Browse Topic: Computer integrated manufacturing

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Updates in Development to the Digital Thread and CFD Modeling Framework for Robust Rotorcraft DesignF-0080-2024-13265/7/2024
Rapid advances in high fidelity modeling and high performance computing capabilities have enabled their routine utilization in support of aircraft design. Analysts are able to generate orders of magnitude more data that must then be turned into actionable intelligence to guide design. Enabling effective application of advanced analysis to design requires a robust end-to-end digital transformation to make the simulation processes reusable, repeatable, traceable, scalable and minimize setup errors. This is achieved through the development of a Computational Fluid Dynamic (CFD) modeling framework where streamlining and automation are inserted within the current CFD workflow that involves model setup, simulation and post processing. Workflow automation techniques have been implemented in simulation pre and post processing that reduce the overall process time or enhance the fidelity of the simulation. To conduct CFD evaluations through flight envelope efficiently, space filling methods that take into account uncertainties of complex systems are needed and have driven updates to the boundary condition and design of experiments (DOE) generation within the workflow. Vehicle sub-system design can be highly iterative, performed by a large number of participants in multidisciplinary groups. To ensure traceability across the digital thread, a provenance and metadata storage methodology has been implemented to capture information about CFD simulations and construct a query able database while a model-based systems engineering (MBSE) framework provides a structured and integrated approach to managing information throughout the product lifecycle. The SIM-FIX-SIM approach enabled with a robust analysis framework for digital flight assessment prior to first flight will contribute to the overall goal of reducing development timelines and achieving cost reduction goals for cutting-edge rotorcraft development programs.
Bernier, Daniel, Neerarambam, Shyam, Halline, Dana, Cotton, Rebecca, Lamb, Donald, Coleman, Dustin, Keomany, Stephanie, Dusablon, Lindsey, Alexander, Michael, Willmot, Ryan, Eshcol, Ritu, Fernandes, Stanrich
Health-Aware Digital Enterprise - A Blueprint for Digital Thread Integration for Future Vertical Lift SustainmentF-0076-2020-1627110/5/2020
A primary factor for the development of military avionics systems is the requirement for a Modular Open System Architecture (MOSA). The US Department of Defense (DoD) is driving MOSA-compliant systems to achieve benefits in cost and flexibility within their procurements. MOSA definitions are examined in light of advances in computing disciplines that open the interfaces necessary for the aircraft operator to update and manage their fleet's Health Awareness Systems (HAS). Opening the relevant HAS interfaces via software configuration toolsets and MOSA building blocks avoids contracting for costly software changes and gives control of the update to the operator. Two business related factors are presented for consideration in developing the best way forward while using MOSA principles to guide development. These factors are (1) Intellectual Property (IP) and (2) the underlying investments companies make to develop IP. The need to routinely update the HAS to incorporate fleet lessons learned is inherent in the system's support. Updates may also reflect new methodologies that deliver the desired system control to the operator. The paper demonstrates a MOSA-compliant architecture via an example. Within the example, efficiencies are driven by an end-to-end Digital Thread that minimizes errors and rework while reducing the overall cost of change for the full platform lifecycle. The approach enables organic operator support, lowering the overall cost of aircraft operations. The design and support of the platform’s Health Awareness System benefits from the application of linked-automation.
Thomson, Mark, Caraway, Logan, Tucker, Brian
U.S. Army Rotary-wing Airframe Defect Trending, Modeling, and AnalysisF-0076-2020-1631310/5/2020
The U.S. Army monitors the structural integrity of its rotary-wing aircraft fleet through annual evaluations and reporting via the Airframe Condition Evaluation (ACE) program. ACE evaluations capture the location and character of structural defects for each aircraft, which are then available for trending and detailed analysis by engineers with the U.S. Army Combat Capabilities Development Command Aviation & Missile Center (CCDC AvMC). As analytic methods are increasingly advanced through the digital thread, CCDC AvMC has sought to improve available trending, modeling, and analysis tools beyond status quo to provide higher fidelity visuals to both aid communication with decision makers, and also to reveal structural defect trends which may not otherwise be evident. This paper will detail the development and utility of the ACE Color Mapping Application within the ACE Mapping Module and its impact on product support of U.S. Army aircraft with regard to airframe structural integrity.
Peltier, Jared, Chhotu, Prasant
Improving Robotic Accuracy through Iterative Teaching2020-01-00143/10/2020
Industrial robots have been around since the 1960s and their introduction into the manufacturing industry has helped in automating otherwise repetitive and unsafe tasks, while also increasing the performance and productivity for the companies that adopted the technology. As the majority of industrial robotic arms are deployed in repetitive tasks, the pose accuracy is much less of a key driver for the majority of consumers (e.g. the automotive industry) than speed, payload, energy efficiency and unit cost. Consequently, manufacturers of industrial robots often quote repeatability as an indication of performance whilst the pose accuracy remains comparatively poor. Due to their lack in accuracy, robotic arms have seen slower adoption in the aerospace industry where high accuracy is of utmost importance. However if their accuracy could be improved, robots offer significant advantages, being comparatively inexpensive and more flexible than bespoke automation. Extensive research has been conducted in the area of improving robotic accuracy through re-calibration of the kinematic model. This approach is often highly complex, and seeks to optimise performance over the whole working volume or a portion thereof, rather than optimising performance of a particular task. In this paper, a method for iteratively teaching poses on a standard industrial robot is presented, and an investigation into the limits on the achievable pose accuracy and the required recalibration period is conducted. Through experimental work on a KUKA KR 240 R2900 ultra robot equipped with a drilling end-effector and measured in 3DoF using a laser tracker, it is demonstrated that the achievable accuracy approaches the stated repeatability of the robot. Finally, investigation results into the accuracy of the robot over short distances to allow small corrections to be applied from these taught poses to compensate for work-piece alignment or thermal effects are presented.
Sawyer, Daniela, Tinkler, Lloyd, Roberts, Nathan, Diver, Ryan
Collaboration: A Powerful, Effective Strategy for Medtech Companies Moving to Embrace Industry 4.0 and Drive Digital TransformationTBMG-362763/1/2020
The digital revolution under way in medtech manufacturing will continue to transform the industry into a more connected, efficient, and agile ecosystem. However, the challenge for many companies is to plot the best way to embrace various existing and new technologies and move toward smarter manufacturing — their version of the “factory of the future.” Every company is at a different stage of digital transformation. Some companies are wholeheartedly piloting, integrating, and scaling disruptive technologies within their operations in a bid to realize greater supply chain and internal operational benefits. Others are at a different place in their digital journey, identifying incremental opportunity areas where they can demonstrate initial impact and justify further investment.
Digital DHRs: Automating the Last Mile of the Production ProcessTBMG-362743/1/2020
The smart factory has been a top manufacturing initiative for years as shop floors continue to become digital, automated, and intelligent. Today, companies are investing heavily in smart manufacturing, intelligent automation, and advanced robotics. A 2019 report from PricewaterhouseCoopers and the Manufacturing Institute found that 73 percent of manufacturers planned to increase their investment in smart factory technology over the next year.1
Leading Women in Engineering & Science: Mahsa Nakhjiri, Senior Director of Technical Product Management, FlexTBMG-362473/1/2020
Implementing an Aerospace Factory of the FutureTBMG-360562/1/2020
Companies across a wide range of segments are introducing Industry 4.0 (i4.0) technology at a rapid pace, turning the next-generation vision of manufacturing — the Factory of the Future — into reality. Many of the advances in this transformation have been in highly automated industries such as vehicle manufacturing. Conversely, the aerospace industry, with its staged approach to assembling aircraft, satellites and other products, has only begun to investigate how i4.0 technologies can improve operations, throughput, quality control and cost challenges.
Smart Manufacturing ControlTBMG-359972/1/2020
The manufacturing process of today involves many challenges, from mass production down to a lot size of one. The CNC controls in factories have to master this market trend without an adequate amount of skilled labor in the US manufacturing world. In essence, manufacturing is facing a renaissance in the CNC control technology shift.
Implementing an Aerospace Factory OF THE FUTURE20AERP02_042/1/2020
Companies across a wide range of segments are introducing Industry 4.0 (i4.0) technology at a rapid pace, turning the next-generation vision of manufacturing - the Factory of the Future - into reality. Many of the advances in this transformation have been in highly automated industries such as vehicle manufacturing. Conversely, the aerospace industry, with its staged approach to assembling aircraft, satellites and other products, has only begun to investigate how i4.0 technologies can improve operations, throughput, quality control and cost challenges.
5G in Manufacturing: What’s Here and What’s to ComeTBMG-359672/1/2020
Industry 4.0 — the term that originated in Germany to describe the fourth industrial revolution of cyber-physical systems — is being closely connected today with 5G, which is often referred to as the fifth-generation mobile network. This connection allows manufacturers to further improve factory automation, human/machine interfaces, and mobility in their processes.
Going Beyond the Basics: Innovative Step Motor Designs Give Machine Designers More Options for Motion ControlTBMG-360022/1/2020
Machine and system designers now have greater options in choosing a motor to meet motion control requirements. While basic step motors with open-loop control schemes abound in the marketplace, different motor and drive designs offer interesting solutions for smarter, faster, quieter operations with more torque. Some incorporate smart drives for higher-level streaming commands or onboard motion control, while others add encoders for greater torque and accuracy. These options can offer better solutions as applications become more sophisticated and demanding, while companies address initiatives for greener operations. This article outlines different step motor options available on the market and considerations for their use.
Precision 3D BioprinterTBMG-360572/1/2020
nScrypt Inc. Orlando, FL 407-275-4720
In-House PCB Prototyping with Additive ManufacturingTBMG-358131/1/2020
If you're interested in pursuing in-house PCB prototyping and testing, there are several routes you can take to create functional prototypes for new products. The best one depends on a number of factors, with product complexity being the primary consideration. For highly complex, low-volume products, using an additive manufacturing system is often the best choice for rapid prototyping thanks to its high throughput and fixed cost structure.
The Role of Sensors in the Evolution of RoboticsTBMG-3560912/1/2019
At one time, robotics was considered more science fiction than reality. That's changing. Today, robots are increasingly playing a role in our everyday lives. They're zooming around our homes to pick up dust, helping surgeons perform operations with even more precision, sniffing out suspicious packages for law enforcement, and on the factory floor, they're performing all kinds of tasks for automotive, electronics, and industrial manufacturing companies.
Streamlining Post-Processing in Additive ManufacturingTBMG-3566612/1/2019
Undoubtedly there are many benefits associated with the use of additive manufacturing (AM) as a production technology. On a pan-industrial basis, manufacturers exploit the fact that through the use of AM they can not only build complex parts, in one piece, which were previously impossible, but they can also build stronger, lighter-weight parts, reduce material consumption, and benefit from assembly component consolidation across a range of applications. These advantages have all been well documented during the last 10-20 years as AM has emerged as a truly disruptive technology for prototyping and production, and are invariably seen as being enabled by the additive hardware that builds the parts. In reality, however, this is a partial picture, particularly for serial production applications of AM. AM hardware systems are actually just one part – albeit a vital part – of an extensive ecosystem of technologies that enable AM, both pre- and post-build.
Streamlining Post-Processing in Additive Manufacturing19AERP12_0412/1/2019
Undoubtedly there are many benefits associated with the use of additive manufacturing (AM) as a production technology. On a pan-industrial basis, manufacturers exploit the fact that through the use of AM they can not only build complex parts, in one piece, which were previously impossible, but they can also build stronger, lighter-weight parts, reduce material consumption, and benefit from assembly component consolidation across a range of applications. These advantages have all been well documented during the last 10-20 years as AM has emerged as a truly disruptive technology for prototyping and production, and are invariably seen as being enabled by the additive hardware that builds the parts. In reality, however, this is a partial picture, particularly for serial production applications of AM. AM hardware systems are actually just one part - albeit a vital part - of an extensive ecosystem of technologies that enable AM, both pre- and post-build. By focusing just on the AM build process, a fundamental part of the production process chain is often overlooked, namely the post-processing steps once the part is out of the AM machine. Manufacturers using (or considering using) AM for serial production applications need to first identify the appropriate additive process for their targeted application. From there the post-processing requirements must be identified and focused on, otherwise the use of AM as a viable alternative to traditional manufacturing processes may end up being negated completely.
Vision Based Surface Roughness Characterization of Flat Surfaces Machined with EDM2019-28-014810/11/2019
Surface roughness measurement is an important one in any manufacturing next to dimensions. In this investigation, a vision system and image processing tools were used to develop reliable surface roughness characterization technique for Electrical Discharge Machined surfaces. A CMOS camera with red LED light source were used for capturing images of EDMed surfaces. A separate signal vector generated for all the images from its image pixel intensity matrices. The mean, skewness and kurtosis were obtained from the signal vector. The mean, skewness and kurtosis of the images signal vector correlates very well with the stylus measured hybrid roughness parameters Rda and Rdq. Hence the technique may be preferred for online surface roughness characterization of Electrical Discharge Machined (EDMed) surfaces.
Ali, Mahashar, Jailani, Siddhi, Mariappan, Murugan, Anandan, Mangalnath, Pavithran, Vignesh
Automation: The Future of Medical ManufacturingTBMG-3536710/1/2019
Manufacturers in the medical industry face unique challenges in terms of product mix, throughput requirements, quality standards, and regulatory guidelines. Whether a company is developing imaging equipment, orthopedic implants, or diagnostics, the manufacturing process must be absolutely error free while delivering high throughput. Device companies are looking more and more to factory automation to ensure that they are addressing these disparate requirements.
Step & Repeat: Reduce Derivative Aircraft Development Risk with Design Reuse2019-01-18719/16/2019
The complex and risky process of designing derivative aircraft, especially when it comes to electrical systems, can be a daunting task at best. There are a number of design strategies that can be employed to mitigate risk and increase the overall efficiency. Quite simply, the current methods of manual processes, design and integration approaches that were optimized from mechanical approaches, are no match for today’s complexities. One method gaining significant traction is to employ a central database serving global interface definitions for the entire design process. Automation through generative design minimizes manual intervention and repetitive work. Furthermore, detecting changes through design rule checks allows system engineers to verify their designs, capturing both inadvertent and planned changes. The ability to instantly update the design content from the new definition streamlines the change management process. Employing these technologies in a digital, connected thread, ensures that intelligent information is leveraged at every step along the way from aircraft conception, realization, and finally to utilization - thereby minimizing risk and maximizing efficiency.
Askar, Muhammad
Build IIoT Networks with Smart Control and HMI SoftwareTBMG-348798/1/2019
Programmable automation controllers (PACs) play the primary role in IIoT systems. Also referred to as machine controllers, PACs provide a centralized architecture; they act as the central programmable logic controller (PLC) as well as motion, vision, pneumatic, hydraulic controller, and even embedded human-machine interface (HMI) or visualization (Figure 1). The benefit of the PAC approach is that the program does not need to share tags between devices due to components being part of the same device and using the same logic. This facilitates IIoT capabilities and reduces programming time. This is critical to IIoT as it allows the flow of accurate, actionable data to easily transfer within the machine and out to the user or server to make critical decisions with that data.
Introduction to Advanced ManufacturingR-4637/24/2019
Introduction to Advanced Manufacturing was written by two experienced and passionate engineers whose mission is to make the subject of advanced manufacturing easy to understand and a practical solution to everyday problems. Harik, Ph.D. and Wuest, Ph.D., professors who have taught the subject for decades, combined their expertise to develop both an applied manual and a theoretical reference that addresses many different needs. Introduction to Advanced Manufacturing covers the following topics in detail: • Composites Manufacturing • Smart Manufacturing • Additive Manufacturing • Computer Aided Manufacturing • Polymers Manufacturing • Assembly Processes • Manufacturing Quality Control and Productivity • Subtractive Manufacturing • Deformative Manufacturing Introduction to Advanced Manufacturing offers a new, refreshing way of studying how things are made in the digital age. With academics and industry professionals in mind, Introduction to Advanced Manufacturing paves the ground for those interested in the new opportunities of Industry 4.0.
Harik, Ramy, Wuest, Thorsten
Vision Sensors in Factory AutomationTBMG-345776/1/2019
There are a number of ways to extract data from a production line. In factory automation, sensors are used in work cells to gather data for inspection or to trigger other devices. These sensors fall into multiple categories – photoelectric, fiber optic, proximity, ultrasonic, and vision are the most common.
The Future of Airplane Factory: Digitally Optimized Intelligent Airplane AssemblyR-4665/28/2019
The Future of Airplane Factory: Digitally Optimized Intelligent Airplane Factory defines the architecture, key building blocks, and roadmap for actualizing a future airplane factory (FAF) that is digitally optimized for intelligent airplane assembly. They fit and integrate with other FAF building blocks that aggregate to a Digitally Optimized Intelligent Airplane Factory (DOIAF). The word "intelligent" refers to the ability of a system to make right decisions and take right action in the highly dynamic and fluid environment of the modern airplane manufacturing space. The event-driven dynamics inherent in the complexity of this environment drive the need for expert knowledge which resides in intelligence systems incorporating the experience of experts. Expert knowledge need not be smart, brilliant, or possess genius as long as the outcomes are derived from right decisions resulting in right actions-applied rapidly to sustain an optimized factory enterprise. Complete factory enterprise visibility requires a higher order of decision capability that current operating systems do not have. A highly visible factory collects and displays data and information as it happens-at a rate beyond the ability of humans and current systems to analyze, process, decide, and act upon. Expert systems are constructed to present humans with right decisions in the form of optimal choices for right actions by incorporating the knowledge of experts into the logic for the decision. Structured Knowledge-Based Expert Systems (SKBES) are incorporated in this book and defined as a critical component for full enterprise actionable visibility. The power of the Digitally Optimized Intelligent Airplane Factory not only is found in its ability to unify the factory, reduce touch labor, improve quality, and streamline throughput but it also enables a significant reduction in above-the-shop-floor support and management. Such an ecosystem frees the human to focus on the complexity of interpersonal responsibilities. If the use of a DOIAF can be viewed as a holistic mechanism, then the human can be the agent engaging with that mechanism; improving negotiations for pricing, contracts, or other person-to-person events that require instinct and relationship.
Bullen, George Nicholas
Ford demos latest digital tools at flagship transmission plant19AUTP05_135/1/2019
Ford recently provided media with a look at some of its latest digital manufacturing tools, opening up the floor at one of the world's largest transmission plants to showcase the quality- and productivity-driven initiative. The tour of Ford's Livonia Transmission Plant (LTP) was part of a Detroit-area Manufacturing in America conference hosted by Siemens. Though showcasing the latest tools in use today, Ford stressed that this was a journey that began in earnest over a decade ago-and is only just beginning to be leveraged. The digital systems Ford is employing permit a more efficient path between its computer-aided engineering (CAE), the creation of production/supply systems and the assembly process itself, improving quality by validating metrics in real time and gathering a swarm of data for analysis. Exceptional granularity in its component traceability provides a wealth of on-site data to improve quality, but leveraging such data in the cloud also can improve vehicle-specific characteristics at distant, final-assembly locations.
Seredynski, Paul
NASA Marshall Space Flight CenterTBMG-343945/1/2019
Founded on July 1, 1960, Marshall Space Flight Center in Huntsville, AL is one of NASA’s largest field centers. Marshall engineers designed, built, tested, and helped launch the Saturn V rocket that carried Apollo astronauts to the Moon. Marshall developed new rocket engines and tanks for the fleet of space shuttles, built sections of the International Space Station (ISS), and now manages all the science work of the astronauts aboard the ISS from a 24/7 Payload Operations Integration Center. Marshall also manages NASA’s Michoud Assembly Facility in New Orleans — the agency’s premier site for the manufacture and assembly of large-scale space structures and systems.
Going DIGITAL & ELECTRIC @ bauma 201919TOFHP04_054/1/2019
Digitalization and electrification are dominant themes in the equipment and technology being revealed at this year's largest trade show for construction and mining. Digitalization, efficiency and sustainability are three megatrends that off-highway OEMs and suppliers will be touting this month at the triennial bauma trade fair in Munich, when they reveal their technology-laden machines and the intelligent systems that help make them smarter, cleaner and safer. Particular focal areas for many of these companies include electric mobility, telematics and networked construction sites, and increasingly autonomous operation. Some construction machines are already equipped with a range of sensors and communication interfaces that provide comprehensive data on aspects like job performance, location and fuel consumption. While entire fleets can be managed by telematics, many companies struggle with how to implement digital technologies and services.
Gehm, Ryan
Streamlining Additive Manufacturing for Spinal ImplantsTBMG-342624/1/2019
Acollaboration with innovative technology companies demonstrated the capability of metal additive manufacturing (AM) technology to produce lightweight spinal implants that mimic the mechanical properties of bone. As part of the project, manufacturing research organization Irish Manufacturing Research (IMR) designed and manufactured a series of representative spinal implants. IMR designed the implants using software from nTopology and produced them on a Renishaw RenAM 500M metal AM system.
Digital Manufacturing Helps Medtech Firm's Goal to Improve Patient OutcomesTBMG-342614/1/2019
As often happens in the medical industry, innovative ideas hatched in university research settings spawn innovative companies, which create innovative products. A case in point: HemoSonics. The Charlottesville, VA-based medical device company was started in 2005 by two professors and a post-doctoral research student at the University of Virginia School of Medicine's Bio-Medical Engineering program — Bill Walker, Mike Lawrence, and Francesco Viola, respectively. The trio identified a method for measuring the stiffness of blood clots by using ultrasound imaging technology and created a system built around that technology aimed to improve patient outcomes and reduce costs.
Axiomatic Design of a Reconfigurable Assembly System for Aircraft Fuselages2019-01-13593/19/2019
Modern aerospace industry develops assembly process lines for new aircraft which is produced on a single production line while shortening production times by new technologies. Production processes are developed with systems such as lightweight fixtures, reconfigurable tools, automated part positioning, automated scanning countersink control, automated riveting, robotic measurement etc. These systems provide the necessary flexibility for aircraft fuselage and wing assembly projects. Aerospace manufacturers invest in assembly lines in order to increase production rates and meet growing customer demands. Most of the investments are allocated to state-of-the-art robots for drilling and riveting, sealing, coating and painting applications, in addition to material handling, carbon fiber layup and different types of machining operations. In this study, an assembly system design methodology is developed by using axiomatic design principles in order to propose a solution to design complexity for aircraft fuselage structures assembly. Framework of design methodology is shaped based on system design methods, academic research, industry requirements and industrial case studies. Axiomatic design and reconfigurability principles integrated to developed methodology. Holistic and hierarchical design approach is demonstrated. Aircraft fuselage panel assembly case study is carried out for better understanding of how the methodology is applied. It has been shown in the study that the methodology transforms the reconfigurability requirements into a flexible and scalable system. This study can be used as a reference guide to assembly system design not only for aerospace industry but also whole assembly systems in different industry branch.
Celek, Osman Emre, Yurdakul, Mustafa, Ic, Tansel
Demonstration of Transformable Manufacturing Systems through the Evolvable Assembly Systems Project2019-01-13633/19/2019
Evolvable Assembly Systems is a five year UK research council funded project into flexible and reconfigurable manufacturing systems. The principal goal of the research programme has been to define and validate the vision and support architecture, theoretical models, methods and algorithms for Evolvable Assembly Systems as a new platform for open, adaptable, context-aware and cost effective production. The project is now coming to a close; the concepts developed during the project have been implemented on a variety of demonstrators across a number of manufacturing domains including automotive and aerospace assembly. This paper will show the progression of demonstrators and applications as they increase in complexity, specifically focussing on the Future Automated Aerospace Assembly Phase 1 technology demonstrator (FA3D). The FA3D Phase 1 demonstrated automated assembly of aerospace products using precision robotic processes in conjunction with low-cost reconfigurable fixturing supported by large volume metrology. This was underpinned by novel agent-based control for transformable batch-size-of-one production. The paper will conclude by introducing Phase 2 of the Future Automated Aerospace Assembly Demonstrator - currently in development - that will translate the Evolvable Assembly Systems research to a higher technology readiness level and address the challenges of scalable and transformable manufacturing systems.
Sanderson, David, Turner, Alison, Shires, Emma, Chaplin, Jack, Ratchev, Svetan
Enabling Expanded Aerospace Automation Using Tactile Cognition Analytics2019-01-13603/19/2019
Aerospace assembly operations are still highly dependent on human labor and processes. This paper will describe and illustrate the transformational technologies that will enable replication of the human cognitive (in context) textural ability to assemble airplane and space structure. The paper will also provide use case examples where these innovative technologies have been applied successfully. Without context, data are just dots, floating around without meaning. With context data becomes an enlightened component of knowledge that brings value to information. In-context enlightened knowledge provides manufacturing visibility within factory operations. Visibility is a key component of the Smart, Brilliant, or Intelligent Factory.
Bullen, George Nicholas
Smart Actuators Deliver on the Promise of Industry 4.0TBMG-3335712/1/2018
As Industry 4.0 initiatives bring more and more industrial axes of motion into the realm of automation, the need for cost-effective control across them grows as well. Advances in robotics, connectivity, cloud computing, artificial intelligence, data analysis, mobility, and numerous other areas are converging to push global industry to new plateaus of operational efficiency and creating roles for automated actuators in places previously thought impractical.
Improving Manufacturing Efficiencies through Industry 4.0 Technologies in Aerospace2018-01-192910/30/2018
1 In the age of 4th industrial revolution, operational and information technologies are increasingly getting converged to help organizations improve their topline through new innovative products and services, and improve bottom line by improving efficiencies. This transformation is driven by convergence of many advanced technologies such as advanced sensor and communication technologies, big data, advanced analytics, Artificial Intelligence (AI), robotics, additive manufacturing, virtual and augmented reality (VR/AR). Enterprises digitization journey continues to adopt advanced technologies through multi-pronged approach to achieve their near-term and long-term goals. This paper summarizes Industry 4.0 journey, its relevance and applications to aerospace. It also summarizes how Industry 4.0 concepts can be applied to a composite manufacturing shop floor of aerospace components, how effective convergence of IoT, analytics, machine learning, AI and AR/VR help in improving the overall efficiency, reliability, availability and quality of the manufacturing shop floor by monitoring real time data to evaluate the overall performance of manufacturing plant “As Designed” Vs “As Operated” quantifying the business value.
Veluri, Sastry, Kumar, Ravi, Vasudevan, Ramji, Gorur, Ravi Prakash, Nampuraja, Enose, Shankaraiah, Mahesh, Tanjore, Simha, Rao, Shama
Digital Transformation for a CONNECTED ENTERPRISETBMG-3301910/1/2018
Manufacturers around the world are grappling with the challenge of continuous innovation in the face of increasing complexity. In aerospace and defense (A&D), complexity is nothing new, but digital transformation to become a more connected enterprise that allows programs to run independently while achieving enterprise-wide processes remains an elusive goal. Today, organizations around the world are rethinking their strategies and turning to more open and agile approaches to create a connected enterprise that can enable faster innovation.
Automated Guided Vehicles for Small Manufacturing Enterprises: A Review05-11-03-00249/17/2018
Automated guided vehicle systems (AGVS) are the prominent one in modern material handling systems used in small manufacturing enterprises (SMEs) due to their exciting features and benefits. This article pinpoints the need of AGVS in SMEs by describing the material handling selection in SMEs and enlightening recent technological developments and approaches of the AGVS. Additionally, it summarizes the analytical and simulation-based tools utilized in design problems of AGVS along with the influence of material handling management and key hurdles of AGVS. The current study provides a limelight towards making smart automated guided vehicles (AGVs) with the simplified and proper routing system and favorable materials and more importantly reducing the cost and increasing the flexibility.
Kumbhar, Surajkumar Goraksha, Thombare, Rachana B., Salunkhe, Amitkumar B.
Utilization of Man Power, Increment in Productivity by Using Lean Management in Kitting Area of Engine Manufacturing Facility - A Case Study05-11-03-00208/8/2018
The project of lean management is implemented in General Motors India Private Limited, Pune, India plant. The aim of the project is to improve manpower utilization by removing seven types of wastes using lean management system in kitting process. Lean manufacturing or management is the soul of Just-In-Time philosophy and is not new in Automobile manufacture sector where it born. Kitting area is analogs to the modern supermarket where required components, parts, consumables, subassemblies are kept in bins. These bins are placed in racks so that choosing right part at right time can be achieved easily. Video recording, in-person observation, feedback from online operators and other departments such as maintenance, control, supply chain etc. are taken. It is observed that the work content performed by current strength of operators can be performed by less number of operators. After executing this project, it was possible to reduce one operator and increase manpower utilization. Continuous improvement is a part of lean management the organization is striving for it.
Vairagde, Harshwardhan Rajeshkumar, Hans, Naresh
IMTS2018 PreviewTBMG-324698/1/2018
Presented by the Association for Manufacturing Technology (AMT), the International Manufacturing Technology Show (IMTS) has been the premier manufacturing technology show in the Northern Hemisphere. IMTS is held every even year and attracts attendees from more than 117 countries. The 2018 edition will be the 32nd show.
Digital Manufacturing Helps Revolutionize Surgical StaplerTBMG-297487/1/2018
Modern science has allowed surgeons to fix the human body amazingly fast yet leave behind only small traces where repairs were performed. One of the more commonly used methods to achieve this is by a minimally invasive technique called laparoscopic surgery, where small incisions are made into a patient's skin, a laparoscope is inserted to provide a magnified view of the patient's organs, the procedure is performed, and the incision is closed by stitching or surgical staples. You can have your gallbladder removed before breakfast and be binge-watching Netflix from the comfort of your couch by dinner.
Data, Data Everywhere: Why the Medical Device Industry Must Embrace the Fourth Industrial RevolutionTBMG-291156/1/2018
We live in a fast-changing world that is delivering rapid advances in technology and greater consumer expectations. Along with changing healthcare reimbursement models, which are moving to support improved patient outcomes, there is increasing demand for personalized products and precision medicines requiring increased complexity in medical devices. This is spawning a new era of digital and mobile medical devices and healthcare techniques, which are using the Internet of Medical Things (IoMT) to connect technology, people, and processes. These include innovations such as lab on a chip and remote monitoring of patient testing devices. One company has even introduced the concept of cloth-based diagnostic monitoring technology; using undergarments to remotely monitor cardiac performance. To respond to these modern demands and to survive in the future marketplace, medical device manufacturers need to be more agile, innovate more quickly, and adapt to remain competitive.
Understanding Smart Machines: How They Will Shape the FutureTBMG-288635/1/2018
Powered by smart machines, the new industrial revolution is changing how machine builders design, and how manufacturers operate today and in the future. To remain competitive and profitable, plants and machines will have to be smarter: better connected, more efficient, more flexible, and safe.
Smart Interoperable Logistics and Additive Manufacturing - Modern Technologies for Digital Transformation and Industry 4.02018-01-12034/3/2018
As a result of new challenges such as flexible, adaptable manufacturing systems and customized products, the complexity of new technologies for digital transformation and Industry 4.0 [36] is increasing. In this context, logistics and additive manufacturing are seen as two out of nine future technologies for modern production industries. For future developments it is crucial to find effective and flexible approaches for the connection of heterogeneous systems and, above all, data structures. A promising approach is concerned with the interoperable connection of these complex structures. The first approach to be described in the paper deals with the smart interoperable connection of systems in the domain of logistics. A concept of a system approach is presented, in which smart logistics objects communicate with each other via defined levels and provide services with certain characteristics for smart value-added processes or applications for the modern factory and production environment. The second approach deals with effects and potentials of the application of additive manufacturing for small and medium-sized enterprises. At the beginning, digital transformation and Industry 4.0 and their latest developments in industrial manufacturing will be introduced. After this, in the second part, the first research approach will be presented which a short introduction to interoperability, followed by an overview of the current approaches to interoperability and a presentation of the approach for the development of a smart interoperable logistics environment. The last part of the paper will describe an approach to evaluate effects and potentials of additive manufacturing in context of Industry 4.0. A summary and outlook complete the paper. Both presented approaches will aid managerial decision making in relation to the presented technologies and the design of further concepts and for further research. The two approaches combine approved research concepts in the domains of logistic and interoperability as well as additive and conventional manufacturing and adapt this to new sustainable concepts for digital transformation and industry 4.0.
Forkel, Eric, Baum, Jens, Schumann, Christian-Andreas, Mueller, Egon
Logistics Planning and Its Applications for Engine Plant under ‘Industry 4.0’2018-01-12054/3/2018
With the arrival of Industry 4.0 era, traditional manufacturing industries will convert to intelligent systems. In addition to the computerization of manufacturing systems, logistics system will require automatic and IT-controlled processes integrated with Industry 4.0. This paper presents an analysis of the scope, hierarchy, and principles of logistics planning with emphasis on the concepts required to achieve intelligent logistic system. Integrated logistics system will directly connect and manage the entire distribution chain visually from the material source to the end customer upwards and at the same time, connect to the warehouse of suppliers downwards. The logistics planning processes can be optimized by setting up mathematical models and logical relationship with virtual simulation and verification tools. Relying on big data and cloud computing for sales forecasts permits better adjustment of inventory levels across the entire supply chain. A real case study by the application of logistics planning under Industry 4.0 and the advantages that come with it is given in this paper. Consequently, the processes and results in this study provide a reference for logistics planning conducted in the context of Industry 4.0, and this study can be helpful for researchers and managers in their work.
LI, Fengzhu, Sijun, Li, Cui, Yanjun
Real-Time Path Correction of an Industrial Robot for Adhesive Application on Composite Structures2018-01-13904/3/2018
Due to their unique and favorable properties as well as high strength to weight ratio, composite materials are finding increasing applications in automotive, aircraft and other vehicle manufacturing industries. High demand, production rates and increasing part complexity, together with design variations require fast, flexible and fully automated assembly techniques. In automotive and aircraft manufacturing, widely used bonding and sealing processes are automated using industrial robots due to their speed, flexibility and large working volume. However, there are limitations in achieving complete automation of these processes due to the inherent inaccuracies of the industrial robots, workpiece positioning and process tolerances. Currently, the robot programs are generated in CAD/CAM environment and are adjusted manually according to the actual workpiece. An alternate solution is proposed with an on-board vision based sensor setup to adapt the robot path compensating for the robot kinematic inaccuracies, workpiece referencing errors and unique local deformations of the workpiece via a real-time interface. The realized setup consists of a prototype dosing system with two laser line triangulation sensors on the end-effector of a serial robot. The developed real-time application computes the 5 Degrees of Freedom (DOF) deviations and corresponding robot correction signals. The robot executes the generated offline programs for the application process. The implemented “real-time” control scheme adapts the programmed trajectory in accordance with the position, orientation and tolerances of the actual workpiece so that the process tolerances are met.
Shah, Nihar Hasmukhbhai, Subramanian, Shivaprakash, Wollnack, Jörg
Understanding Network TopologyTBMG-285363/1/2018
Sensor networks are the backbone of the Internet of Things (IoT) and Industry 4.0. They provide the data that drives automated systems: both feedback for control loops and status information for all of the components (nodes) of the connected systems. Sensor data has to be reliable and available as closely as possible to real time, that is, with minimum latency. How this data is communicated is therefore critical. There are different topologies for establishing sensor communication networks. Understanding them is key to building a successful system.
Mixing 3D Printing Technologies Helps Optimize ProductsTBMG-285703/1/2018
Stratasys Eden Prairie, MN
Simulation key to additive manufacturing analysis17TOFHP12_0212/1/2017
Advanced simulation tools help to optimize 3D printing processes before physical build. When 3D printing first hit the consumer market, it was considered a novelty and a gimmick. However, the professional market has leveraged the technology, incorporated other materials and systems, and created the burgeoning field of additive manufacturing (AM) that is revolutionizing the industry. Borja Lazaro Toralles and the Manufacturing Technology Centre (MTC) in the UK have recognized additive manufacturing as a field that is going to play a vital role in the future across multiple industries. MTC created the National Centre for Additive Manufacturing (NCAM) in 2015. The purpose of the center was to develop production-ready AM processes, overcoming the barriers to wide-scale adoption and working on legislative and standardization issues in the emerging field.
Borst, Matthew, Gehm, Ryan
Trends in Hydraulic FiltrationTBMG-2794212/1/2017
Proper filtration plays an important role in ensuring that hydraulic systems operate trouble-free. High-performance filters maintain the cleanliness of the hydraulic fluid over its entire service life. In addition, designers are faced with ever-changing application requirements — longer filter change intervals, higher operating safety, increased separation efficiencies, and increased compatibility with the new generation of hydraulic oils. Following is an overview of some important technologies and trends in the industry, and their impact on users of hydraulic systems.
Fully Automated Quality Control of Cylinder Bores from Internal Combustion Engines and Its Implications for Industry 4.02017-36-008211/7/2017
Internet has transformed all industries and the automotive sector is on its list. It is true that manufacturing has experienced great advances in recent years, but the massive use of internet in industry is about to revolutionize it once again. The Internet of Things (IoT), the Big Data Analytics and the use of RFID technology will revolutionize manufacturing, giving to the so called “smart factories” the ability for self-diagnosis, self-configuration and self-optimization. That is what we call Industry 4.0, or the fourth industrial revolution. However, how will Industry 4.0 affect automakers and end users of vehicles? What are the challenges to bring Industry 4.0 innovations to the manufacturing industry? The present work discusses future trends in engine manufacturing, focusing on the quality control of its main components. Also, a fully automated inspection technique for quality control of cylinder bores from internal combustion engines is presented. The proposed method, which is based upon topography decomposition and multiscale analysis, was used to compare two honing variants. The results show that standardized roughness parameters are not enough to properly evaluate honed surfaces. Finally, this work shows that the proposed methodology for characterization of honed surfaces can not only increase quality and reliability of engine components, but can also allow more significant advances in engine optimization. Thereby, the described method can support automakers to attend the demands of increasingly stringent markets.
Obara, R.B., Guedes, L.C.
DIGITALIZATION: The New Critical Success FactorTBMG-275299/1/2017
The terms Industry 4.0, Big Data, the Internet of Things, and the Digital Factory are being pitched around like a rugby ball, and almost always with a decided lack of clear definition. Let’s set the record straight.
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