Use of simulation in the analysis of shop floor operations

The use of computers in actual system applications is increasing with the availability of intelligent terminals on the shop floor. These terminals can be used by management as tools in the decision making process of planning shop floor operation. This paper discusses a pilot simulation study in the use of conventional Fortran-based simulation programs by shop floor management to:

1. 1. Participate in the evaluation of proposed FMS systems,

2. 2. Assess the impact of FMS acquisition on existing facilities,

3. 3. Assist in the identification of operational alternatives in “bottle neck” situations.

The pilot study employs a batch-oriented MRP system to provide daily updates of outstanding production center loadings on a monthly planning horizon. Two intelligent terminals are used to access a mini computer facility that executes the simulation models. The terminals have AT-compatible capabilities and are also used as data acquisition devices that support the numerically controlled operations within each work center.

The simulation models represent the 13 work centers of the firm and provide information about the average utilization of each work center, the number of parts in each queue and the average delay of parts in the queues. Future extensions of the models are planned to utilize the terminals' graphic animation capabilities to display the flow of production orders through the manufacturing facility.     

SESAM-69—A general purpose finite element method program

The multilevel superelement method in combination with extensive data generators materialized in the program system SESAM-69 introduce a new dimension to the concept of the Finite Element Method (FEM).The paper describes the superelement method and the program system SESAM-69 in brief terms. However, the major part contains some of the program analytics in connection with this method. The multilevel superelement method is an extension of the better known substructure technique, or reduction procedure. The method applies to both statics and dynamics.     

An optimal gas-fired heating system

Utilizing a prescribed system configuration, this paper discusses the mathematical models of the system components used and formulates a method for controlling a domestic heating system in accordance to a prescribed criterion. The optimal problem treated is one of reducing the room temperature deviation from a prescribed reference value to zero, while at the same time minimizing the value of some predetermined performance or cost functional J. The development proceeds in essentially five steps.

1. (a) The development of the mathematical models for each of the elements of the heating system;

2. (b) Combining the mathematical models into a form which is suitable for the application of optimization techniques;

3. (c) Defining an optimization criterion which incorporates the main objective for minimizing room temperature variations with respect to a prescribed reference temperature;

4. (d) Choosing the optimization technique best suited for the problem;

5. (e) Constructing an optimal control system employing the optimization technique developed.

A numerical example compares the performance of the optimal system with a system of the conventional type which can be found in many American homes.     

Fuzzy multiple attributes and multiple hierarchical decision making

A procedure is proposed to solve the multiple attributes and multiple hierarchical system under fuzzy environment. The approach is based on:

1. (1) fuzzy representation;

2. (2) hierarchical performance evaluation structure,

3. (3) gradient eigenvector method for rating the fuzzy criteria weighting, and

4. (4) using the max-min paired elimination method for aggregation.

To illustrate the approach, an example on the evaluation of teaching performance in higher education is solved.     

The monadic second-order logic of graphs X: Linear orderings

Graphs are finite and handled as relational structures. We give some answers to the following general questions:

1. (1) For which classes of graphs is it possible to specify a linear ordering of the set of vertices of each graph of by fixed monadic second-order formulas?

2. (2) For which classes of graphs does there exist an extension of monadic second-order logic such that a subclass L of is recognizable if and only if it is the class of graphs in that satisfy a formula of ? (In this paper, recognizability is understood in an algebraic sense, relative to a finite set of graph operations and basic graphs that generate all graphs of .)

3. (3) For which classes of graphs is it possible to construct, in every graph of the class, and by fixed formulas of a suitable extension of monadic second-order logic, its hierarchichal structure, i.e., a finite term written with the operations and basic graphs of (2), that defines the considered graph?

Applications concern dependency graphs of partially commutative words, partial k-paths, cographs, and graphs, the modular decomposition of which uses prime graphs of bounded size.     

Observer-based multivariable flatness control of a cold rolling mill

The synthesis methodology developed by Kimura (1985) based on the design theory of output regulators essentially due to Wonham (1974) has been applied successfully to the flatness control system for a 6-high cold rolling mill. The system has the following remarkable features.

1. (1) The structure of the controller is simple. This makes it easy to tune the control system.

2. (2) The controller copes well with the detection time delay, and thus high performance is obtained even at a low rolling speed.

3. (3) The flatness error caused by the rolling force variation in mill acceleration and deceleration time would be kept to a minimum by the function to adjust roll bending force using the signal of rolling force.

Application of AI in software and information engineering

Methodologies already exist for information systems analysis and design (e.g. SSADM, JSP, Merise, etc.) and supporting tools, namely, CASE (Computer Aided Software Engineering) and RDBMS (Relational Database Management System) and/or 4GL tools. All of these tools contain a data dictionary at the core of certain facilities.

In the underlying research and in this paper, the following questions need to be addressed:

• —How can the capability of a recently available data dictionary be enhanced with some knowledge-based modules?

• —What would be the architecture of such a system, based on the data dictionary of some CASE tools?

• —How can the informal and formal modelling approach information system design be combined?

• —What sort of knowledge-representation techniques would be suitable for the different tasks during the analysis and the design of the system?

The system outlined here would work as an intelligent assistant and workbench supporting the developer, but not as an automatic programming environment.     

Robot simulator in TIPS/Geometric Simulator

With the growth of factory automation, the need for off-line robot programming is increasing rapidly. Off-line programming requires a robot simulator. This is the reason for the development of a TIPS/GS (Geometric Simulator), accompanied by a robot simulator. TIPS/GS has been developed as a project in the TIPS Research Association. The goal of this project is to extend the functions and applications of the solid modeler TIPS-1. Four simulators (i.e. the assembly simulator, engineering, NC simulator and robot simulator) have been developed for these extended applications.

The robot simulator described in this paper has the following special features:

• • When a robot motion is prescribed by the VAL-G language, the result can be seen on a CRT display in several patterns.

• • High-speed dynamic display which can almost keep up with real-time movements.

• • A shaded as well as wire-frame picture is used for the high-speed display entioned above.

• • Supported by the solid modeler, any robot and environment can be used with this system.

• • The preparation of a precise interference checker based on an analytical methods.

This paper is a report on the development of the robot simulator.     

Database considerations in manufacturing systems integration

This paper deals with ideas that could form a basis for manufacturing integration. In recent times more attention is being paid to the idea of applying artificial intelligence (AI) techniques to manufacturing. However, very little attention is being paid to the proper use of these techniques. This research work explores three basic ideas:

1. 1. Applications of the entity-relationship approach to knowledge representation.

2. 2. The basic philosophy of expert database systems and

3. 3. Integration of manufacturing systems from the above two concepts.

The approaches for 1 and 2 are explained with actual implementation experiences, while a framework for integration is proposed from a more philosophical perspective.     

CIM includes the experimental shop

Integration of computers in the manufacturing process has rightfully emphasized their use in electronically conveying complex product geometry from engineering design and drafting to the design of manufacturing fixtures and part programming. The relative absence of literature and software relating to the use of micro-computers in the Experimental (prototype) Shop suggests that at best, their usage is limited and at worst, not amenable to very small lot size production quantities.

Experience with a trial program suggests the contrary. While the project described in this paper is far from a full implementation, early results suggest that micro-computers can be effectively use to:

1. 1) Improve communications between the designer and the shop.

2. 2) Assist the shop in purchasing, process planning, and control of spare part inventories.

Also included in the paper is an overview of the software as contrasted with conventional high volume production planning and inventory control systems to emphasize the fundamental differences in functional usage. The paper concludes with a discussion of future extensions to provide networking and graphic capabilities that shows promise of improving the feedback loop to Engineering Design and Manufacturing.     

Advanced process monitoring—a major step towards adaptive control

Adaptive Control (AC) of machine tools requires many kinds of measured input data. The more information about the complex metal cutting process that can be obtained, the better the process can be controlled.

The paper describes an Adaptive Control Optimization (ACO) system for turning operations. The system continuously chooses Optimal Cutting Data (OCD), taking into account both economical criteria and technical limitations.

The system operates at three different levels:

• • Advanced Process Monitoring

• • Adaptive Control Constraint (ACC)

• • Adaptive Control Optimization (ACO).

Two commercial monitoring systems perform process monitoring. In addition, five independent measurement systems have been developed.

A dedicated vision system has been installed in the lathe to measure the tool flank wear between cuts. The flank wear data are utilized to predict the tool life. Based upon these predictions economical optimum cutting data can be calculated at the ACO level.

To obtain in-process real-time control of the metal cutting process the cutting forces are measured during machining. The forces are measured with conventional piezoelectric force transducers which are located between the turret housing and the cross-slide. The measured force signals are processed by a dedicated microcontroller at the ACC level and cutting data adjustments are fed back to the machine control.

A vibration measurement system, which either can be connected to an accelerometer or use the dynamic force signal from the piezoelectric force transducer, is part of a vibration control module at the ACC level. An ultra-fast signal processor performs the signal analysis.

The remaining two measurement systems—a high frequency tool signal analysis system and a power spectra analysis system—are mentioned in the paper but not further discussed.

Finally, the paper deals with how the strategies at the three different levels will be combined, in order to form an AC system. The monitoring tasks will always reside in the background and be activated if any failure occurs. The ACO subsystem will act as a path-finder and suggest cutting data. The active control tasks will, however, be carried out at the ACC level.     

MAKEBASE, an on-line information retrieval system for structural mechanics

MAKEBASE is a special purpose database system under development at Linköping Institute of Technology, Division of Solid Mechanics.

This database includes literature references covering the finite element and boundary element techniques, and detailed information on the finite element and boundary element software, as well as information on pre/postprocessors interfacing the finite element and boundary element programs.

MAKEBASE is designed for a selective, on-line information retrieval (author, subject, software options) for researchers and other workers in the field of structural mechanics.

The database is regularly updated, implemented on VAX-11/780 computers. The presented paper describes the database, and outlines its application and future development.     

An analysis of research topics in software engineering – 2006

This paper is the first in a new annual series whose goal is to answer the following question: what are the active research focuses within the field of software engineering? We considered 7 top journals and 7 top international conferences in software engineering and examined all the 691 papers published in these journals or presented at these conferences in 2006. Consequently, we have a number of findings.

(1) Seventy-three percent of journal papers focus on 20% of subject indexes in software engineering, including Testing and Debugging (D.2.5), Management (D.2.9), and Software/Program Verification (D.2.4).

(2) Eighty-nine percent of conference papers focus on 20% of subject indexes in software engineering, including Software/Program Verification (D.2.4), Testing and Debugging (D.2.5), and Design Tools and Techniques (D.2.2).

(3) Seventy-seven percent of journal/conference papers focus on 20% of subject indexes in software engineering, including Testing and Debugging (D.2.5), Software/Program Verification (D.2.4), and Management (D.2.9).

(4) The average number of references cited by a journal paper is about 33, whereas this number becomes around 24 for a conference paper.

Discrete warehouse problem

A discrete warehouse is a collection of two-dimensional unit-square objects (robot and obstacles), which are allowed to move horizontally and vertically along grid lines. In this paper, we consider motion planning problems in a discrete warehouse with movable obstacles. In such a setup one is allowed to move some of the obstacles in order to:

1. (1) navigate the robot between an initial and a final position of the warehouse, and

2. (2) construct a clearing (path) between two specified points.

The final positions of the obstacles are unimportant for our problems.

We consider two forms of obstacle manipulations:

1. (a) remote, when the obstacles are moved by a remote mechanism, and

2. (b) contact, when the obstacles are moved only by direct contact of the robot.

We present necessary and sufficient conditions for the existence of a motion in both cases, and propose efficient algorithms for constructing feasible motions.     

POOSS: A Parallel Object-Oriented Stable Storage

This article describes the design and implementation of a parallel object-oriented stable storage (POOSS) system in the context of the PRISMA project.

The main issues of the POOSS system include atomic access of generic objects, fault tolerance, parallelism, and the issues in designing a fast disk file system. These issues are approached by constructing the POOSS system as a hierarchical one, with each layer attacking different issues, resulting in a system which is easier to understand, implement and maintain.

The multiple layers of the POOSS system are interfaced by a restricted set of UNIX compatible routines. By exposing the internal interfaces of different layers to external users, the POOSS system is able to provide the application programs with multiple services of a different nature: the normal local file service, the parallel global file service, the parallel stable file service, and the parallel object-oriented stable file service. Implemented in a 100-node parallel machine environment, the POOSS system could not only process multiple files simultaneously, but also be partitioned into multiple independent subsystems.

The performance measurement of the current implementation has shown good results for the system and also identified bottlenecks, candidates for further optimizations.     

A survey of simple transfer-function derivations from high-order state-variable models

The problem of the derivation of simple transfer function models from high order state variable models is reviewed. Methods of reduction are classified according to whether they involve

1. (a) the computation of the time or frequency responses

2. (b) the derivation, as an intermediate step, of a transfer function which is the ratio of two polynomials, the denominator being of the same order as the state variable model, or

3. (c) a set of characterising functions.

Particular reduction methods considered are those based on fitting the step or frequency responses, on determining the intermediate, high order transfer function and reducing it by continued fraction expansion and on fitting the moments of the impulse response. An example illustrating these methods is given. The form of the simple model, the criteria of goodness of fit and the practical difficulties involved in the use of these methods are discussed.     

Finite element programming and C

In finite element programming, data have to be dealt with which are of different types but belong together in a logical sense. It would be very effective, with respect to program readability and maintainability, to store these data as a single unit. Effcient software design requires that all parts of information, which belong together logically, are stored as a single data unit. This can be accomplished utilizing structured data types.

Dynamic memory allocation allows the definition of dynamic variables which can be created and destroyed during run-time. Dynamic memory management is handled in C by pointers. In other conventional languages, e.g. Fortran 77, the programmer has the responsibility to select adequate array sizes for the largest problem to be solved. This often leads in engineering practice to array oversizing and to memory wasting. By allocating memory dynamically during program execution according to actual problem size, wasting can be avoided.

The combination of structured data and pointers along with the dynamic memory allocation capabilities of C allows the creation of linked lists. Utilizing these concepts, an effective and easy-to-read C program has been written for finite element analysis. The C program presented demonstrates the use of these techniques for interactive finite mesh generation. The strengths of C are compared to that of Fortran 77 and Fortran 90. It has been found that for finite element programming C is in many aspects superior to Fortran 77. However, it has some disadvantages in comparison with Fortran 90 concerning array processing.     

Solution of linear equations with skyline-stored symmetric matrix

Fortran IV subroutines for the in-core solution of linear algebraic systems with a sparse, symmetric, skyline-stored coefficient matrix are presented. Such systems arise in a variety of applications, notably the numerical discretization of conservative physical systems by finite differences or finite element techniques. The routines can be used for processing constrained systems without need for prearranging equations. The application to ‘superelement’ condensation of large-scale systems is discussed.     

Program families: Program construction by context independent refinements

The concept of program families is a generalisation of the conventional stepwise refinement paradigm. We formalise program families by allowing Hoare-triplets to be parameterized. Next we derive a simple calculus to develop programs which are known a priori to be correct with respect to explicitly formulated pre- and postconditions.

Program families deal with at least two important problems of conventional refinement steps, i.e. program families are not context dependent and they apply just as well to top-down decomposition as to the bottom-up or middle-out approach. It turns out that the meaning of a pseudostatement in the context of program families is quite different from its meaning in the conventional refinement process.

A couple of examples illustrate the technique: the 1000 primes problem, a palindrome filter and a sorting routine.

The discussion relates program families to Morgan's refinement calculus, Knuth' literate programming and Soloway's programming plans.     

A practical procedure for conceptual design and testing of machine tool structure

This paper discusses the initial development of a machine tool and its structure (concept, calculation, design) and the verification of the prototype. The topics studied include two issues: static rigidity and dynamic stability. For static rigidity several experiments and modelling studies using the finite element method have been carried out in order to identify the model parameters. In this way differences between models of bolted joints, slideways and the cross-section of the structural elements have been determined. The model is formed by design documentation and later verified through experiments on the prototype of the machine. The approach is different in the case of dynamic stability. The model is not made on the basis of design documentation or static calculations, but by experiments performed on the prototype. This relates to an oriented transfer function; parameters are determined by fitting experimental transfer function curves. With this model, the stability is analyzed under different machining conditions. Specific features of this methodology are as follows:

• • The finite element method is used for qualitative comparison of different machine tool structure concepts during the conceptual and design stages. Only after completion of the prototype may the parameters of the prototype model be adjusted for the purpose of obtaining quantitative indicators.

• • Dynamics are analyzed by parameter identification of the oriented transfer function model. The dominant degree of freedom is naturally selected by experiment and not from hypotheses about the behavior of structures obtained from mathematical manipulations such as expansion of the model according to the finite element method. If necessary another machine tool structure may be modelled; in this way hypotheses are drawn about the stability of the reconstructed prototype.

Such a procedure has been applied and verified on the machine tool structure of a horizontal machining center. Results for static rigidity and dynamic stability have been obtained from the model and experiments performed on the prototype. The following techniques have been used:

• • finite element method for qualitative identification of static behavior,

• • self-excitation of the machine,

• • digital signal processing on the FFT basis,

• • smoothing of curves and digital filtration,

• • function fitting of the transfer function (modal analysis),

• • coefficient calculus and oriented transfer function,

• • stability assessment of the fitted model under different machining conditions, and

• • modelling of the regenerative machining effect by cutting.

Necessary tests have been done by instruments required for the use of the above techniques.

Such a combined static-dynamic criteria procedure for structuring a machine tool enables efficient follow-up of all results and facilitates necessary future expansion, the utilization of universal equipment, the combination of modelling and experiments, and the synthesis of simple models of the examined machine with behavior identical to the machine. The well-known machining system dynamic stability theories are applied to such models.