Agent-based fractal architecture and modelling for developing distributed manufacturing systems

For their timely response to the rapidly changing manufacturing environment and markets, future manufacturing systems must be flexible, adaptable, and reusable. Recently, bionic (or biological), holonic, and fractal manufacturing systems (FrMS) have been discussed as potential candidates for the next generation of manufacturing systems. This study focuses on the FrMS, which is based on the concept of autonomous cooperating agents referred to as fractals. The major component of the FrMS is a basic fractal unit (BFU). It consists of five functional modules: observing module (observer), analysing module (analyser), resolving and executing module (resolver), organizing module (organizer), and reporting module (reporter). Although the FrMS has many conceptual advantages, the implementation of the system has been known to be difficult. This paper is a preliminary study of the basic components and the architecture with an eye toward the future implementation of FrMS. In order to describe the characteristics of a fractal, this paper presents several models including function models using IDEF0, working models using Petri-net, and static/dynamic models using the unified modelling language (UML).     

A client-server architecture for distributed measurement systems

This paper describes a client-server architecture for the remote control of instrumentation over the Internet network. The proposed solution allows multiuser, multi-instrument sessions by means of a queueing and instrument locking capability. Client applications can be easily developed by using conventional high-level programming languages or well-assessed virtual instrumentation frameworks. Performance tests are reported; they show the low overhead due to network operation with respect to the direct control of instrumentation     

A coordination strategy for distributed multi-agent manufacturing systems

This paper proposes a distributed multi-agent approach for dynamic part routing in automated manufacturing systems. In particular, each part in the system is associated to an intelligent software agent that must select its next destination autonomously (i.e. ignoring the actions of the other agents) and in real time (i.e. at each time it completes an operation on a workstation). Differently from other existing approaches, we overcome the typical myopia of negotiation algorithms based on dispatching rules by allowing the part agents to take decisions not only about the imminent operation, but also for the subsequent ones. The anticipated decisions are transmitted to workstation agents, which are also designated to detect and resolve conflicts by modifying part agents’ decisions. To describe the single agents and their interaction schemes in a formal way, we take advantage of DEVS discrete-event modelling tools, which also allow us to develop a detailed simulation platform for our multi-agent system. The simulation experiments obtained on a detailed model of a manufacturing system derived from the literature confirm the effectiveness of the proposed approach.     

Accounting for quality in data integration systems: a completeness-aware integration approach

Scientometrics - Ensuring the quality of integrated data is undoubtedly one of the main problems of integrated data systems. When focusing on multi-national and historical data integration systems,...     

A synthesis approach to distributed supervisory control design for manufacturing systems with Grafcet implementation

In supervisory control, computational complexity and implementation flexibility represent major challenges when a large number of local components compose a target system. To overcome these difficulties, we propose a formal approach to distributed control synthesis and implementation for automated manufacturing systems (AMS). We assume that the system is modelled with automata in a local modular fashion. Local control specifications are defined for each local subsystem by means of logical equations to construct local controllers (LCs). Then, global control specifications, stated as logical implications, are applied to the LCs, which allows synchronisation and cooperative interaction among the subsystems. This paper makes two contributions. First, it outlines a formal method for constructing minimally restrictive and deadlock-free distributed controllers (DCs). Second, it proposes a method for the interpretation of these DCs into Grafcet, which is a graphical modelling formalism widely used to design the controller’s dynamic behaviour for AMS. An experimental manufacturing system illustrates the approach.     

A learning-based methodology for dynamic scheduling in distributed manufacturing systems

To enhance productivity in a distributed manufacturing system under hierarchical control, we develop a framework of dynamic scheduling scheme that explores routeing flexibility and handles uncertainties. We propose a learning-based methodology to extract scheduling knowledge for dispatching parts to machines. The proposed methodology includes three modules: discrete-event simulation, instance generation, and incremental induction. First, a sophisticated simulation module is developed to implement a dynamic scheduling scheme, to generate training examples, and to evaluate the methodology. Second, the search for training examples (good schedules) is successfully fulfilled by the genetic algorithm. Finally, we propose a tolerance-based learning algorithm that does not only acquire general scheduling rules from the training examples, but also adapts to any newly observed examples and thus facilitates knowledge modification. The experimental results show that the dynamic scheduling scheme significantly outperforms the static scheduling scheme with a single dispatching rule in a distributed manufacturing system.     

Optimal design for additive manufacturing of heterogeneous objects using ultrasonic consolidation

Rapid prototyping (RP) technologies, such as Laser Engineering Net Shaping (LENS®) and Ultrasonic Consolidation (UC), can be used to fabricate heterogeneous objects composed of more than one material, wherein spatially varied microscopic structural details produce continuously or discretely changing mechanical or thermal properties on a macroscopic scale. These objects are engineered to achieve a potentially enhanced functional performance. Past research on the design of such objects has focused on representation, modeling, and desired functional performance. However, the inherent constraints in RP processes, such as system capability, size and shape of raw materials, and processing time, lead to fabricated objects that may not meet the designer's original intent. To overcome this situation, the research presented in this paper focuses on developing an approach— Design for Additive Manufacturing (DfAM)—to implement identified manufacturing constraints into the design process. Previous work has applied DfAM to the design of heterogeneous objects fabricated using the LENS® process. Two manufacturing constraints for this process, namely the achievable volume fractions and the processing time, were identified and incorporated into the DfAM. In this paper, the DfAM approach is extended to the design and manufacture of heterogeneous objects for the UC process. Constraints on the possible volume fraction values and on the gradient material direction are two identified manufacturing limitations, which are incorporated into the design process. An element-based finite element (FE) representation is extended to model layered heterogeneous objects. Each element is composed of metal foils of different materials according to specific design parameters. An evolutionary-based optimizer is used for its ability to handle the type of multi-modal problems encountered in the design of heterogeneous objects. The multi-criteria design problem, consisting of finding the optimal material composition along the build direction, that satisfies the functions of minimum weight and structural deformation, is implemented and solved. A three-dimensional I-beam made of two materials—aluminum for lightweight and steel for better strength characteristics—is used to illustrate the DfAM approach and its implementation for the design of heterogeneous objects using the UC process.     

Optimal design for additive manufacturing of heterogeneous objects using ultrasonic consolidation

Rapid prototyping (RP) technologies, such as Laser Engineering Net Shaping (LENS®) and Ultrasonic Consolidation (UC), can be used to fabricate heterogeneous objects composed of more than one material, wherein spatially varied microscopic structural details produce continuously or discretely changing mechanical or thermal properties on a macroscopic scale. These objects are engineered to achieve a potentially enhanced functional performance. Past research on the design of such objects has focused on representation, modeling, and desired functional performance. However, the inherent constraints in RP processes, such as system capability, size and shape of raw materials, and processing time, lead to fabricated objects that may not meet the designer's original intent. To overcome this situation, the research presented in this paper focuses on developing an approach— Design for Additive Manufacturing (DfAM)—to implement identified manufacturing constraints into the design process. Previous work has applied DfAM to the design of heterogeneous objects fabricated using the LENS® process. Two manufacturing constraints for this process, namely the achievable volume fractions and the processing time, were identified and incorporated into the DfAM. In this paper, the DfAM approach is extended to the design and manufacture of heterogeneous objects for the UC process. Constraints on the possible volume fraction values and on the gradient material direction are two identified manufacturing limitations, which are incorporated into the design process. An element-based finite element (FE) representation is extended to model layered heterogeneous objects. Each element is composed of metal foils of different materials according to specific design parameters. An evolutionary-based optimizer is used for its ability to handle the type of multi-modal problems encountered in the design of heterogeneous objects. The multi-criteria design problem, consisting of finding the optimal material composition along the build direction, that satisfies the functions of minimum weight and structural deformation, is implemented and solved. A three-dimensional I-beam made of two materials—aluminum for lightweight and steel for better strength characteristics—is used to illustrate the DfAM approach and its implementation for the design of heterogeneous objects using the UC process.     

A modular architecture for rapid development of CAPP systems for agile manufacturing

Current manufacturing planning software systems, such as computer aided process planning (CAPP) systems, are general and in a closed form. It is very difficult to modify these systems to respond to a user's dynamically changing needs. These systems are no longer suitable for agile manufacturing. This paper presents research aimed at developing a novel architecture for the rapid development of CAPP systems. The architecture supports the construction of CAPP systems from prepackaged, plug-compatible software components. Specifications of the architecture and its building blocks are defined. Several important issues in architecture implementation are discussed, and an experimental system is illustrated. Finally, an Internet-based distributed CAPP system architecture is presented as a preview of next generation CAPP system development.     

A multi-agent-based approach for conceptual design synthesis of multi-disciplinary systems

It is encouraged that designers should explore in wide multi-disciplinary solution spaces for finding novel and promising principle solutions to desired functions during conceptual design. However, due to lack of sufficient multi-disciplinary knowledge, it is often difficult for human designers to explore in wide multi-disciplinary solution spaces. Therefore, this paper proposes a multi-agent-based approach for assisting designers in achieving multi-disciplinary conceptual design synthesis. The roles of different kinds of designing agents are identified, and the collaborative mechanisms among these agents are also elaborated. The conceptual design test case of a solar toy demonstrates that the proposed multi-agent-based design synthesis approach, compared with our previous approach, can achieve higher efficiency and better robustness through collaborative conceptual design synthesis.     

A systems approach to photolithography process optimization in an electronics manufacturing environment

There are many complex problems in the optimization of an electronics manufacturing environment, and it is the view of the authors that these problems should not be solved and optimized in isolation, but analysed in the framework of a system. A systems approach offers an overall approach for solving problems, and optimizing the whole of the system as well as discrete subsystems. The research introduced in this paper integrates several techniques, namely: Integrated computer aided manufacturing DEFinition (IDEF), and experimental design and response surface methods for the analysis, control and optimization of electronic manufacturing processes. Electronics manufacturing includes three major processes; Printed Circuit Board (PCB) manufacturing, semiconductor device manufacturing and electronics assembly. This paper describes a novel generic systematic methodology that has been used to create a model to optimize the photolithography process in PCB manufacture. For this, photolithography has been considered as a whole system made up of several sub-systems. This is shown in the process map for PCBs that focuses on photolithography and its subprocesses. A model of the manufacturing process is then given with the results of this being validated using an industrial study. Optimized settings for processing equipment are given resulting in an increase in process yield within industry.     

A branch-and-bound approach for machine selection in just-in-time manufacturing systems

Equipment selection issues are very important in the early stages of implementation of just-in-time (JIT) manufacturing systems. This paper addresses the problem of determining the number of machines for each stage of a JIT system by minimizing production, imbalance and investment costs. The problem is modelled as a mixed-integer nonlinear optimization program and a branch-and-bound algorithm is developed for its solution. This algorithm guarantees the global optimum of the problem and is enhanced by simple, yet very effective, upper bounding heuristics. The solutions obtained by the developed branch-and-bound approach are compared to solutions that have appeared in the literature using heuristic approaches. The comparisons indicate that the proposed algorithm leads to significant economic savings, averaging 17% on a set of problems from the literature. The paper also considers the application of the algorithm to large-scale, industrially-relevant, problems with up to 10 stages and 200 products. Even for the largest of these problems, the search for the integer optimum requires modest computational times. This demonstrates the potential practical impact of the proposed methodology.     

A computational approach for the optimal conceptual design synthesis based on the distributed resource environment

Optimal conceptual design synthesis is the very starting and key phase in the product design. Its result is the optimal alternative in the solution space, and will be further completed and improved into the final product design scheme in the next detailed design works. With the progress of the Internet technology, a large number of design resources actually construct an increasingly growing distributed resource environment. If these rich resources can be fully introduced into the optimal conceptual design synthesis, the design efficiency and product innovation will be promoted largely. Therefore, a computational approach was proposed for the optimal conceptual design synthesis based on the distributed resource environment. In this approach, the distributed resource environment is modelled as a set of numerous functional units (FUs), and the optimal conceptual design synthesis is concluded into a process of generating the optimal objective FU chain. Here, the main workload is completed by a proposed computer algorithm. To prove the feasibility of this approach, a computer programme called Optimal Conceptual Design Synthesis System (OCDSS) was established. A garbage-powered lighting system was designed with OCDSS as an illustration.     

A possibilistic approach for designing hybrid cellular manufacturing systems

In this paper, a hybrid cellular manufacturing (HCM) system is presented in which the main sources of uncertainty, e.g. the demands of parts and unit costs are treated as fuzzy numbers in the form of possibilistic distributions. The basic concept of HCM is that high variation in demand might disturb cell efficiency, so forming cells with only those parts that have stable demand, will profit. Thus, to design stable and robust manufacturing cells, a two-phase method is proposed in which a fuzzy adaptive ranking method is first applied to identify those parts with low and non-repetitive demands (i.e. the special parts) which will then be assigned to a functional cell. Afterwards, an interactive possibilistic programming model is applied to cell formation of remaining regular parts while considering both part sequences and multiple routes. To show the capability and usefulness of the proposed method, an illustrative example is also provided. Finally, concluding remarks are reported.     

Concept of integrated data processing in computer controlled manufacturing systems (FMS)

An adequate and economic automation of production plants demands standardized and transferable solutions especially as far as computer controlled production is concerned. New developments of hardware and software components offer potential users extendable systems which, depending on the degree of extension, are capable of coping with both the technical and the organizational information flow within the production plant. In course of research developments concerned with the automation of production installation, a DNC-system was. first built using standardized process peripherals (CAMAC) and modular process control software written in a high-level language (PROCESS-FORTRAN) and later implemented in industry.

In the current set-up are two complex flexible manufacturing systems, one for profile milling pieces and one for rotational pieces. These DNC-systems are being equipped with additional functions necessary for data processing as well as for material-flow, handling functions and process monitoring. The presentation deals with the development and set-up of these two systems.     

网络化制造系统联邦集成的关键技术

联邦集成架构(FIA)是异构网络化制造系统集成的新方法.本文按照FIA接口规范,实现了FIA中的联邦执行支撑环境(FEI).对系统的关键技术--分布自治结构的联邦管理技术、支持跨系统任务协作的访问控制与授信技术、跨系统的分布式共享资源调度技术、服务搜索与匹配技术等进行了研究,并给出了相应的解决方案.该联邦集成系统已在北京网络化制造系统集成中得到了实际应用.应用结果表明,联邦模式的集成方案是一种适用于构建大规模服务共享的集成模式,能够适应网络化制造服务异构及运营目标多样化的应用环境.     

A cognitively based approach to computer integration for design systems

The kind of relationship a designer will have with a design assisting tool is dependent upon the kind of dialogue possible between the two, and any dialogue will be conditioned by the degree of mutual understanding existing between designer and assistant. In the first part of this paper we examine the methodology, currently prevalent in the computer-aided building design domain, that is supposed to address this problem: product modelling. We argue that product modelling is inherently incapable of fulfilling the goals that it sets itself, primarily because it is an attempt to move a methodology from, and appropriate to, a closed domain to an unbounded domain. In doing so, it fails to address the basic problem: it fails to provide a medium for dialogue. Dialogue entails mutual understanding; to support a dialogue between tools and designer, it is not sufficient for the designer to learn about the tool, the tool's designers must develop a strategy for enabling the tool to understand the designer. The second part of this paper comprises the theoretical background for a pragmatic strategy for classifying representations held by design agents by mapping the internal structures of differing representations of objects onto one another. Research in cognitive science has shown that such structure mappings can form the cognitive basis for certain kinds of classification decisions. We briefly describe ongoing work aimed at applying these insights in order to enable machines to classify, and thereby interpret, nonspecific design representations.     

A Petri net-based decomposition approach in modelling of manufacturing systems

This paper discusses the decomposition problem in the modelling and simulation of manufacturing systems. Petri nets are chosen as the modelling tool in a manufacturing system control study. The parallelism properly in the manufacturing system operations are extracted by the developed decomposition procedure. A system can be divided into several subsystems based on this decomposition procedure. Subsystems then can be analysed or simulated concurrently. This process generates the parallel processing activity for modelling and simulating manufacturing systems.     

Features of in-process gauging in flexible manufacturing systems for mechanical processing

The potential for assuring stable performance of the process of facet milling of a workpiece under the conditions of a flexible manufacturing module is considered. A mathematical model for determining the constituent processing errors on the basis of the results of coordinate measurements by means of a detecting head is presented. The potential for compensation of the errors that arise in the course of processing and conditions for realization of compensation are considered.