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.     

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

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 second part of the report (Part II). It will focus on the development of knowledge-based expert design system for assembly oriented design. The knowledge-based assembly oriented design system, i.e., the assembly oriented design expert system (AODES) is constructed to integrate assembly modeling and design, assembly planning, assemblability analysis and evaluation within a concurrent engineering environment. This intelligent system is implemented by integrating object-oriented representation, constraint-based modeling, rule-based reasoning, truth maintenance, and interfacing to database management system and CAD module, in which fuzzy logic based knowledge representation and inference technique are also applied to deal with uncertain data and knowledge in the design process. The developed system differs from the existing systems adopting part-first bottom-up modeling technique, in which a comprehensive intelligent framework is used for assembly modeling and design in a top-down manner from the conceptual level to the detailed level. It is able to help obtain better design ideas, provide users with suggestions so as to create and improve a design, and therefore give users the possibility to assess and reduce the total production cost at an early stage during the design process. Through the use of the system, the concurrent engineering knowledge can be effectively incorporated into the assembly design process in an integrated manner. A case assembly design shows that the intelligent modeling and design system is feasible.     

Developing a quantitative intelligent system for implementing concurrent engineering design

This research focuses on the development of a quantitative intelligent system for implementing concurrent engineering design. The paper first discusses the task of concurrent engineering design and the basic requirements for conducting integrated concurrent engineering design. The proposed quantitative intelligent system approach combines qualitative reasoning, based upon design and manufacturing knowledge, and quantitative evaluation and optimization, conducted using design information and manufacturing data generated in the knowledge-based reasoning. The method allows considerations on non-operating principle aspects of a product to be incorporated into the design phase, such as manufacturing, maintenance, service, recycle, etc., with an emphasis on production costs. The proposed method serves as a convenient software tool for gathering information required in the concurrent engineering design process and integrates tasks from different parts of the product development life cycle, particularly function design, manufacturability analysis and production cost estimation. A prototype software system is developed based upon this method using Smalltalk-80. In the prototype system, concurrent engineering design is carried out by: (1) describing and representing design requirements; (2) generating feasible design candidates and evaluating their design functions; (3) representing design geometry; (4) finding the associated production processes and predicting the production costs of each feasible design; and (5) identifying the costeffective design that satisfies given design requirements and requires minimum production costs.     

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.     

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.     

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 object-oriented constraints-based system for concurrent product development

This research work aims to develop an intelligent constraint-based system that enables designers to consider at the early stages of the design process all activities associated with product’s life cycle. One of the most important aspects of these activities is the evaluation and optimisation of manufacturing processes that require various type of information from the different aspects of product’s life cycle. This research article discusses the development of a prototype system for manufacturing process optimisation using a combination of both mathematical methods and constraint-programming techniques. This approach enables designers to evaluate and optimise feasible manufacturing processes in a consistent manner as early as possible during the design process. This helps in avoiding unexpected design iterations that wastage a great amount of time and effort, leading to longer lead-time. The development process has passed through the five major stages: Firstly, an intelligent constraint-based design system for concurrent product and process design has been developed. Secondly, a manufacturing process optimisation module has been constructed. Thirdly, the product features, processes, cost, time and constraints to be used for carrying out various design tasks has been represented in the format of constraints, frames, objects, and rules. Fourthly, the process optimisation and evaluation rules for the selection of feasible processes for complex features, and finally, the information management system that ensures consistency in information exchange and decision making activities have been developed.     

Simultaneous optimal selection of design and manufacturing tolerances with alternative manufacturing process selection

Tolerance specification is an important part of mechanical design. Design tolerances strongly influence the functional performance and manufacturing cost of a mechanical product. Tighter tolerances normally produce superior components, better performing mechanical systems and good assemblability with assured exchangeability at the assembly line. However, unnecessarily tight tolerances lead to excessive manufacturing costs for a given application. The balancing of performance and manufacturing cost through identification of optimal design tolerances is a major concern in modern design. Traditionally, design tolerances are specified based on the designer’s experience. Computer-aided (or software-based) tolerance synthesis and alternative manufacturing process selection programs allow a designer to verify the relations between all design tolerances to produce a consistent and feasible design. In this paper, a general new methodology using intelligent algorithms viz., Elitist Non-dominated Sorting Genetic Algorithm (NSGA-II) and Multi Objective Particle Swarm Optimization (MOPSO) for simultaneous optimal selection of design and manufacturing tolerances with alternative manufacturing process selection is presented. The problem has a multi-criterion character in which 3 objective functions, 3 constraints and 5 variables are considered. The average fitness factor method and normalized weighted objective functions method are separately used to select the best optimal solution from Pareto optimal fronts. Two multi-objective performance measures namely solution spread measure and ratio of non-dominated individuals are used to evaluate the strength of Pareto optimal fronts. Two more multi-objective performance measures namely optimiser overhead and algorithm effort are used to find the computational effort of NSGA-II and MOPSO algorithms. The Pareto optimal fronts and results obtained from various techniques are compared and analysed.     

A logic-based mechanical system constraint model

This paper: (1) classifies design constraints of mechanical systems from a multi-disciplinary, concurrent engineering point of view from three orthogonal bases: application, object, and expression, (2) presents some initial developments in extending data models to include design constraints, formally defining entity relationships using first order predicate logic, and modeling assembly related geometry constraints for mechanical systems using predicates. Axioms and atomic formulas of mechanical assemblies are developed. Two frequently used assembly relationships-fit and against—are defined and used to explain the assembly definition axiom of a piston assembly of an engine model. Such a geometry constraint modeling method builds a basis for design change propagation and change management.     

Intelligent design and planning of manual assembly workstations: A neuro-fuzzy approach

The design of manual assembly workstations, as with most forms of designs, is highly iterative and interactive. The designer has to consider countless constraints and solutions for contradictory goals. In order to assist the designer in design process, it is required to develop a new intelligent methodology and system. This paper develops a neuro-fuzzy hybrid approach to intelligent design and planning of manual assembly workstations. Problems, related to workstation layout design, planning, and evaluation, are discussed in detail. A fuzzy neural network is used to predict the ranges of anatomical joint motions and to design or adjust workstations and tasks. The neuro-fuzzy computing scheme is integrated with operator's posture analysis and evaluation. For training and test purposes, experiment is carried out to simulate assembly tasks on a multi-adjustable assembly workstation equipped with a flexible PEAK motion measurement and analysis system. The trained neural network is capable of memorizing and predicting the joint angles associated with a range of workstation configurations. Thus, it can also be used for the design/layout and on-line adjustment of manual assembly workstations. Thus, the developed system provides a unified, computational intelligent framework for the design, planning and simulation of manual assembly workstations.     

Designing for operations: Towards a sociotechnical systems and cognitive engineering approach to concurrent engineering

In the practice of concurrent engineering, the factors that are considered early in the product design process include manufacturability, assembly, and cost. A set of issues that are not typically considered revolve around the operational requirements for human workers in the manufacturing system. What tasks will human workers accomplish? How will these tasks be organized and coordinated? What information and resources need to be shared? Will the workers have a coherent set of job responsibilities? How should the manufacturing environment be designed to support effective work practices? How can a manufacturing process be designed that also informs organizational structure and takes into account the quality of working life?

The field of sociotechnical systems theory (STS) focuses on exactly these kinds of issues. Rather than subscribing to the usual view of technological determinism — that a complex human-machine system is designed solely with respect to optimization of technical criteria — the goal of STS is to jointly optimize both human and technological considerations in system design and operation. The spirit of STS has much in common with recent work in cognitive systems engineering that advocates the design of joint cognitive systems in which machines serve as flexible, context-sensitive resources for human problem solving. Furthermore, a focus on design teams necessitates the study of the relationship between group work and technology as studied in the field of computer-supported cooperative work (CSCW). This paper briefly reviews current research in sociotechnical systems theory, computer-supported cooperative work, and cognitive systems engineering and proposes a framework for integrating operational concerns into the concurrent engineering process. Relevance to industry

To be competitive, organizations need to effectively manage human and technological resources. A key issue is the nature of the information and technological infrastructure that both enables and supports ‘best practice’ across the enterprise. This paper describes such an approach in the context of the ‘operational enterprise’ and provides both a philosophical stance as well as specific examples of software support.     

A domain-oriented CIM shell: A new perspective

This paper proposes a domain-oriented layer above a relational data base management system (DBMS) software in the creation of a computer integrated manufacturing (CIM) shell. The shell consists of two parts: an intelligent database design environment (IDDE) which will aid the design and implementation of an integrated database system; the deductive capability which will aid the subsequent implementation of decision support systems. The application domain is represented by the discrete engineering manufacturing industry.     

Development of a feature-based and object-oriented concurrent engineering system

Product information modeling is critical to the integration of mechanical CAD/CAM systems and to the implementation of a concurrent engineering system. This paper presents a recent development of a feature-based and object-oriented concurrent engineering system with its focus on a product information modeling technique implemented in the system. The technique was developed to capture product definition data including form features and their spatial relationships and to store them as an object-oriented information model during the design process. The paper also describes the implementation of the information modeling technique and its application to manufacturing process planning in an object-oriented environment.     

Computer-aided analysis of reconfigurable fixtures and sheet metal parts for robotic drilling

This paper presents an automated manufacturing system for drilling sheet metal parts. All stand-alone systems such as the robot, a set of reconfigurable fixtures and the CAD/CAM workstation have been integrated into a flexible manufacturing system. This system analyzes and evaluates a given fixturing layout and assembles the reconfigurable fixtures automatically using a robot manipulator. An optimum fixturing layout and assembly are achieved by examining the workpart from a stress-strain point of view. In addition, issues such as geometric constraints, yielding and buckling, database design, collision detection, fixturing sequential control and the automatic assembly of fixture elements are considered. The computational and analytical concepts for the reconfigurable fixturing and drilling system are also presented in this paper.     

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.     

PACT: an experiment in integrating concurrent engineering systems

The Palo Alto Collaborative Testbed (PACT), a concurrent engineering infrastructure that encompasses multiple sites, subsystems, and disciplines, is discussed. The PACT systems include NVisage, a distributed knowledge-based integration environment for design tools; DME (Device Modeling Environment), a model formulation and simulation environment; Next-Cut, a mechanical design and process planning system; and Designworld, a digital electronics design, simulation, assembly, and testing system. The motivations for PACT and the significance of the approach for concurrent engineering is discussed. Initial experiments in distributed simulation and incremental redesign are reviewed, and PACT's agent-based architecture and lessons learned from the PACT experiments are described     

Form tolerance-based measurement points determination with CMM

In an intelligent manufacturing environment, computer aided inspection (CAI) provides a critical role in closing the computer aided design (CAD) to computer aided manufacturing (CAM) loop. A coordinate measuring machine (CMM) is often used as a measurement tool in a mechanical part manufacturing environment. Feature-based measurement (FBM) with CMM plays an important role in the concurrent engineering environment (Fig. 1) (Yau and Menq, 1993). It measures a part and feedbacks the results to the concurrent control center to modify related process attributes. Feature-based computer aided inspection (CAI) systems define various measurement attributes for different features (Jacobohn et al., 1990). Part of the system determines the number of measurement points for a feature. In this research, a computer aided feature-based statistical concept is used to calculate sufficient measurement points for a feature. Circular and cylindrical parts are used to demonstrate the proposed methodology for determining the number of measurement points. The results show that the measurement error is significantly lower with the proposed method in determining the number of measurement points as compared to the method commonly used with a CMM. The proposed methodology is also computerized for on-line applications.     

Introduction to assembly features: an illustrated synthesis methodology

The article is an introduction to a new concept of assembly features able to support intelligent design and manufacturing of complex products. An assembly feature is defined as a generic solution referring to two groups of parts that need to be related by a relationship so as to solve a design problem. The concept of assembly feature encompasses the notions of design intent, technical function, technological solution and manufacturing process as well as it provides a justification for the use of part features. After a general introduction and a justification of the interest of assembly features, some guidelines are provided to show how assembly features can be characterized in any domain of application concerned with engineering design of assemblies. As an illustration of the proposed methodology, the concept is finally applied to the engineering phase of aeroplane design.     

Physics-based virtual reality for task learning and intelligent disassembly planning

Physics-based simulation is increasingly important in virtual manufacturing for product assembly and disassembly operations. This work explores potential benefits of physics-based modeling for automatic learning of assembly tasks and for intelligent disassembly planning in desktop virtual reality. The paper shows how realistic physical animation of manipulation tasks can be exploited for learning sequential constraints from user demonstrations. In particular, a method is proposed where information about physical interaction is used to discover task precedences and to reason about task similarities. A second contribution of the paper is the application of physics-based modeling to the problem of disassembly sequence planning. A novel approach is described to find all physically admissible subassemblies in which a set of rigid objects can be disassembled. Moreover, efficient strategies are presented aimed at reducing the computational time required for automatic disassembly planning. The proposed strategies take into account precedence relations arising from user assembly demonstrations as well as geometrical clustering. A motion planning technique has also been developed to generate non-destructive disassembly paths in a query-based approach. Experiments have been performed in an interactive virtual environment including a dataglove and motion tracker that allows realistic object manipulation and grasping.     

A CAE-integrated distributed collaborative design system for finite element analysis of complex product based on SOOA

Large-scale finite element analysis of complex product needs a wider support from external CAE resources. This paper proposes a method of the distributed concurrent and collaborative design in the distributed intelligent resources environment to use Web-based extended manufacturing resources for product development. The CAE-integrated distributed collaborative design system architecture and enabling techniques are presented. Distributed CAE service resources on the Internet are achieved through Jini^TM and service object-oriented architecture technologies. These CAE software tool resources are encapsulated as service providers in the system. A case study of railway bogie development is presented, and the Pro/E, HyperMesh, Ansys and HumanExpert service providers dynamically invoked and integrated as a temporary service federated environment with no need to know the exact location of a provider beforehand, flexibility can be well achieved, and collaborative design in the system can be implemented in the distributed dynamic environment. Compared with the traditional design system, some preliminary results indicate this architecture can shorten the cycle of service exchange, and strongly support concurrent and collaborative design of the complex product.