Leo De Vin

SIMULATION-BASED DECISION SUPPORT FOR MANUFACTURING SYSTEM LIFE CYCLE MANAGEMENT

Previous research has highlighted the role of virtual engineering tools in the development of manufacturing machinery systems. Simulation models created for this purpose can potentially be used to provide support for other tasks, such as operational planning and service and maintenance. This requires that the simulation models can be fed with historic data as well as with snapshot data. Furthermore, the models must be able to communicate with other business software. The paper describes how simulation models can be used for operational production planning and for service and maintenance support. Benefits include a better possibility to verify production plans and the possibility to monitor and service manufacturing machinery from remote locations. Furthermore, the expanded and continuously updated models provide a good tool to study the effect of, for instance, planned new product introduction in existing manufacturing systems. The paper also presents directions for future research. One ambition is to add AI tools to the system so as to develop a semi-autonomous system for decision support.

Curvature prediction in air bending of metal sheet

Abstract The paper describes the use of bending models for air bending and focuses in particular on the importance of adequate determination of sheet curvatures, especially the curvature under the punch nose. After an introduction to air bending, the principles of models which are based on the assumption that the sheet wraps around the punch are described. This ‘wrap-around’ assumption is a limitation and often not in accordance with industrial practice. A method to predict the sheet curvature under the punch, thus eliminating the need for the wrap-around assumption, is discussed and its results are compared with experimental results. The paper then describes how models based on this method can be used to improve adaptive control methods in air bending.

Ergonomics analysis in a virtual environment

Simulation can support the design of an ergonomic workplace by enabling early assessment of ergonomic conditions in a virtual environment. An important feature is the possibility to study alternative solutions or the effect of improvements from an ergonomics perspective. To be able to conduct an efficient and reliable evaluation in a virtual environment, an objective analysis method is essential. Such an analysis method should be integrated in the simulation software, and support a companys everyday ergonomics work process. In order to gain from existing ergonomics knowledge within a company, the possibility to implement such wisdom in the current simulation software becomes important. This paper presents an implementation work done with the purpose of integrating an established ergonomics work process into a virtual environment. It describes the benefits of an ergonomics work process where simulation and evaluation at early stages of a design process are key factors. The paper will also describe the integration process, i.e., the technical issues as well as the change in work methods.

Expecting the unexpected, a must for accurate brakeforming

Abstract The paper describes the problems related to an oversimplification of the air bending process. It is explained that the bending process can consist of several stages, in particular the final stage can be different from case to case. Not recognising this often results in bending errors that are not understood. The behaviour of the sheet curvature during the bending process and for different tool parameters is described. The understanding of this behaviour is crucial for the correct calculation of the punch penetration and the bend allowance. The paper describes how these can be calculated in a correct manner, and also explains the consequences of applying models, standards or thumb rules that are valid for one phase to another phase. The problems emanating from this are discussed, and solutions are suggested. The main conclusion is that expecting the unexpected is the first step towards predicting the unexpected. This is a requirement for the successful use of air bending.

DISTRIBUTED VIRTUAL MANUFACTURING FOR DEVELOPMENT OF MODULAR MACHINE SYSTEMS

To support all phases of an agile modular manufacturing machine life cycle with CAE and Virtual Manufacturing tools, a number of different engineering applications (e.g. specialist software based tools) are typically used for design, simulation, analysis, programming, control and monitoring of a machine. These applications mainly exist today as small applications islands where each of them manages their own data. When a manufacturing machine is designed, simulated, programmed, analyzed, tested, or operated, the information, connected to that specific machine, used and generated by each application island is stored separately by each application. These application islands often use different storage technologies. Each one of the applications has an information structure to separate the information connected to each machine; however, they do not necessarily use the same information structure. Another issue concerning these applications is the functionality that is implemented in them to manage information; ...

Advanced machine service support using Internet-enabled three-dimensional-based virtual engineering

In the era of globalization, one of the key factors for manufacturing machine builders/suppliers to remain competitive is their capability to provide cost-effective and comprehensive machine service and maintenance for their clients at anytime, anywhere. Previous research has highlighted the role of virtual engineering tools in the design and development life cycle of manufacturing machinery systems. Virtual engineering models created during the development phase can potentially be used to provide valuable functions for many other tasks during the operational phase, including service and maintenance support. This paper introduces an innovative Internet-enabled three-dimensional-based virtual engineering framework that can be used for such purposes. Specifically, it addresses a system architecture that is designed to facilitate the tight integration between virtual engineering tools and a set of Internet-based reconfigurable modular maintenance supporting tools. This system architecture has been verified by implementations using different toolsets atop of various Internet technologies (e.g. XML Web services and LabViews Datasocket). Implementation details and successful industrial-based test cases are also provided in this paper.

Omnidirectional robotic telepresence through augmented virtuality for increased situation awareness in hazardous environments

This paper proposes a novel low-cost robotic telepresence approach to situation awareness, initially aimed for hazardous environments. The robot supports omnidirectional movement, wide field of vision, haptic feedback and binaural sound. It is controlled through an augmented virtuality environment with an intuitive position displacement scheme that supports physical mobility. The operator thereby can conduct work away from danger whilst retaining situation awareness of the real environment.

Karlstad lean factory: an instructional factory for game-based lean manufacturing training

Abstract Simulation for training lean manufacturing ranges from simple paper-based or LEGO®-based games to larger scale simulation environments, for instance push car assembly. Some models for game-based learning are discussed and a model for lean manufacturing training is adopted. Many types of simulation may be suitable for teaching some basic elements of Lean manufacturing to students, but they are often less suitable for training industry workers in applying Lean manufacturing in their work environment. The latter group is more used to intuitive learning than to formal instruction. Thus, it is important that a training environment for this group more realistically represents the work environment; otherwise training transfer will be limited. For this reason, a lean training environment that includes materials processing stations as well as assembly areas was created. The stations exhibit some realistic behaviour such as stochastic breakdowns. Based on a comparison between factory workers and university students, five hypotheses for testing in future work are proposed.

Simulator-Assisted Lean Production Training and Education

In Lean Production training and education, simulators are often used. These can take the form of for instance desktop games, computer simulations, or full-scale simulators. Most evidence of trainin ...