & Lyapunov’s rule. In PSO control parameters of PID controller is tuned by using the concept of particle swarm optimization to get optimized operating point for minimum integral square error (ISE) condition. The results show the adjustment of PID parameters converting into the optimal operating point and the good control response can be obtained by the PSO technique.

Keywords: Model reference adaptive control (MRAC), optimal control, particle swarm optimization (PSO).

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Authors: Justyna Rybicka, Ashutosh Tiwari, Shane Enticott

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In the age of automation and computation aiding manufacturing, it is clear that manufacturing systems have become more complex than ever before. Although technological advances provide the capability to gain more value with fewer resources, sometimes utilisation of the manufacturing capabilities available to organisations is difficult to achieve. Flexible manufacturing systems (FMS) provide a unique capability to manufacturing organisations where there is a need for product range diversification by providing line efficiency through production flexibility. This is very valuable in trend driven production set-ups or niche volume production requirements. Although FMS provides flexible and efficient facilities, its optimal set-up is key in achieving production performance. As many variables are interlinked due to the flexibility provided by the FMS, analytical calculations are not always sufficient to predict the FMS’ performance. Simulation modelling is capable of capturing the complexity and constraints associated with FMS. This paper demonstrates how discrete event simulation (DES) can address complexity in an FMS to optimise the production line performance. A case study of an automotive FMS is presented. The DES model demonstrates different configuration options depending on prioritising objectives: utilisation and throughput. Additionally, this paper provides insight into understanding the impact of system set-up constraints on the FMS performance and demonstrates the exploration into the optimal production set-up.

Keywords: Automotive, capacity performance, discrete event simulation, flexible manufacturing system.

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Authors: Amira Kheriji Abbes, Faouzi Bouani, Mekki Ksouri

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Model Predictive Control (MPC) is an established control technique in a wide range of process industries. The reason for this success is its ability to handle multivariable systems and systems having input, output or state constraints. Neverthless comparing to PID controller, the implementation of the MPC in miniaturized devices like Field Programmable Gate Arrays (FPGA) and microcontrollers has historically been very small scale due to its complexity in implementation and its computation time requirement. At the same time, such embedded technologies have become an enabler for future manufacturing enterprisers as well as a transformer of organizations and markets. In this work, we take advantage of these recent advances in this area in the deployment of one of the most studied and applied control technique in the industrial engineering. In this paper, we propose an efficient firmware for the implementation of constrained MPC in the performed STM32 microcontroller using interior point method. Indeed, performances study shows good execution speed and low computational burden. These results encourage to develop predictive control algorithms to be programmed in industrial standard processes. The PID anti windup controller was also implemented in the STM32 in order to make a performance comparison with the MPC. The main features of the proposed constrained MPC framework are illustrated through two examples.

Keywords: Embedded software, microcontroller, constrainedModel Predictive Control, interior point method, PID antiwindup, Keil tool, C/Cµ language.

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Authors: T. C. Kuo

Abstract:

In this paper, a novel adaptive fuzzy sliding mode control method is proposed for the robust tracking control of robotic manipulators. The proposed controller possesses the advantages of adaptive control, fuzzy control, and sliding mode control. First, system stability and robustness are guaranteed based on the sliding mode control. Further, fuzzy rules are developed incorporating with adaptation law to alleviate the input chattering effectively. Stability of the control system is proven by using the Lyapunov method. An application to a three-degree-of-freedom robotic manipulator is carried out. Accurate trajectory tracking as well as robustness is achieved. Input chattering is greatly eliminated.

Keywords: Fuzzy control, sliding mode control, roboticmanipulator, adaptive control.

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Authors: Viraj Tyagi, Ajai Jain, P. K. Jain, Aarushi Jain

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This paper presents a genetic algorithm based loading methodology for a capacity constrained job-shop with the consideration of alternative process plans for each part to be produced. Performance analysis of the proposed methodology is carried out for two case studies by considering two different manufacturing scenarios. Results obtained indicate that the methodology is quite effective in improving the shop load balance, and hence, it can be included in the frameworks of manufacturing planning systems of job-shop oriented industries.

Keywords: Manufacturing planning, loading, genetic algorithm, Job-Shop

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Authors: F.B. Georgise, K. D. Thoben, M. Seifert

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This paper presents a research agenda on the SCOR model adaptation. SCOR model is designated to measure supply chain performance and logistics impact across the boundaries of individual organizations. It is at its growing stage of its life cycle and is enjoying the leverage of becoming the industry standard. The SCOR model has been developed and used widely in developed countries context. This research focuses on the SCOR model adaptation for the manufacturing industry in developing countries. With a necessary understanding of the characteristics, difficulties and problems of the manufacturing industry in developing countries- supply chain; consequently, we will try to designs an adapted model with its building blocks: business process model, performance measures and best practices.

Keywords: developing countries, manufacturing industry, SCOR model adaptation

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Authors: S. Z. Sarwar, N. Ehsan , I, Mirza, J. L. Piracha, M. Azeem, A. Ishaque

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The public sector losses are the major cause of stagnant growth of Pakistan. Public sector automotive manufacturing industry is one of the major contributors of these losses. This research has been carried out in order to identify the major barriers of productivity of this industry and suggest measures for improvement. This qualitative and quantitative research consisted of informal interviews, discussions augmented by closed ended questionnaire. Three major manufacturing units were chosen for this research and responses from 103 employees were collected. It was found out in this research that numerous productivity flaws exist in the system which requires immediate attention. Besides highlighting flaws this research also suggests corrective actions and areas for future research to overcome these problems.

Keywords: Automotive manufacturing industry, barriers ofproductivity, Public sector losses.

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Authors: Yanting Cao, Kazumitsu Nawata

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The UK has strong economic growth, which attracts other countries to invest there through globalization. This research process will be based on quantitative and qualitative descriptive analysis using interviews. The secondary analysis will involve a case study approach to understand the important aspects of leadership skills. The research outcomes will be identifying the strength and weakness of the leadership skills of UK automobile manufacturing enterprises and suggest the best practices adopted by the respective countries for better results.

Keywords: engineering management, leadership, industrial project management, project managers, automobile manufacturing

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Authors: Nassier A. Nassir, Robert Birch, Zhongwei Guan

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The aim of this study is to investigate the fundamental science/technology related to novel S-glass fiber reinforced polyether- ketone-ketone (GF/PEKK) composites and to gain insight into bonding strength and failure mechanisms. Different manufacturing techniques to make this high-temperature pre-impregnated composite (prepreg) were conducted i.e. mechanical deposition, electrostatic powder deposition, and dry powder prepregging techniques. Generally, the results of this investigation showed that it was difficult to control the distribution of the resin powder evenly on the both sides of the fibers within a specific percentage. Most successful approach was by using a dry powder prepregging where the fibers were coated evenly with an adhesive that served as a temporary binder to hold the resin powder in place onto the glass fiber fabric.

Keywords: Dry powder technique, PEKK, S-glass, thermoplastic prepreg.

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Authors: Abdelaziz Sahbani, Kamel Ben Saad, Mohamed Benrejeb

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This paper deals with the comparison between two proposed control strategies for a DC-DC boost converter. The first control is a classical Sliding Mode Control (SMC) and the second one is a distance based Fuzzy Sliding Mode Control (FSMC). The SMC is an analytical control approach based on the boost mathematical model. However, the FSMC is a non-conventional control approach which does not need the controlled system mathematical model. It needs only the measures of the output voltage to perform the control signal. The obtained simulation results show that the two proposed control methods are robust for the case of load resistance and the input voltage variations. However, the proposed FSMC gives a better step voltage response than the one obtained by the SMC.

Keywords: Boost DC-DC converter, Sliding Mode Control (SMC), Fuzzy Sliding Mode Control (FSMC), Robustness.

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Authors: Steven W. Su , Hung Nguyen, Rob Jarman, Joe Zhu, David Lowe, Peter McLean, Shoudong Huang, Nghia T. Nguyen, Russell Nicholson, Kaili Weng

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This paper proposed a nonlinear model predictive control (MPC) method for the control of gantry crane. One of the main motivations to apply MPC to control gantry crane is based on its ability to handle control constraints for multivariable systems. A pre-compensator is constructed to compensate the input nonlinearity (nonsymmetric dead zone with saturation) by using its inverse function. By well tuning the weighting function matrices, the control system can properly compromise the control between crane position and swing angle. The proposed control algorithm was implemented for the control of gantry crane system in System Control Lab of University of Technology, Sydney (UTS), and achieved desired experimental results.

Keywords: Model Predictive Control, Control constraints, Input nonlinearity compensation, Overhead gantry crane.

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Authors: Robert Gold

Abstract:

Control flow graphs are a well-known representation of the sequential control flow structure of programs with a multitude of applications. Not only single functions but also sets of functions or complete programs can be modeled by control flow graphs. In this case the size of the graphs can grow considerably and thus makes it difficult for software engineers to analyze the control flow. Graph reductions are helpful in this situation. In this paper we define reductions to subsets of nodes. Since executions of programs are represented by paths through the control flow graphs, paths should be preserved. Furthermore, the composition of reductions makes a stepwise analysis approach possible.

Keywords: Control flow graph, graph reduction.

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

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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: Zundong Zhang, Limin Jia, Yuanyuan Chai

Abstract:

Control of complex systems is one of important files in complex systems, that not only relies on the essence of complex systems which is denoted by the core concept – emergence, but also embodies the elementary concept in control theory. Aiming at giving a clear and self-contained description of emergence, the paper introduces a formal way to completely describe the formation and dynamics of emergence in complex systems. Consequently, this paper indicates the Emergence-Oriented Control methodology that contains three kinds of basic control schemes: the direct control, the system re-structuring and the system calibration. As a universal ontology, the Emergence-Oriented Control provides a powerful tool for identifying and resolving control problems in specific systems.

Keywords: Complex System Control, Emergence, Emergence- Oriented Control Methodology.

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Authors: S. Bouhouche, M. Lahreche, S. Ziani, J. Bast

Abstract:

Modern manufacturing facilities are large scale, highly complex, and operate with large number of variables under closed loop control. Early and accurate fault detection and diagnosis for these plants can minimise down time, increase the safety of plant operations, and reduce manufacturing costs. Fault detection and isolation is more complex particularly in the case of the faulty analog control systems. Analog control systems are not equipped with monitoring function where the process parameters are continually visualised. In this situation, It is very difficult to find the relationship between the fault importance and its consequences on the product failure. We consider in this paper an approach to fault detection and analysis of its effect on the production quality using an adaptive centring and scaling in the pickling process in cold rolling. The fault appeared on one of the power unit driving a rotary machine, this machine can not track a reference speed given by another machine. The length of metal loop is then in continuous oscillation, this affects the product quality. Using a computerised data acquisition system, the main machine parameters have been monitored. The fault has been detected and isolated on basis of analysis of monitored data. Normal and faulty situation have been obtained by an artificial neural network (ANN) model which is implemented to simulate the normal and faulty status of rotary machine. Correlation between the product quality defined by an index and the residual is used to quality classification.

Keywords: Modeling, fault detection and diagnosis, parameters estimation, neural networks, Fault Detection and Diagnosis (FDD), pickling process.

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