Knowledge-based approach and system for assembly oriented design,Part I: the approach

Assembly is one of the most important stages for product development. Assembly-oriented design (AOD) is a new approach to designing assemblies, which uses a number of design and analysis tools to help the designer plan out and analyze candidate assembly schemes prior to having detailed knowledge of the geometry of the parts. Using this approach, many assembly schemes can be inexpensively evaluated for their ability to deliver the important characteristics of the final product. This research proposes a knowledge-based approach and develops an expert design system to support top-down design for assembled products. The presentation of research report is divided into two parts: the knowledge-based approach (Part I) and the knowledge-based expert design system (Part II). This paper is the first part of the report (Part I), which mainly proposes a knowledge-based approach and framework for intelligent assembly oriented design. The proposed approach focuses on the integration of product design, assemblability analysis and evaluation, and design for assembly with economical analysis. It differs from the existing approaches adopting the part-first bottom-up modeling technique, in which a hybrid model related to design problem-solving including function–behavior–structure model, feature-based geometric model, and parametric constraint model is used as a comprehensive intelligent framework for assembly modeling and design in a top-down manner from the conceptual level to the detailed level. Through the use of intelligent approach and framework, concurrent engineering knowledge can be effectively incorporated into the assembly design process, and a knowledge-based expert design system can be implemented.     

A knowledge intensive multi-agent framework for cooperative/collaborative design modeling and decision support of assemblies

Multi-agent modeling has emerged as a promising discipline for dealing with decision making process in distributed information system applications. One of such applications is the modeling of distributed design or manufacturing processes which can link up various designs or manufacturing processes to form a virtual consortium on a global basis. This paper proposes a novel knowledge intensive multi-agent cooperative/collaborative framework for concurrent intelligent design and assembly planning, which integrates product design, design for assembly, assembly planning, assembly system design, and assembly simulation subjected to econo-technical evaluations. An AI protocol based method is proposed to facilitate the integration of intelligent agents for assembly design, planning, evaluation and simulation process. A unified class of knowledge intensive Petri nets is defined using the O-O knowledge-based Petri net approach and used as an AI protocol for handling both the integration and the negotiation problems among multi-agents. The detailed cooperative/collaborative mechanism and algorithms are given based on the knowledge objects cooperation formalisms. As such, the assembly-oriented design system can easily be implemented under the multi-agent-based knowledge-intensive Petri net framework with concurrent integration of multiple cooperative knowledge sources and software. Thus, product design and assembly planning can be carried out simultaneously and intelligently in an entirely computer-aided concurrent design and assembly planning system.     

A reasoning method for a ship design expert system

Abstract: The ship design process is a highly data‐oriented, dynamic, iterative and multi‐stage algorithm. It utilizes multiple abstraction levels and concurrent engineering techniques. Specialized techniques for knowledge acquisition, knowledge representation and reasoning must be developed to solve these problems for a ship design expert system. Consequently, very few attempts have been made to model the ship design process using an expert system approach. The current work investigates a knowledge representation–reasoning technique for such a purpose. A knowledge‐based conceptual design was developed by utilizing a prototype approach and hierarchical decompositioning. An expert system program called ALDES (accommodation layout design expert system) was developed by using the CLIPS expert system shell and an object‐oriented user interface. The reasoning and knowledge representation methods of ALDES are explained in the paper. An application of the method is given for the general arrangement design of a containership.     

An object-oriented knowledge based Petri net approach to intelligent integration of design and assembly planning

Artificial intelligence can play an important role in the reduction of manufacturing costs and the enhancement of production efficiency and product quality. In order to assist designers in the early stages of a product development this paper develops an intelligent methodology for integration of design and assembly planning processes, including product design, assembly evaluation and redesign, assembly process planning, design of assembly system and assembly simulation, subjected to both econo-technical and ergonomic evaluations. A new unified class of object-oriented knowledge based Petri nets called OOKPNs, incorporating knowledge based expert systems and fuzzy logic into ordinary place–transition Petri nets, is defined and used for the representation and modeling of the distributed design processes. A prototype intelligent integrated design and assembly planning system (IIDAP) is implemented through distributed blackboard structure with concurrent integration of multiple cooperative knowledge sources and software. It consists essentially of the networked agents and the meta-system, each of which is a knowledge Petri net system with the capabilities of problem solving, learning and conflict resolution, and can be obtained through the inheritance, polymorphism and dynamic binding of instances of OOKPNs. In IIDAP system, both C/C++ language and COOL (CLIPS object-oriented language) are used to incorporate a Petri net tool, a geometric modeling and design tool, a planner and simulator and an evaluation tool. By use of this system, product design and assembly planning can be carried out simultaneously and intelligently in an entirely computer-aided concurrent design and assembly planning system. The design of manufacturable, cost-effective, usable products can therefore be achieved rapidly and flexibly. The developed methodology and system have been successfully applied to assembly design and planning of a micro switch.     

Integrated knowledge-based Petri net intelligent flexible assembly planning

Automatic assembly planning is recognized as an important tool for reducing manufacturing costs in concurrent product and process development. A novel knowledge-based Petri net (KBPN) is defined, based on the incorporation of expert systems into the usual Petri nets, and used for a unified assembly knowledge representation scheme. A KBPN-approach integrated with a sequence generation algorithm is proposed for the modeling, planning, simulation, analysis and evaluation of the flexible assembly system (FAS). The developed KBPN-based assembly planning system (KAPS) can automatically adjust the deviations between the theoretical planning parameters and the process parameters of real assembly operations to guarantee the best strategies and plans (sequences) for flexible assembly. The research findings are exemplified with a simple assembly to show the effectiveness of the method.     

Knowledge intensive Petri net framework for concurrent intelligent design of automatic assembly systems

The integration of design and planning of flexible assembly system has been recognized as a tool for achieving efficient assembly in a production environment that demands assembly with a high degree of flexibility. This paper proposes a concurrent intelligent approach and framework for the design of robotic flexible assembly systems. The principle of the proposed approach is based on the knowledge Petri net formalisms, incorporating Petri nets with more general problem-solving strategies in AI using knowledge-based system techniques. The complex assembly systems are modeled and analyzed by adopting a formal representation of the system dynamic behaviors through knowledge Petri net modeling from the specifications and the analysis of those models. A template is first defined for a knowledge Petri net model, and then the models for assembly system individuals are established in the form of instances of the template. The design of assembly systems is implemented through a knowledge Petri net-based function–behavior–structure model. The research results show that the proposed knowledge Petri net approach is applicable for design, simulation, analysis and evaluation, and even layout optimization of the flexible assembly system in an integrated intelligent environment. The integration of assembly design and planning process can help reduce the development time of assembly systems.     

Intelligent process-control system design

The use of expert systems has vast potential in an intelligent process-control system. In this paper, the issue of process-control system design using a knowledge-based approach is discussed. Expert-system techniques have been used for the design of controllers for process-control systems. The expert system is developed in conjunction with the successful application of a systematic design approach. Design knowledge has been represented using rules, facts and frames. The design process consists of a sequence of operations obtained by heuristics and experience in the design techniques.     

EFDEX: A Knowledge-Based Expert System for Functional Design of Engineering Systems

This paper presents a knowledge-based system, ‘EFDEX’, the Engineering Functional Design Expert, which was developed using an expert system shell, CLIPS 6.1, to perform intelligent functional design of engineering systems. On the basis of a flexible, causal and hierarchical functional modeling framework, we propose a knowledge-based functional reasoning methodology. By using this intelligent functional reasoning strategy, physical behavior can be reasoned out from a desired function or desired behavior, and inter-connection of these behaviors is possible when there is compatibility between the functional output of one and the corresponding functional requirement (e.g. driving input) of the next one. In addition, a complicated, desired function which cannot be matched with the functional output of any behavior after searching the object-oriented behavior base, will be automatically decomposed into less complex sub-functions by means of relevant function decomposition rules. An intelligent system for the functional design of an automatic assembly system provides an application of this intelligent design environment, and a demonstration of its methodology. In this paper, a knowledge-based functional representation scheme which integrates two popular AI representation techniques (object-oriented representation and rule-based representation) is also proposed as a prelude to a knowledge-based functional design system     

A knowledge-based simulation environment for hierarchical flexiblemanufacturing

This article presents an approach to embedding expert systems within an object oriented simulation environment. The basic idea is to create classes of expert system models that can be interfaced with other model classes. An expert system shell is developed within a knowledge-based design and simulation environment which combines artificial intelligence and systems modeling concepts. In the given framework, interruptible and distributed expert systems can be defined as components of simulations models. This facilitates simulation modeling of knowledge-based controls for flexible manufacturing and many other autonomous intelligent systems. Moreover, the structure of a system can be specified using a recursive system entity structure (SES) and unfolded to generate a family of hierarchical structures using an extension of SES pruning called recursive pruning. This recursive generation of hierarchical structures is especially appropriate for design of multilevel flexible factories. The article illustrates the utility of the proposed framework within the flexible manufacturing context     

Integration of the STEP-based assembly model and XML schema with the fuzzy analytic hierarchy process (FAHP) for muti-agent based assembly evaluation

Assemblability analysis and evaluation plays a key role in assembly design, operation analysis and planning. In this paper, we propose an integrated intelligent approach and framework for evaluation of assemblability and assembly sequence for electro-mechanical assemblies (EMAs). The approach integrates the STEP (STandard for the Exchange of Product model data, officially ISO 10303)-based assembly model and XML schema with the fuzzy analytic hierarchy process for assembly evaluation. The evaluation structure covers not only the geometric and physical characteristics of the assembly parts but also the assembly operation data necessary to assemble the parts. The realization of the integration system is implemented through a multi-agent framework. Through integration with the STEP-based product modeling agent system, CAD agent system and assembly planning agent system, the developed assembly evaluation agent system can effectively incorporate, exchange, and share concurrent engineering knowledge into the preliminary design process so as to provide users with suggestions for improving a design and also helping obtain better design ideas. The applications show that the proposed approach and system are feasible. Received: July 2004 / Accepted: January 2006     

An integrated case-based reasoning approach for intelligent help desk fault management

As modern business functions become more complex and knowledge-intensive, with increasing demands for quality services, there is an emerging trend for organisations to develop and deploy intelligent knowledge-based systems for mission-critical operations. Some of the challenges in successfully implementing this breed of systems depend on how well the intelligent system is integrated with conventional existing information systems and workflow, and the quality of the intelligent system itself. Developing quality expert systems lies in the effective modelling of cognitive processes of human experts and representation of various forms of related knowledge in a domain. An integrated intelligent system called the Intelligent Help Desk Facilitator (IHDF), has been developed for computer and network fault management. The system, which comprises various modules including an expert system, is successfully deployed in a problem response help desk environment of a local bank. This paper describes a cognitive-driven approach to the development of the expert system based on a hybrid knowledge representation and reasoning strategy. The approach incorporates a hybrid case-based reasoning (CBR) framework of techniques which include case memory organisation structures (discrimination networks and shared-featured networks), case indexing and retrieval schemes (fuzzy character-matching, nearest-neighbour similarity matching and knowledge-guided indexing); and an interactive and incremental style of reasoning. The paper discusses the design and implementation of the expert system component of IHDF and illustrates the appropriateness of the hybrid architecture for problem resolution and diagnostic types of applications.     

Manufacturing cost modelling for concurrent product development

This research work aims to develop an intelligent knowledge-based system that accomplishes an environment to assist inexperienced users to estimate the manufacturing cost modelling of a product at the conceptual design stage of the product life cycle. Therefore, a quicker response to customers’ expectations is generated. This paper discusses the development process of the proposed system for cost modelling of machining processes. It embodies a CAD solid modelling system, user interface, material selection, process/machine selection, and cost estimation techniques. The main function of the system, besides estimating the product cost, is to generate initial process planning includes generation and selection of machining processes, their sequence and their machining parameters. Therefore, the developed system differs from conventional product cost estimating systems, in that it is structured to support concurrent engineering. Manufacturing knowledge is represented by hybrid knowledge representation techniques, such as production rules, frames and object oriented. To handle the uncertainty in cost estimation model that cannot be addressed by traditional analytical methods, a fuzzy logic-based knowledge representation is implemented in the developed system. Based on the analysis of product life cycle, the estimated cost included material, processing, machine set-up and non-productive costs. A case study is discussed and demonstrated to validate the proposed system.     

Principled Modeling and Automatic Classification for Enhancing the Reusability of Problem Solving Methods of Expert Systems

Software reuse is widely believed to be a key to improving software productivity and quality in conventional software. In expert systems, much of the knowledge has been compiled (i.e., compressed and restricted into effective procedures) and this makes reusability difficult. One of the issues in modeling expert systems for enhanced reusability is capturing explicity the underlying problem solving designs. Principled knowledge representation schemes have been used to model components of complex software systems. However, the potential for applying these principled modeling techniques for explicitly capturing the problem solving designs of expert systems has not been fully explored. To overcome this omission, we use an Artificial Intelligence knowledge representation scheme for developing an ontology of the software components to facilitate their classification and retrieval. The application of our ontological approach is of both theoretical and practical significance. This method facilitates the reuse of high-level design. We illustrate the application of principled domain modeling using two real world applications of knowledge-based systems.     

Support system for finite element analysis

This paper describes work aimed at developing an intelligent support system for finite element modeling and a methodology for managing input data model. Analyzing various statement structures of input data, three structural interface models — the hierarchical browser, the spread sheet and the model generator — are proposed for advanced representation and editing. Two knowledge models composed of macro visual data representation (user oriented model) and micro regularized data representation (processor oriented model) are revealed in conformity with the approach of object-orientation. Moreover, an extended relational schema composed of a composite object (assembly of functional elements) and several abstracted scalar indexes has been implemented for case retrieval.     

Expert system application on preliminary design of water retaining structures

Design of liquid retaining structures involves many decisions to be made by the designer based on rules of thumb, heuristics, judgment, code of practice and previous experience. Various design parameters to be chosen include configuration, material, loading, etc. A novice engineer may face many difficulties in the design process. Recent developments in artificial intelligence and emerging field of knowledge-based system (KBS) have made widespread applications in different fields. However, no attempt has been made to apply this intelligent system to the design of liquid retaining structures. The objective of this study is, thus, to develop a KBS that has the ability to assist engineers in the preliminary design of liquid retaining structures. Moreover, it can provide expert advice to the user in selection of design criteria, design parameters and optimum configuration based on minimum cost. The development of a prototype KBS for the design of liquid retaining structures (LIQUID), using blackboard architecture with hybrid knowledge representation techniques including production rule system and object-oriented approach, is presented in this paper. An expert system shell, Visual Rule Studio, is employed to facilitate the development of this prototype system.     

SAPT—Knowledge-based CAPP system

The system for automatic programming technology (SAPT system) is a part of the designer-expert system. The new developments in artificial intelligence are promising for design and use knowledge-based expert systems. For a manufacturing process planning knowledge base, the method of knowledge representation and reasoning strategy are given. GT and TT concepts are discussed in detail from a KB approach. Production rules are given for knowledge sources, tasks and meta-knowledge. For two real life, examples, a LISP-program has been written and executed. The results obtained are encouraging and further research is in progress.     

IKOOPPS: an intelligent knowledge-based object-oriented process planning system for the manufacture of progressive dies

Abstract: This article describes an intelligent knowledge-based object-oriented process planning (IKOOPP) system for the manufacture of progressive die plates. A die assembly is designed using a variety of standardised components based on a computer-aided design (CAD) system. A feature recognition module extracts all the pertinent geometrical properties and functional attributes of each machining feature from the CAD representation models. These properties and attributes are converted into an object-oriented representation. Knowledge of the functions of the machining feature allows process planning information to be automatically deduced. Specialised tool engineering knowledge are formulated as production rules or procedures to establish the required set of cutting tools, together with the machining allowances and sequence of operations.     

Concurrent intelligent rapid prototyping environment

Rapid prototyping technology enables rapid production of complex objects directly from a computer-aided design model without involving any tooling or conventional part programming. This has created a new set of problems associated with part design, process planning, support design and value engineering analysis of rapid prototyping parts. In this paper, a methodology for resolving these problems is described, which uses concurrent engineering, distributed blackboard, value engineering, knowledge-based and feature-based technologies. The functionality, design methodology and knowledge representation techniques of a concurrent intelligent rapid prototyping system for stereolithography form the main focus of this paper.     

Automated functional design of engineering systems

This paper presents a prototype intelligent system, the knowledge-based functional design automation system (KBFDA) for automating the functional design process of engineering products/systems. An integrated knowledge representation scheme combines rule-based and object-oriented representation methods to represent functions and function related design characteristics in an intelligent design environment. A knowledge-based functional reasoning strategy uses this representation to automatically generate physical behaviors from desired functions or behaviors. The required behaviors are then combined in different configurations to develop a set of potential concept variants that meet the functional requirements and functional constraints given in a design specification. Finally, the variants are ranked according to the degree to which they meet non-functional constraints. The variant with the lowest rank (score) is selected as the best solution. A case study design of a terminal insertion unit is presented to demonstrate the practicality of the proposed approach.     

KIMS—A knowledge-based computer vision system for production line inspection

the aim of this paper is to discuss a generic expert system prototyped for image analysis and interpretation tasks. The system christened KIMS is a knowledge-based image management system which oversees the entire process of image processing, segmentation, feature extraction, knowledge representation along with an expandable capability for image understanding task. We discuss the architecture of KIMS, its modeling environment, and demonstrate its usefulness with photo-to-image inspection as applied to a manufacturing line.