Knowledge-based integrated product design framework towards sustainable low-carbon manufacturing

With a global challenge on the serious ecological problems, low-carbon manufacturing aiming to reduce carbon emission and resource consumption is gaining the ever-increasing attention. Due to the significant impact on the product lifecycle, low-carbon product design is considered as an effective and attractive approach to improve the eco-market trade-off of electromechanical products. Existing low-carbon product design approaches focus on solving specific low-carbon problems, and how to explore and navigate the integrative design space considering low-carbon and knowledge in a holistic perspective is rarely discussed. In response, this paper proposes a knowledge-based integrated product design framework to support low-carbon product development. An ontology-based knowledge modelling approach is put forward to represent the multidisciplinary design knowledge to facilitate knowledge sharing and integration. Subsequently, a function–structure synthesis approach based on case-based reasoning is presented to narrow down the design space to generate suitable design solutions for achieving desired functions. A multi-objective mathematical model is established, and the multi-objective particle swarm optimization is adopted to solve the low-carbon product optimization. Furthermore, a decision-making ranking approach based on the closeness degree is employed to prioritize the potential solutions from Pareto set. Finally, a case study of low-carbon product design of hydraulic machine is demonstrated to show the effectiveness.     

Overview of entity-based integrated design product and process models

The development of computer-integrated systems for engineering design requires models to describe and organize the information and activities involved in design. A product model describes the information created during the design process, and a process model describes the associated design activities. Product and process models can be integrated into a single model. An entity-based approach is one way to carry out this integration. An entity-based integrated model uses product entities and process entities to represent design information and design activities, respectively. The relationships among these entities include organizational, interaction and sequence relationships. Organizational relationships organize entities into hierarchies, interaction relationships characterize the nature of entity interactions, and sequence relationships identify the sequences in which process entities are initiated during the design process. This paper presents an overview of the product and process entities, and the organizational, interaction and sequence relationships of entity-based integrated design product and process models. Formal concepts and notation used to represent these entities and relationships are described using a simple design example. © 1998 Published by Elsevier Science Limited. All rights reserved.     

An integrated implementation for product design

This paper represent an integrated implementation to shorten the product development cycle. The developed system uses machine vision techniques to automate the creation of CAD models for existing parts of prototypes. It extracts the manufacturing features based on the created CAD database and the tolerances that are to be added to the created CAD dabatase for CAD/CAM practice and concurrent analysis. The geometric features are organized in a database which can be imported to an automated process planning and cost estimation system. This integrated implementation is capable of providing manufacturing feedback during the product development stage. This paper outlines the development of the vision system, the creation of the CAD model, and the design of the database.     

A constraint-based system for product design and manufacturing

Constraint-based modeling is one of the most modern methods of product design. This paper illustrates a collaborative design and manufacture procedures based on a new approach under the constraint-based solver for product design. Such a method can be used for the collaborative computer-aided design/manufacture systems. A developing model will be constructed from conceptual design to tool-paths generation, and a case study of how to make a playing doll house was presented to verify this system.     

Optimizing modular product design for reconfigurable manufacturing

The problem of optimizing modular products in a reconfigurable manufacturing system is addressed. The problem is first posed as a generalized subset selection problem where the best subsets of module instances of unknown sizes are determined by minimizing an objective function that represents a trade-off between the quality loss due to modularization and the cost of reconfiguration while satisfying the problem constraints. The problem is then formulated and solved as an integer nonlinear programming problem with binary variables. The proposed method is applied to the production of a modular drive system composed of a DC motor and a ball screw. The study is a first attempt toward developing a systematic methodology for manufacturing modular products in a reconfigurable manufacturing system.     

An integrated form-feature-based design system for manufacturing

Much of the knowledge that is applied in or communicated between design and manufacturing activities is primarily shape based or shape indexed. Previous attempts to acquire and organize shape knowledge have been mostly concentrated on feature recognition from solid models, group technology (GT) coding schemes, and feature-based modeling. This paper presents the development of an efficient form-feature-based modeling system, and addresses the important issue of utilizing feature information for manufacturing, which has not been extensively discussed by previous work. In this paper we first present a Euler operator-based approach for efficient and effective form-feature encoding and manipulation in a feature-based design environment. Subsequently, a hybrid representation scheme called enhanced CSG tree of feature (ECTOF), which integrates feature model with solid model in a tree structure, is discussed. A feature interference resolution methodology to maintain the correct and consistent feature information in an ECTOF is also deliberated. Finally, we present a machinability-checking module, which employs global accessibility criteria to analyze a feature's machinability on a three-axis machining center. By developing feature interference resolving and machinability testing techniques and integrating with an efficient feature-based design system, this research makes the development of an integrated feature-based design and manufacturing system possible.     

Function and process modeling for integrated product and manufacturing system platforms

Manufacturing companies face increasingly tougher individual customer requirements that force them to revise conceptual solutions for the redesigning of products. This situation limits the reuse of ready-made components and requires physical changes to the manufacturing system. In these settings, platforms must be prepared with greater flexibility to allow development over time. The corresponding platform models need to include conceptual considerations for products and manufacturing systems. The literature advocates functional modeling to capture these considerations but applies it separately to either the product domain or to the manufacturing domain. Further, its relationship to manufacturing processes is not expounded. Thus, functional modeling falls short of its potential to facilitate the integrated development of products and manufacturing systems.This paper puts forth an integrated platform model using functional modeling to capture the conceptual considerations for products and manufacturing systems together with the manufacturing processes. The model is tested for consistency and then illustrated by studying a real case example from the automotive industry modeled according to the approach suggested. The example shows that the model facilitates an understanding of the design of products and their manufacturing systems, including functions shared across domains and across lifecycle phases. Thus, the model is proposed for the conceptual phase of designing, aimed at reusing and redesigning components, machinery, manufacturing processes and design solutions.     

A knowledge system for integrated product design

This paper discusses the architecture and implementation issues for a knowledge system to assist in product design. The goals of the concurrent Design Advisor (CODA) are to enhance the quality of designs by 25 percent and the efficiency by a factor of 10. The improvement springs from the integration of diverse knowledge bases, ranging from customer needs to product evaluation, and from process configuration to production control. One source of efficiency is the automation of many routine tasks, thereby increasing user productivity. Another source is the increase in the quality of initial designs, which obviates the need for numerous iterations in the design process due to poor manufacturability. CODA is based on the general architecture of the Creativity Support System, an expert system for assisting users in specific domains requiring creative solutions. The bilevel structure of the system consists of a domain-independent module containing general tools and techniques for creative problem-solving, and a domain-dependent module incorporating knowledge specific to particular fields of application. The utility of this approach is illustrated in the realm of concurrent product design by demonstrating a CODA within the general architecture of the system.     

An integrated CSCW architecture for integrated product/process design and development

Computer Supported Collaborative Work (CSCW) is increasingly being used by engineering design teams to reach a consensus on a range of design issues. CSCW systems are designed to increase the effectiveness of decision-makers by facilitating information exchange, retrieval, sharing and use. They encourage interactive information exchange and have the potential to reduce diseconomies associated with design activities, member dominance, social pressure, inhibition of expression, and other difficulties encountered by project teams. The use of CSCW is expected to have a favorable impact on the group decision-making process and the quality of the resulting decision. In this paper, a general CSCW architecture has been developed to support integrated product/process design and development will be presented. The architecture has been tested extensively on a representative industrial problem. The case study and evaluation of the architecture will also be discussed in this paper. The integrated architecture will facilitate information access, sharing, and analysis among design teams members using the open World Wide Web platforms and resources to make product/process decisions.     

Developing distributed applications for integrated product and process design

A heterogeneous computing environment characterizes today's manufacturing situation. This is a stumbling block for the efficient implementation of manufacturing concepts such as integrated product and process design (IPPD). A computing environment for IPPD would require the seamless integration of the various product and process design software systems. The exchange of information between these systems should be efficient, compatible and synchronous. This article presents an approach for developing distributed manufacturing applications that are compatible and synchronized and thus, able to support IPPD. The approach involves the use of a common manufacturing application ‘middleware’, which is distributed between a central geometric modelling server and application clients. The portability of the middleware is ensured through the use of Java for code portability and XML for data portability. The compatible product model problem is solved through the use of common data structures developed using reusable application client classes. Efficient transfer of product data is proposed using compressed model information embedded in a product data XML schema. Synchronization of design changes among all applications is achieved through the creation of relationships on an Application Relationship Manager.     

Model of an integrated intelligent design and manufacturing system

The expert system STATEXS is presented for dimensioning, optimization and manufacture of gears and gearings. The optimum dimensions of the gearing were determined using genetic algorithms, well suited to such problems especially because of their robustness and their ability to detect global extremes. After completion of the calculations and optimization of the gears or gear pairs, there follows one of the most difficult operations, the manufacture of the product with theoretically determined and optimized properties. To this end we have also started to use the genetic algorithm approach for the manufacture of various products with demanding shapes.     

An integrated methodology for manufacturing systems design using manual and computer simulation

Traditional approaches to manufacturing systems design utilize a sequential procedure that focuses on production capacity requirements, with human operator task design developed late in the systems design phase. Implementing manufacturing systems in this way is difficult when operations management must design flexible and efficient processes, with an often incomplete understanding of how people can best perform within the system. This study developed an integrated methodology that uses both manual and computer simulations to evaluate system performance and ergonomic issues early in the system design process. Information about operator performance and ergonomics is obtained in the manual simulations, while estimates of operator utilization and system throughput is obtained through computer simulations. An iterative design process is used, with the results of manual and computer simulations informing each other during subsequent simulations. An industrial case study is presented here to demonstrate the effectiveness of this methodology. The results show that the methodology can be used to design manufacturing systems with significant savings in labor cost and improved manufacturing system flexibility. © 2003 Wiley Periodicals, Inc. Hum Factors Man 13: 19–40, 2003.     

Reverse innovative design — an integrated product design methodology

Today’s product designer is being asked to develop high quality, innovative products at an ever increasing pace. To meet this need, an intensive search is underway for advanced design methodologies that facilitate the acquisition of design knowledge and creative ideas for later reuse. Additionally, designers are embracing a wide range of 3D digital design applications, such as 3D digitization, 3D CAD and CAID, reverse engineering (RE), CAE analysis and rapid prototyping (RP). In this paper, we propose a reverse engineering innovative design methodology called Reverse Innovative Design (RID). The RID methodology facilitates design and knowledge reuse by leveraging 3D digital design applications. The core of our RID methodology is the definition and construction of feature-based parametric solid models from scanned data. The solid model is constructed with feature data to allow for design modification and iteration. Such a construction is well suited for downstream analysis and rapid prototyping. In this paper, we will review the commercial availability and technological developments of some relevant 3D digital design applications. We will then introduce three RE modelling strategies: an autosurfacing strategy for organic shapes; a solid modelling strategy with feature recognition and surface fitting for analytical models; and a curve-based modelling strategy for accurate reverse modelling. Freeform shapes are appearing with more frequency in product development. Since their “natural” parameters are hard to define and extract, we propose construction of a feature skeleton based upon industrial or regional standards or by user interaction. Global and local product definition parameters are then linked to the feature skeleton. Design modification is performed by solving a constrained optimization problem. A RID platform has been developed and the main RE strategies and core algorithms have been integrated into SolidWorks as an add-in product called ScanTo3D. We will use this system to demonstrate our RID methodology on a collection of innovative consumer product design examples.     

Single users' affective responses models for product form design

This paper presents a neural network based approach to modeling consumers' affective responses for product form design. A theoretical framework for a single user's perception is developed. On the basis of this theoretical framework, a mathematical model which enables single users' responses to different products to be predicted was developed. The results obtained show that the mathematical models developed achieved highly accurate predictions.For the purpose of obtaining a global model various individual mathematical models were created, which were based on the opinions of users representing different groups of opinion. The results suggest that, under some conditions, the combined use of various models of individual users can perform as well as a single model generated on the basis of mean market responses.     

Machine learning and CBR integrated mechanical product design approach

Many works based on case-based reasoning (CBR) and rule-based reasoning (RBR) have been done to obtain a product concept intelligently, but researches on automatic and intelligent methods for the detailed design process are still lacking. To achieve the intelligent design of the whole process for mechanical product development, an approach based on cases and knowledge is proposed. First, considering that the actual product cases sample is small, correlations among product features and relationships between product features and requirements are evaluated based on design knowledge. According to these correlations and relationships, a design problem is decomposed into multiple parallel small-scale sub-problems not only to increase data samples but reduce data dimensions. Moreover, a hybrid method that combined Hamming distance with Euclidean distance is generated to retrieve similar cases, which can address both numerical and encoding factors. In addition, K-Nearest-Neighbor (KNN) algorithm and Linear regression are adopted to adapt the classification and numeric parameters, respectively, so that the detailed design process can be achieved without fixed knowledge template. Finally, a tool design software is developed based on Visual studio 2015 to verify the practicability of the proposed method.     

Computer aids to the design of integrated manufacturing systems

Building an Integrated Manufacturing System is a complicated and expensive task. There are very few companies anywhere that will deliver turn-key CAD/CAM systems, far less produce a full line of hardware and software products covering every function required. In designing such a system we are faced with the problem of the proper interfacing and coordination of several hundreds of functional sub-systems. It is, therefore, a natural endeavour to use CAD methods in the design of CAD/CAM systems. Brief outlines are given of a highly interactive system having formalized diagrams and alphanumeric information on the input side, and readable system documentation and analysis reports, on the output side - both interacting to widely accepted extant techniques. The structure of a more complex system affording further facilities is also presented.     

Traceability and management of dispersed product knowledge during design and manufacturing

Product development processes comprise highly creative and knowledge-intensive tasks that involve extensive information exchange and communication among geographically distributed teams. Due to the geographical and institutional separation between the different systems involved in the product lifecycle, product knowledge sharing is becoming a key issue in the information systems of extended enterprises. This paper addresses the issue and challenges of product knowledge traceability during the product development. The aim of this research effort is to enhance the sharing and use of product knowledge acquired during the development process using traceability information.A standardized approach is proposed to trace and share product knowledge and key constructs to support traceability during the product development process are identified and formalized. This research effort is based on the premise that an important step towards achieving product knowledge sharing is providing traceability across various product knowledge elements that are used in product development phases, i.e. design and manufacturing. Two disjointed but complementary case studies illustrating the benefit of traceability are presented. The potential role of traceability is described, first to support the decision making process during engineering change management (ECM), and second to support product-oriented modelling for knowledge sharing and exchanging to meet the quality requirements. The proposed approach has been implemented using the MEGA Suite tool and applied to each of the case studies and could be integrated to PLM systems currently in use.     

An integrated neuro-genetic approach incorporating the Taguchi method for product design

Product design is a multidisciplinary activity that requires the integration of concurrent engineering approaches into a design process that secures competitive advantages in product quality. In concurrent engineering, the Taguchi method has demonstrated an efficient design approach for product quality improvement. However, the Taguchi method intuitively uses parameters and levels in measuring the optimum combination of design parameter values, which might not guarantee that the final solution is the most optimal. This work proposes an integrated procedure that involves neural network training and genetic algorithm simulation within the Taguchi quality design process to aid in searching for the optimum solution with more precise design parameter values for improving the product development. The concept of fractals in computer graphics is also considered in the generation of product form alternatives to demonstrate its application in product design. The stages in the general approach of the proposed procedures include: (1) use of the Taguchi experimental design procedure, (2) analysis of the neural network and genetic algorithm process, and (3) generation of design alternatives. An electric fan design is used as an example to describe the development and explore the applicability of the proposed procedures. The results indicate that the proposed procedures could enhance the efficiency of product design efforts by approximately 7.8%. It is also expected that the proposed design procedure will provide designers with a more effective approach to product development.     

Multiple platforms design and product family process planning for combined additive and subtractive manufacturing

Industry 4.0 promotes the utilization of new exponential technologies such as additive manufacturing in responding to different manufacturing challenges. Among these, the integration of additive and subtractive manufacturing technologies can play an important role and be a game changer in manufacturing products. In addition, using product platforms improves the efficiency and responsiveness of manufacturing systems and is considered an enabler of mass customization. In this paper, a model to design multiple platforms that can be customized using additive and subtractive manufacturing to manufacture a product family cost-effectively is proposed. The developed model is used to determine the optimal number of product platforms, each platform design (i.e. its features set), the assignment of each platform to various product variants, and the macro process plans for customizing the platforms while minimizing the overall product family manufacturing cost.The multiple additive/subtractive platforms and their process plans are determined by considering not only the commonality between the product variants but also their various manufacturing cost elements and the customer demand of each variant. The design of multiple product family platforms and their process plans is NP-hard problem. A genetic algorithm-based model is developed to reduce the computational complexity and find optimal or near optimal solution. Two case studies are used to illustrate the developed multiple platform model. The model results were compared with a single platform model in literature and the results demonstrate the multiple platform model superiority in manufacturing product families in lower cost. The use of the developed model enables manufacturing product families cost efficiently and allows manufacturers to manage diversity in products and market demands.