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Adaptive Mobile Robot Scheduling in Multiproduct Flexible Manufacturing Systems Using Reinforcement Learning 基于强化学习的多产品柔性制造系统中的自适应移动机器人调度
IF 4 3区 工程技术 Q3 ENGINEERING, MANUFACTURING Pub Date : 2023-07-11 DOI: 10.1115/1.4062941
Muhammad Waseem, Qing Chang
The integration of mobile robots in material handling in flexible manufacturing systems is made possible by the recent advancements in Industry 4.0 and industrial artificial intelligence. However, effectively scheduling these robots in real-time remains a challenge due to the constantly changing, complex and uncertain nature of the shop floor environment. Therefore, this paper studies the robot scheduling problem for a multiproduct flexible production line using a mobile robot for loading/unloading parts among machines and buffers. The problem is formulated as a Markov Decision Process and the Q-learning algorithm is used to find an optimal policy for the robot's movements in handling different product types. The performance of the system is evaluated using a reward function based on permanent production loss and the cost of demand dissatisfaction. The proposed approach is validated through a numerical case study that compares the resulting policy to a first-come-first-served policy, showing a significant improvement in production throughput of approximately 23%.
工业4.0和工业人工智能的最新进展使移动机器人在柔性制造系统的材料处理中的集成成为可能。然而,由于车间环境的不断变化、复杂和不确定性,有效地实时调度这些机器人仍然是一个挑战。因此,本文研究了多产品柔性生产线的机器人调度问题,该生产线使用移动机器人在机器和缓冲器之间装载/卸载零件。该问题被公式化为马尔可夫决策过程,并使用Q学习算法为机器人在处理不同产品类型时的运动找到最优策略。使用基于永久生产损失和需求不满足成本的奖励函数来评估系统的性能。通过一个数值案例研究验证了所提出的方法,该研究将所得策略与先到先得的策略进行了比较,表明生产吞吐量显著提高了约23%。
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引用次数: 0
Characterization of ultrasonically assisted orthogonal cutting of bone using digital image correlation analysis 利用数字图像相关分析表征超声辅助骨正交切割
IF 4 3区 工程技术 Q3 ENGINEERING, MANUFACTURING Pub Date : 2023-07-11 DOI: 10.1115/1.4062942
W. Bai, Yuhao Zhai, Jiaqi Zhao, Xuzhe Jia, Guangchao Han, Liming Shu, Dong Wang, Jianfeng Xu
Bone cutting with high performance material removal is critical for enhancing orthopedic surgery. Ultrasonically assisted cutting (UAC) is an advanced process with the potential to improve the material removal. However, strain and other intermediate variables in bone cutting are difficult to obtain because of the lack of suitable measurement methods, especially for high-frequency vibration-assisted cutting. In this study, digital image correlation (DIC) analysis was applied for the first time to investigate the mechanism of crack development during conventional cutting (CC) and ultrasonically assisted cutting of cortical bone. A novel method for calculating cutting and thrust forces under the mixed fracture mode of bone was also proposed. Extensive experimental results showed that the average strain and strain rate of cortical bone decreased after the application of UAC, but the maximum transient strain rate in UAC was greater than that in CC, and the crack-affected area and shear band width in UAC were smaller than those in CC. In addition, the strain parameters obtained by the DIC analysis were used to calculate the cutting and thrust forces in the hybrid fracture mode. The calculated values of forces matched well with the measured results, indicating the strong feasibility of DIC applications in orthogonal bone cutting research. This study has significant theoretical and practical value since it reveals the fracture mechanism of cortical bone in UAC, demonstrates a non-contact full-field measurement method for tissue strain calculation, and provides inspiration for optimizing the design of innovative orthopedic instruments.
具有高性能材料去除的骨切割对于加强骨科手术至关重要。超声波辅助切割(UAC)是一种先进的工艺,有可能改善材料的去除。然而,由于缺乏合适的测量方法,尤其是对于高频振动辅助切割,骨切割中的应变和其他中间变量很难获得。在本研究中,首次应用数字图像相关(DIC)分析来研究传统切割(CC)和超声辅助切割皮质骨过程中裂纹发展的机制。还提出了一种计算混合骨折模式下的切削力和推力的新方法。广泛的实验结果表明,应用UAC后,皮质骨的平均应变和应变速率降低,但UAC的最大瞬态应变速率大于CC,UAC的裂纹影响面积和剪切带宽度小于CC。此外,通过DIC分析获得的应变参数用于计算混合断裂模式下的切削力和推力。力的计算值与测量结果吻合良好,表明DIC在正交骨切削研究中的应用具有很强的可行性。该研究揭示了UAC中皮质骨的骨折机制,展示了一种非接触式全场测量组织应变的方法,并为创新骨科器械的优化设计提供了启示,因此具有重要的理论和实践价值。
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引用次数: 0
Bast Fiber Decortication for Biocomposites by a Mastication Process 生物复合材料中韧皮纤维的脱胶工艺
IF 4 3区 工程技术 Q3 ENGINEERING, MANUFACTURING Pub Date : 2023-07-10 DOI: 10.1115/1.4062913
D. Walczyk, Jiachen Yang, Jennifer Gilbert-Jenkins
This paper discusses a new method for decorticating bast fiber stalks through a mastication process without damaging the fiber for use in biocomposites. Conventional automated decortication methods provide high stalk processing throughput, but they significantly damage the bast fibers and adversely affect their performance in biocomposite applications. Initial experiments with industrial hemp using a matched set of tools indicate that indexing the stalk by, at most, half a tooling period for each mastication cycle maximizes both the crushed stalk flexing action and dehurding efficiency. Further process insight was gained through simple stalk crushing experiments (force vs. deflection) between matching teeth with no indexing, where force spikes correspond to initial collapse of the stalk cross section and initial hurd bending fracture along the stalk length. A more extensive experimental design with stiffer tooling reveals that adding spaces in the bottom die for hurd to fall through, and using the smallest practical indexing distance less than half a tooling period and also more teeth maximizes hurding efficiency. However, shorter indexing and more teeth also decreases throughput rate and complicates stalk handling. Future work for optimizing and commercializing the process are suggested.
本文讨论了一种在不损坏生物复合材料中使用的韧皮纤维的情况下,通过胶粘工艺对韧皮纤维茎进行脱胶的新方法。传统的自动去壳方法提供了高的秸秆处理量,但它们会严重损坏韧皮纤维,并对其在生物复合材料应用中的性能产生不利影响。使用一套匹配的工具对工业大麻进行的初步实验表明,在每个咀嚼循环中,将秸秆分度至多半个工具周期,可以最大限度地提高粉碎秸秆的弯曲作用和除湿效率。通过在没有分度的匹配齿之间进行简单的秸秆粉碎实验(力与偏转),获得了进一步的过程见解,其中力尖峰对应于秸秆横截面的初始塌陷和沿着秸秆长度的初始hurd弯曲断裂。使用更硬的工具进行的更广泛的实验设计表明,在底模中增加空间,使跨栏通过,并使用不到半个工具周期的最小实际分度距离和更多的齿,可以最大限度地提高跨栏效率。然而,更短的分度和更多的齿也会降低生产率,并使秸秆处理复杂化。提出了优化和商业化该工艺的未来工作。
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引用次数: 0
Cyber Physical Production Systems for Deep Drawing 深拉深用网络物理生产系统
IF 4 3区 工程技术 Q3 ENGINEERING, MANUFACTURING Pub Date : 2023-07-07 DOI: 10.1115/1.4062903
Robert O. Jung, F. Bleicher, S. Krall, Christian Juricek, Rainer Lottes, Karoline Steinschuetz, T. Reininger
Deep Drawing is an essential manufacturing technology for car body parts. High process stability is a key for reducing scrap and therefore the ecological footprint during the production. To deal with an unknown fluctuation of the incoming material properties and uncertainties considering the friction, an adaptive process needs to be implemented. Various approaches have been pursued in the past, but not all of them are suited for an industrial series production with high demands for equipment durability, cost efficiency and flexibility. For this reason, a new concept for cyber physical production systems (CPPS) in deep drawing is presented, linking the data from the simulation, tool, press, material and finished part quality. Two common application scenarios are distinguished. These are firstly large outer parts with a complex geometry and high value, typically produced with tandem presses. Secondly smaller structural parts from high strength steel for the body in white (BIW), usually produced through a transfer or progressive die. Non destructive material testing, supplier material certificates and data measured directly in the forming tool are considered regarding the input. A variation of the servo curve and blank holder force (BHF) operate as control instances. Within the two application scenarios, a reactive and a preventive solution are characterized. As a first step towards the implementation of the CPPS, material inflow and force sensors are installed in an industrially relevant deep drawing tool.
深拉深是汽车车身零件的一项重要制造技术。高工艺稳定性是减少废料的关键,从而减少生产过程中的生态足迹。为了处理来料性能的未知波动和考虑摩擦的不确定性,需要实现自适应过程。过去已经采取了各种方法,但并非所有方法都适合对设备耐用性,成本效益和灵活性有高要求的工业系列生产。为此,提出了一种将仿真、工具、压力机、材料和成品质量数据连接起来的深拉深加工网络物理生产系统(CPPS)的新概念。区分了两种常见的应用场景。这些首先是具有复杂几何形状和高价值的大型外部部件,通常由串联压力机生产。其次,较小的结构件由高强度钢制成,用于白车身(BIW),通常通过转移或级进模生产。非破坏性材料测试、供应商材料证书和在成形工具中直接测量的数据是作为输入考虑的。伺服曲线的变化和压边力(BHF)作为控制实例。在两种应用场景中,反应性解决方案和预防性解决方案具有特征。作为实施CPPS的第一步,材料流入和力传感器安装在工业相关的深拉深工具中。
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引用次数: 0
Effects of bubbles on manufacturing gold dendrites and silicon nanowires through the fluoride-assisted galvanic replacement reaction 气泡对氟辅助电流置换反应制备金枝晶和硅纳米线的影响
IF 4 3区 工程技术 Q3 ENGINEERING, MANUFACTURING Pub Date : 2023-07-03 DOI: 10.1115/1.4062878
Pee-Yew Lee, H. Huang, T. Ko, Ying-Lun Hung, Li-Yan Wu, Jianhua Fan, Yung-Sheng Lin
Abstract The fluoride-assisted galvanic replacement reaction is a conventional method for fabricating metallic dendrites on silicon wafers. However, whether bubbles affect manufacturing metallic dendrites is unclear. This study investigated the effects of bubbles on manufacturing Au dendrites and silicon nanowires through metal-assisted chemical etching. The results of manufacture under three conditions (standard, shaking, and vacuum conditions) were compared. Synchronous growth of Au dendrites and silicon nanowires were observed on the silicon wafers. The Au dendrite deposition rate was higher than the silicon etching rate. Compared with the standard condition, the vacuum condition increased the synthesis rates of Au dendrites and silicon nanowires by 1.1 and 0.2 μm/min, respectively. Therefore, the elimination of bubbles by vacuum can considerably accelerate manufacturing Au dendrites and silicon nanowires.
摘要氟辅助电流置换反应是在硅片上制备金属枝晶的一种常规方法。然而,气泡是否会影响金属枝晶的制造尚不清楚。本研究研究了气泡对通过金属辅助化学蚀刻制造Au枝晶和硅纳米线的影响。比较了在三种条件(标准条件、振荡条件和真空条件)下的制造结果。在硅片上观察到Au枝晶和硅纳米线的同步生长。Au枝晶沉积速率高于硅蚀刻速率。与标准条件相比,真空条件使Au枝晶和硅纳米线的合成速率分别提高了1.1和0.2μm/min。因此,通过真空消除气泡可以显著加速Au枝晶和硅纳米线的制造。
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引用次数: 0
Multicultural Diversity Workforce and Global Technology Collaboration Empowered Semiconductor Manufacturing Excellence in Taiwan: A Manufacturing Engineer’s Perspective 多元文化的多元化劳动力和全球技术合作助力台湾半导体制造业的卓越:制造工程师的视角
IF 4 3区 工程技术 Q3 ENGINEERING, MANUFACTURING Pub Date : 2023-06-30 DOI: 10.1115/1.4062729
A. Shih
This paper summarizes the perspectives from a manufacturing engineer on how the government policy, global partnership, and diversity of the United States (US), Japanese, European, and traditional Chinese cultures in Taiwan have created a workforce of semiconductor manufacturing talent in the past five decades. The complex interwoven events of Covid-19 pandemic, supply chain resilience, national security, and geopolitical conflicts have made semiconductor manufacturing a key focus of government policy. As a world leader in integrated circuit (IC) design, design software, equipment, and research, the US has struggled in the past few years on the high yield volume manufacturing of the most advanced logic IC and failed to translate research innovations to quality production. Manufacturing, not innovation or equipment, is a key barrier of the US semiconductor industry. Two models for excellence in advanced manufacturing are described. Three pillars of government policy, global collaboration, and multicultural diversity empower semiconductor manufacturing excellence in Taiwan is described. An approach to evaluate, select, educate, and train manufacturing talents is proposed. Directions for semiconductor manufacturing research are discussed. There is no genius in semiconductor manufacturing, which requires extensive experience and continuous improvement without shortcuts to be competitive. The steadfast good government policy, multicultural diversity workforce, and global technology collaboration to achieve semiconductor manufacturing excellence are the focus of the conclusion.
本文总结了一位制造业工程师对台湾过去五十年来政府政策、全球伙伴关系以及美国、日本、欧洲和中国传统文化的多样性如何造就半导体制造业人才队伍的看法。新冠肺炎疫情、供应链韧性、国家安全和地缘政治冲突等复杂交织的事件使半导体制造成为政府政策的重点。作为集成电路(IC)设计、设计软件、设备和研究的世界领导者,美国在过去几年中一直在努力实现最先进逻辑IC的高产量批量生产,未能将研究创新转化为高质量生产。制造业,而不是创新或设备,是美国半导体行业的一个关键障碍。介绍了先进制造业的两种卓越模式。介绍了政府政策、全球合作和多元文化多样性三大支柱为台湾半导体制造业的卓越发展奠定了基础。提出了一种评估、选拔、教育和培养制造业人才的方法。讨论了半导体制造研究的方向。半导体制造业没有天才,它需要丰富的经验和不断的改进,没有捷径可走,才能具有竞争力。坚定不移的良好政府政策、多元文化的多元化劳动力以及实现半导体制造卓越的全球技术合作是结论的重点。
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引用次数: 0
A Two-stage Focal Transformer for Human-Robot Collaboration-based Surface Defect Inspection 基于人机协同的表面缺陷检测的两级焦点变换器
IF 4 3区 工程技术 Q3 ENGINEERING, MANUFACTURING Pub Date : 2023-06-28 DOI: 10.1115/1.4062860
Yiping Gao, Liang Gao, Xinyu Li
Human-robot collaboration has become a hotspot in smart manufacturing, and it also has shown the potential for surface defect inspection. The robot can release workload, while human collaboration can help to recheck the uncertain defects. However, the human-robot collaboration-based defect inspection can be hardly realized unless some bottlenecks have been solved, and one of them is that the current methods cannot decide which samples to be rechecked, and the workers can only recheck all of the samples to improve inspection results. To overcome this problem and realize the human-robot collaboration-based surface defect inspection, a two-stage Transformer model with focal loss is proposed. The proposed method divides the traditional inspection process into detection and recognition, designs a collaboration rule to allow workers to collaborate and recheck the defects, and introduces the focal loss into the model to improve the recognition results. With these improvements, the proposed method can collaborate with workers by rechecking the defects, and improve surface quality. The experimental results on the public dataset have shown the effectiveness of the proposed method, the accuracies are significantly improved by the human collaboration, which are 1.70%~4.18%. Moreover, the proposed method has been implemented into a human-robot collaboration-based prototype to inspect the carton surface defects, and the results also verify the effectiveness. Meanwhile, the proposed method has a good ability for visualization to find the defect area, and it is also conducive to defect analysis and rechecking.
人机协作已成为智能制造领域的一个热点,也显示出表面缺陷检测的潜力。机器人可以释放工作量,而人类协作可以帮助重新检查不确定的缺陷。然而,除非解决了一些瓶颈,否则基于人机协作的缺陷检测很难实现,其中之一是目前的方法无法决定对哪些样本进行复查,工人只能对所有样本进行复查以提高检测结果。为了克服这一问题,实现基于人机协同的表面缺陷检测,提出了一种具有焦点损耗的两阶段变压器模型。该方法将传统的检测过程划分为检测和识别,设计了一个协作规则,允许工人协作并重新检查缺陷,并将焦点损失引入模型中以提高识别结果。有了这些改进,所提出的方法可以通过重新检查缺陷与工人合作,提高表面质量。在公共数据集上的实验结果表明了该方法的有效性,人工协作显著提高了方法的准确率,准确率为1.70%~4.18%。此外,该方法已应用于基于人机协作的纸箱表面缺陷检测原型中,结果也验证了其有效性。同时,该方法具有良好的可视化查找缺陷区域的能力,也有利于缺陷分析和复查。
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引用次数: 0
Behavior and large-scale modeling of multi-sheet aluminum connections with self-piercing rivets 带自穿铆钉的多片铝连接的性能及大规模建模
IF 4 3区 工程技术 Q3 ENGINEERING, MANUFACTURING Pub Date : 2023-06-28 DOI: 10.1115/1.4062859
V. André, M. Costas, M. Langseth, D. Morin
This paper presents an experimental and numerical study on the mechanical quasi-static behavior of self-piercing rivet (SPR) connections with three stacked sheets made from an AA6016-T4 aluminum alloy. The goal was to study the effects of sheet thickness and stack up of the SPR connection under large deformation and failure. Several different types of tests were performed to investigate the initial load-bearing capacity as well as the remaining capacity after partial joint failure. Additionally, the performance of state-of-the-art constraint modeling techniques was evaluated. The parameters for large-scale connector models were found through inverse modeling of the experiments. The models were validated against an additional test configuration where the middle sheet was load-free.
本文对三层AA6016-T4铝合金自穿铆钉连接的力学准静态行为进行了实验和数值研究。目的是研究在大变形破坏条件下,钢板厚度和堆积量对SPR连接的影响。进行了几种不同类型的试验,以研究节点局部破坏后的初始承载能力和剩余承载力。此外,还评估了最先进的约束建模技术的性能。通过实验反建模,确定了大型连接器模型的参数。这些模型是针对另外一个测试配置进行验证的,其中中间的薄片是无负载的。
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引用次数: 0
Characterization of viscoelastic properties of EPDM molding compound for door grommet component using molecular dynamics and phenomenological modeling. 用分子动力学和现象学建模表征三元乙丙橡胶门套件成型胶黏弹性性能。
IF 4 3区 工程技术 Q3 ENGINEERING, MANUFACTURING Pub Date : 2023-06-28 DOI: 10.1115/1.4062858
Salvador Gómez-Jiménez, T. Saucedo-Anaya, V. H. Baltazar Hernandez, Ada Rebeca Contreras-Rodriguez
The automotive industry is evolving by incorporating innovative tools to improve production processes. A proper manufacturing process influences the behavior of the door grommet during its lifetime. In this paper, molecular dynamics simulations are conducted to evaluate the chemical and physical crosslinking of the EPDM rubber over a range of temperatures using a COMPASS force field. Then, once the EPDM model was equilibrated and all possible crosslinks were formed, additional simulations were performed on the model to explore its mechanical behavior. Subsequently, using the superposition principle, viscosity and curing kinetics were evaluated using phenomenological models. To, validate the results of the simulations, three injection tests of the door grommet, were performed at different temperature conditions. The results indicate that the viscosity and elastic properties increase with increasing levels of crosslink density and that the critical gel point decreases with temperature. Molecular dynamics superposition results in phenomenological models are in reasonable agreement with the kinetic and viscoelastic behavior of EPDM during and after the injection process. The results presented in this paper provide novel molecular-level findings on the crosslinking mechanisms of amorphous polymers and their influence on viscoelastic behavior, which could facilitate the design of the injection process for door grommet applications
汽车行业正在通过整合创新工具来改进生产流程。正确的制造工艺影响着门环在其使用寿命期间的性能。本文利用COMPASS力场进行了分子动力学模拟,以评估EPDM橡胶在一定温度范围内的化学和物理交联。然后,一旦EPDM模型平衡并形成所有可能的交联,则对模型进行额外的模拟以探索其力学行为。随后,利用叠加原理,利用现象学模型对粘度和固化动力学进行了评价。为了验证仿真结果,在不同温度条件下对车门密封圈进行了三次注射试验。结果表明,黏度和弹性随交联密度的增加而增加,临界凝胶点随温度的升高而降低。现象学模型的分子动力学叠加结果与EPDM注射过程中和注射后的动力学和粘弹性行为基本一致。本文的研究结果为非晶态聚合物的交联机理及其对粘弹性行为的影响提供了新的分子水平的发现,这将有助于门环应用的注射工艺设计
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引用次数: 0
Freeform bending tool design for rectangular profiles and its influence on the process 矩形型材自由弯曲刀具设计及其对工艺的影响
IF 4 3区 工程技术 Q3 ENGINEERING, MANUFACTURING Pub Date : 2023-06-22 DOI: 10.1115/1.4062811
M. Werner, Lorenzo Scandola, D. Maier, W. Volk
Freeform bending offers a wide range of possibilities in terms of component geometries, material grades and profile cross-sections. In the field of circular solid and hollow profiles, the design of the tool is determined by the circular shape of the profile used. When using rectangular profiles, the cross-section of the tool cannot be easily obtained by an offset of the profile cross-section. The large tolerance ranges of the profile standards require compromises with regard to the shape and tolerances of the tool. Tests have shown that the design of the tool has a great influence on the quality of the component. Furthermore, the trade-off in the tool design can lead to unsuitable tool shapes leading to defects and damages on the profile. These are mainly wrinkling, cross-sectional deformations and strongly deformed profile corners, which in some cases form cracks in the material. In this paper, the influences of the tool design on the bending result and the defects of the profiles are investigated. For this purpose, several tool designs with different variants and combinations of the movable die and the fixed die are compared with each other.
自由弯曲在部件几何形状、材料等级和型材截面方面提供了广泛的可能性。在圆实心和空心型材领域,刀具的设计是由所使用的型材的圆形形状决定的。当使用矩形型材时,刀具的横截面不容易通过型材横截面的偏移量来获得。轮廓标准的大公差范围要求在刀具的形状和公差方面做出妥协。试验表明,刀具的设计对零件的质量有很大的影响。此外,刀具设计中的权衡可能导致刀具形状不合适,从而导致轮廓上的缺陷和损坏。这些主要是起皱、横截面变形和强烈变形的型材角,在某些情况下会在材料中形成裂纹。本文研究了刀具设计对型材弯曲结果和缺陷的影响。为此,对几种具有不同变体和动模与定模组合的刀具设计进行了相互比较。
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引用次数: 0
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