Mass Production Process Research Articles

Exploiting data in smart factories: real-time state estimation and model improvement in metal forming mass production

Modern production systems have numerous sensors that produce large amounts of data. This data can be exploited in many ways, from providing insight into the manufacturing process to facilitating automated decision making. These opportunities are still underexploited in the metal forming industry, due to the complexity of these processes. In this work, a probabilistic framework is proposed for simultaneous model improvement and state estimation in metal forming mass production. Recursive Bayesian estimation is used to simultaneously track the evolution of process state and to estimate the deviation between the physics-based model and the real process. A sheet bending mass production process is used to test the proposed framework. A metamodel of the process is built using proper orthogonal decomposition and radial basis function interpolation. The model is extended with a deviation model in order to account for the difference between model and real process. Particle filtering is used to track the state evolution and to estimate the deviation model parameters simultaneously. The approach is tested and analysed using a large number of simulations, based on pseudo-data obtained from a numerical sheet bending model.

Microfactories and the new economies of scale and scope

PurposeThe purpose of this paper is to explore the microfactory model, the elements that enable it and its implications. The authors argue that microfactories reduce the risks and costs of innovation and that they can move various industries toward more local, adaptive and sustainable business ecosystems.Design/methodology/approachThis conceptual paper explores several processes and practices that are relatively new; hence, it uses online secondary sources (e.g. interviews with CEOs, videos, blogs and trade magazine articles) extensively.FindingsGiven its versatility and high automation levels, the microfactory model can fill the gap between artisanal and mass production processes, boost the rate of innovation, and enable the local on-demand fabrication of customized products.Practical implicationsCurrently, manufacturers generally need to make large investments when launching a new product, despite high uncertainty about customer acceptance, thus risking considerable losses. The microfactory model offers a safer alternative by allowing a firm to develop and fabricate new products and test their acceptance in a local market before mass producing them. Microfactories also enable the local on-demand fabrication of highly customized products.Originality/valueThis paper contributes to the discussion on the economic advantages and disadvantages of scale and scope, which have been insufficiently explored in the digital domain.

A one-pot surface coating process employing a bifunctional hybrid solution for high-Ni cathode materials for lithium ion batteries

A uniform surface coating and control over residual Li on the surface of high-Ni layered transition metal oxides is crucial for development of highly reliable and high-performance cathode materials for lithium ion batteries (LIBs). To suppress undesirable side reactions at the surface of high-Ni layered transition metal oxides, we propose a one-pot TiO2 surface coating process using a bifunctional hybrid solution. We demonstrate that the uniformity and thickness of a TiO2 coating layer can be controlled, and residual Li can be simultaneously reduced during the surface coating process. Structural and electrochemical characterizations support the utilization of an essential bifunctional hybrid solution composed of titanium (IV) isopropoxide (TTIP) in isopropyl alcohol (IPA) and tetrabutyl-ammonium hydroxide (TBAOH) in water for introducing a uniform TiO2 coating layer and eliminating undesirable Li residues on the surface without yielding significant structural degradation. Our approach provides a practical guide to develop advanced cathode materials and simplify the synthetic process for mass production.

Micro-injection molded, poly(vinyl alcohol)-calcium salt templates for precise customization of 3D hydrogel internal architecture

In tissue engineering applications, sacrificial molding of hydrogel monoliths is a versatile technique for creating 3D molds to control tissue morphology. Previous sacrificial templates fabricated by serial processes such as solvent casting and thermal extrusion/fiber drawing can be used to effectively mold internal geometries within rapidly polymerizing, bulk curing hydrogels. However, they display poorer performance in controlling the geometry of diffusion limited, ionically cross-linked hydrogels, such as alginate. Here, we describe the use of poly(vinyl alcohol)-calcium salt templates (PVOH-Ca) fabricated by micro-injection molding, a parallel mass-production process, to conveniently cast internal geometries within both bulk curing hydrogels and ionically cross-linked alginate hydrogels. Calcium salt solubility was discovered to be a critical factor in optimizing the polymer composite’s manufacturability, mechanical properties, and the quantity of calcium released upon template dissolution. Metrological and computed tomography (CT) analysis showed that the template’s calcium release enables precise casting of microscale channel geometries within alginate hydrogels (6.4 ± 7.2% average error). Assembly of modular PVOH-Ca templates to mold 3D channel networks within alginate hydrogels is presented to demonstrate engineering scalability. Moreover, the platform is used to create hydrogel molds for engineering human embryonic stem cell (hESC)-derived neuroepithelial organoids of a microscale, biomimetic cylindrical morphology. Thus, injection molded PVOH-Ca templates facilitate customization of hydrogel sacrificial molding, which can be used to generate 3D hydrogels with complex internal microscale architecture for diverse tissue engineering applications. Statement of SignificanceSacrificial molding of hydrogel monoliths is a versatile technique for creating 3D molds for tissue engineering applications. Previous sacrificial materials fabricated by serial processes have been used to effectively mold internal geometries within rapidly polymerizing, bulk curing hydrogels. However, they display poor performance in molding geometry within diffusion limited, ionically cross-linked hydrogels, e.g. alginate. We describe the use of poly(vinyl alcohol)-calcium salt templates (PVOH-Ca) fabricated by micro-injection molding, an unparalleled mass-production process, to conveniently cast internal geometries within both bulk curing hydrogels and ionically cross-linked alginate hydrogels. Calcium release from the PVOH-Ca templates enables precise sacrificial molding of alginate hydrogels and the process is biocompatible. Moreover, we demonstrate its use to engineer the morphology of hPSC-derived neuroepithelial organoids, and modular PVOH-Ca template designs can be assembled to enable scalable 3D customization of hydrogel internal architecture.

Effects of pressure, boundary conditions, and cutting reliefs on thermo-hydroforming of fiber-reinforced thermoplastic composite helmet based on numerical optimization

Compared with layup techniques, thermo-hydroforming is shown to be a viable process for mass production of thermoplastic composite structures due to its relatively rapid cycle time and low impact on the microstructure of the material. However, unlike layup technique, thermo-hydroforming can produce wrinkles in the formed part. A research was conducted wherein ABAQUS/CAE (6.14-1) was employed to numerically study the impact of thermo-hydroforming process parameters on the formation of wrinkles in a thermoplastic helmet. The optimized properties of the fiber-reinforced polymer composite was previously determined by the authors using the preferred fiber orientation model implemented as a user material subroutine (VUMAT). To account for the interaction between different layers of the laminated composite, the cohesive zone model was employed. The objective of the study was to use the simulation tool to minimize the overall wrinkle density and wrinkle height in the formed helmet as a function of the fluid pressure, boundary conditions, and especially the blank shape and the relief cuts made in the blank.

Industrially applicable mitigation of BO-LID in Cz-Si PERC-type solar cells within a coupled fast firing and halogen lamp based belt-line regenerator – A parameter study

The benefit of sophisticated rear surface passivation quality in highly efficient solar cell structures made of boron-doped oxygen-rich Cz-Si wafers (e.g. PERC) can be reduced if bulk lifetime becomes a limiting factor due to boron-oxygen related light-induced degradation (BO-LID). A permanent lifetime recovery can be achieved through a regeneration treatment under illumination at elevated temperature. To evaluate the applicability of BO mitigation by means of regeneration at industrial relevant conditions, industrially-made PERC solar cell precursors were processed in a coupled fast firing and regeneration tool where the latter comprises an illuminated zone through which the solar cells transit on a belt. The treatment was evaluated by a subsequent intentional degradation. The results show that untreated solar cells suffer from BO-LID while properly treated samples are almost free of BO-LID demonstrating the applicability of a fast (around 15–30 s) and coupled regeneration process in mass production. Furthermore, it is found that fluctuations in precursor quality and/or variations in firing conditions are of minor significance for the BO-LID mitigation process. The firing conditions process window (peak firing temperature and belt velocity) overlaps with the treatment conditions window having the benefit of independent optimization.

Utilizing the superior etch stop quality of HfO2 in the front end of line wafer scale integration of silicon nanowire biosensors

Silicon nanowire (SiNW) biosensors have received a special attention from the research community due to its ability to detect a range of species. The nano feature size of the SiNW has been exploited to fabricate small, low-cost, robust, portable, real-time read-out biosensors. These sensors are manufactured by two methods – top-down or bottom-up. Instead of the bottom-up method, the top-down approach is widely used due to its compatibility with complementary metal-oxide semiconductor (CMOS) process and scope of mass production. However, in the top-down method, the post fabrication microfluidic channel integration to access the SiNW test site remains complex and challenging. Since the nanosensor is expected to operate in a bio environment, it is essential to passivate the metal electrodes while pathways have to be made to access the test site. In this paper, we present a relatively easier method to access the SiNW test site without employing complex microfluidic channels while achieving leakage free passivation of metal electrodes and preserving the integrity of the nanosensor. This is accomplished in the last step of the manufacturing process by employing a lithography mask and reactive ion etching (RIE). HfO2 integrated crystalline silicon nanosensors are manufactured using novel top-down front end of line (FEOL) sidewall transfer lithography (STL) process. HfO2 acts as an etch stop layer while performing RIE in the last step to access the sensor test site. The 100 mm wafer scale results of 20 nm × 60 nm × 6 μm (H x W x L) p-type nanosensors shows an average Ion/Ioff ≥ 105 with maximum turn-on voltage of −4 V and uniform subthreshold slope of 70 mV/dec. In comparison with sensors encapsulated with SiO2, the HfO2 integrated nanosensors were found to improve the threshold voltage variation by 50%. Based on this work, the HfO2 integrated SiNW demonstrates good stability for biosensing application.

Stabilization of Removal Rate in Small Tool Polishing of Glass Lenses

The demand for improving the image quality of cameras has increased significantly, especially in industrial fields such as broadcasting, on-vehicle, security, factory automation, and medicine. The surface of glass lenses as a key component of cameras is formed and finished by polishing using small tools. The existing polishing technologies, however, exhibit serious problems including an unstable material removal rate over time. In our previous work, the mechanism of time variation in material removal rate was clarified. Based on the findings, a vibration-assisted polishing method using polishing pads containing titanium dioxide particles was developed for improving the stability of the material removal rate with the accumulated polishing time. Our experiments revealed that the proposed polishing method suppressed the time variation significantly in the material removal rate. The developed polishing pads, however, possessed a short life because of their poor wear resistance; as such, they could not be applied to the mass-production process of lenses. In this study, we applied the vibration-assisted polishing method to the polishing process using commercial polishing pads that exhibit sufficient wear resistance for practical use. To investigate the effect of vibration on the stability of the material removal rate, polishing experiments and the observation of slurry flow on the surface of the polishing pads during the vibration-assisted polishing process were conducted. Based on the findings, a new polishing method utilizing a large-amplitude high-frequency vibration applied to the polishing pressure was developed. In addition, a new polishing method utilizing the overhang of a polishing pad, where the polishing pad was moved to hang over the edge of the workpiece for incorporating periodic dressing processes of the polishing pad surface during the polishing process, was also developed. Our polishing experiments revealed that both the proposed polishing methods improved the stability of the material removal rate significantly over the course of the polishing process.

Two-Stage Plasma-Thermal Nitridation Processes for the Production of Aluminum Nitride Powders from Aluminum Powders.

The synthesis of aluminum nitride (AlN) powders is traditionally done via the thermal nitridation process, in which the reaction temperature reaches as high as 960 °C, with more than several hours of reaction time. Moreover, the occurrence of agglomeration in melting Al particles results in poor AlN quality and a low efficiency of nitridation. In this study, an atmosphere-pressure microwave-plasma preceded the pre-synthesis process. This process operates at 550 °C for 2–10 min with the addition of NH4Cl (Al: NH4Cl = 1:1) for generating a hard AlN shell to avoid the flow and aggregation of the melting Al metals. Then, the mass production of AlN powders by the thermal nitridation process can be carried out by rapidly elevating the reaction temperature (heating rate of 15 °C/min) until 1050 °C is reached. X-Ray Diffractometer (XRD) crystal analysis shows that without the peak, Al metals can be observed by synthesizing AlN via plasma nitridation (at 550 °C for 2 min, Al: NH4Cl = 1:1), followed by thermal nitridation (at 950 °C for 1 h). Moreover, SEM images show that well-dispersed AlN powders without agglomeration were produced. Additionally, the particle size of the produced AlN powder (usually < 1 μm) tends to be reduced from 2–5 μm (Al powders), resulting in a more efficient synthesizing process (lower reaction temperature, shorter reaction time) for mass production.

Cancer Selective Turn-On Fluorescence Imaging Using a Biopolymeric Nanocarrier.

Most nanoparticle-based bioresearch for clinical applications is unable to overcome the clinical barriers of efficacy (e.g., sensitivity and selectivity), safety for human use, and scalability for mass-production processes. Here, we proposed a promising concept of using a biocompatible nanocarrier that delivers natural fluorescent precursors into cancerous cells. The nanocarrier is a biopolymeric nanoparticle that can be easily loaded with fluorescent precursors to form a fluorescent moiety via a biosynthesis pathway. Once delivered into cancerous cells, the nanocarriers are selectively turned on and distinctively fluoresce upon excitation. We, therefore, demonstrated the efficacy of the selective turn-on fluorescence of the nanocarriers in in vitro coculture models and in vivo tumor-bearing models.

Study of a Plateau Surface Evaluation Method Using a Fast M-Estimation Type Hough Transform

A surface with stratified functional properties (hereafter, referred to as the “plateau surface”) improves the tribological characteristics of sliding surfaces in machine tools, automobile parts, engines, etc. The evaluation methods of the plateau surface are listed in the ISO 13565 standard. However, since the evaluation methods listed in ISO 13565-3 are associated with several problems, these evaluation methods have been rarely used in production management. A plateau surface evaluation method that applied image recognition technology was developed in previous research studies to solve these problems. However, this method is time consuming with a calculation time of approximately 20 s. Therefore, in this research, we developed a new plateau surface evaluation method that applied the fast M-estimation type Hough transformation to achieve a computational time of a few seconds. It is expected that this method will be used in mass production processes.

Electrospinning of Block and Graft Type Silicone Modified Polyurethane Nanofibers.

Silicone modified polyurethane (PUSX) has attracted interest as a useful material by various properties, which are combined with silicone and polyurethane. In this paper, we tried to optimize the electrospinning process of silicone modified polyurethane (PUSX) nanofibers on a lab scale device and a multinozzle pilot scale set-up to investigate the potential and limitations of preparing PUSX nanofibrous sheets using different equipment. The morphology and diameter of the obtained fibers were studied via scanning electron microscopy (SEM). Attenuated total reflectance-Fourier transform infrared spectroscopy (ATR-FTIR) was also carried out to analyze the chemical structure of PUSX nanofibers. As a result, we successfully figured out the optimal parameters of PUSX electrospinning process and demonstrated the great potential of the process for mass production of PUSX nanofibrous sheets from solutions.

Static strength of RTM composite joint with I-fiber stitching process

Resin transfer molding (RTM) is a mass production process that can replace autoclave processes, and composite lap joints are extensively used in composite structures. When a tensile load is applied to a single-lap joint, both shear and tensile peel stresses are generated owing to the eccentric load effect. Reinforcing the composite joint in the thickness direction can reduce the shear and peel stresses generated in the joint, which can contribute considerably to the increase in the strength of the composite joint. Several reinforcing methods have been developed to improve the directional properties along the material’s thickness. Accordingly, a stitching process is typically used. However, the conventional stitching process has disadvantages because a) it requires complex equipment, and b) it cannot use highly elastic brittle fibers, such as carbon fibers. Recently, we proposed an I-fiber stitching process to minimize the bending of carbon fibers to prevent their fracture.In this study, composite, single-lap joint specimens were fabricated with RTM using an I-fiber stitching process, and their strengths were evaluated. The strengths of composite joint specimens fabricated at different stitching intervals and with the use of different patterns were compared with those of specimens fabricated without the use of the stitching process.

Application of PI-VM for management of the metal target plasma etching processes in OLED display manufacturing

Generation of the defect particles during the plasma-assisted metal dry etching process is induced by the various mechanisms. Most of these mechanisms are caused by the non-volatility of metal-halide compounds generated during the etching process. Degeneration of the metal etching process chamber condition is observed as the frequent process fault caused by the defects, but the worse condition is not recovered by itself. Because of this property of the metal etching process, proper work of the preventive maintenance (PM) to restore the process chamber or the addition of a discharge cleaning step is required periodically. However, inadequate PM or discharge cleaning by the uncertain cause analysis of the defect generation should be a just temporary remedy, and might lead the repetition of similar problems. To solve this problem, the virtual metrology (VM) model based on the plasma information (PI) parameters, known as PI-VM, was developed and applied for the defect control of the metal layer dry etching processes in organic light emitting diode (OLED) display manufacturing. To obtain the information about the generation rates of non-volatile compounds and their removal rates by the exhaustion system, PI parameters are designed with the consideration of the reaction kinetics in the metal etching plasma volume, sheath, and reacting surface using the big data of equipment engineering system (EES) and optical emission spectroscopy (OES) accumulated during the mass production process. The developed PI-VM index could be applied to a 2–3 h earlier alarm system for the defect occurrence, and had succeeded over 90% of alarm rate. This PI-VM alarm was applied to predictive control of the process by the early substitution of the discharge cleaning step or by the repair of the proper parts in the process chamber. By the control of processes based on the predicted results of the PI-VM, management of the mass production line with about 30% decreased defect was possible in OLED display manufacturing.

Constructing Process Models of Engine Blade Surfaces for Their Adaptive Machining: An Optimal Approach

In a new blade manufacturing process, manufacturers precisely forge blade billets with the blade suction and the pressure surfaces within tolerance. After that, only two blade edge billets should be machined to the leading- and the trailing-edges within tolerance. If these edge design surfaces are used to generate tool paths for machining the edge billets, the machined edges are not continuous with the suction and the pressure surfaces. To address this problem, an optimal approach to constructing process models of edge surfaces is proposed for adaptive blade machining. Specifically, the modified edge surfaces are optimized within the design tolerance and are continuous with the billet suction and pressure surfaces. These surfaces are used to generate tool paths for machining the edge billets. This approach addresses the current technical challenge in the new blade manufacturing process and can substantially promote this process in blade mass production.

Towards mass production of Au nanoparticles supported on montmorillonite microspheres for catalytic reduction of 4-nitrophenol

Noble metals supported on substrates have been proven as highly efficient catalysts for the reduction of nitro-compounds. However, their large-scale applications are still limited by the problems of fouling and transport during the mass production process. Herein, we first fabricated a spherical montmorillonite (Mt) substrate via spray drying technique, followed by the deposition of Au NPs through polydopamine chemistry to synthesize spherical Au nanoparticles supported Mt (Au@Mt) microspheres. The Au loading is 14.5 wt%, whereas the specific surface area of the Au@Mt microspheres is 47.3 m2 g−1, endowing the prepared Au@Mt microspheres with excellent catalytic activity to the reduction of 4-nitrophenol (4-NP) in the presence of NaBH4 with the optimized apparent reduction rate constant higher than 1.05 min−1. Furthermore, the microspheres can be easily recycled with self-sedimentation without any devices involved and showed excellent stability and recyclability for at least 20 cycles without almost unchanged spherical morphology and catalytic performance. Our straightforward strategy to solve the issue of the mass production process through granulation of amorphous nanomaterial substrate facilitates the practical application of these catalysts in the reduction of nitro-compounds.

The Urbanization and Development of Urban Agglomerations in Siberia and North China in the Context of the New Silk Road

The agglomeration process covers the main trends of settlement changes. Agglomerations of the population concentrate the processes of mass production and nearly all the key elements of the innovation economy. This article presents a complex analysis of the current conditions of the development of cities and urban agglomerations in Russia and China within the areas potentially influenced by the New Silk Road. It analyzes the results of geographical field research (conducted in September 2015) of urban settlements and the formation of urban agglomerations in Russia and China. Finally, it compares Siberian and northern Chinese urban settlements and agglomerations in model territories against the background of general urban changes in both countries.

Two Classes of Pigments, Carotenoids and C-Phycocyanin, in Spirulina Powder and Their Antioxidant Activities.

Arthrospira platensis is the widely available source of spirulina that contains distinctive natural pigments, including carotenoids and C-phycocyanin (C-PC). In this study, the major carotenoid and C-PC contents were determined in seven commercially available spirulina powder products and laboratory-prepared A. platensis trichomes (AP-1) by an LC-DAD method and UV-Visible spectrometry, respectively. The correlation of these two pigment content levels with Hunter color coordinates and antioxidant activity was also evaluated. The L* value failed to show a significant correlation with pigment content, but a positive correlation was observed between a* values and the contents of total carotenoid and C-PC. As b* values decreased, the chlorophyll a and C-PC contents increased. AP-1 exhibited the highest content of total carotenoids, chlorophyll a and C-PC, and antioxidant activities among the samples. This observation could be related to degradation of these pigments during the mass production process. The carotenoid profiles suggested that the commercial spirulina powders originated from two different sources, A. platensis and A. maxima. Total carotenoid and C-PC content exhibited positive significant correlations with antioxidant activities measured by 1,1-diphenyl-2-picrylhydrazyl (DPPH) and 2,2′-azino-bis(3-ethylbenzothiazoline-6-sulphonic acid) (ABTS) assays. These results provide a strong scientific foundation for the establishment of standards for the commercial distribution of quality spirulina products.

Evaluation of grinding wheel loading phenomena by using acoustic emission signals

In the industrial manufacturing field, machining is a major process. Machining operations involve grinding, drilling, milling, turning, pressing, molding, and so on. Among these operations, grinding is the most precise and complicated process. The surface condition of the grinding wheel plays an important role in grinding performance, and the identification of grinding wheel loading phenomena during the grinding process is critical. Accordingly, this present study describes a measurement method based on the acoustic emission (AE) technique to characterize the loading phenomena of a Si2O3 grinding wheel for the grinding mass production process. The proposed measurement method combines the process-integrated measurement of AE signals, offline digital image processing, and surface roughness measurement of the ground workpieces for the evaluation of grinding wheel loading phenomena. The experimental results show that the proposed measurement method provides a quantitative index from the AE signals to evaluate the grinding wheel loading phenomena online for the grinding mass production process, and this quantitative index is determined via some experiments in advance in the same grinding environment to help the monitoring and controlling of the grinding process.

An incremental Inter-agent learning method for adaptive control of multiple identical processes in mass production

Abstract To enhance the individual control performance over the standalone control of each process in mass production, this paper explores information sharing among processes by proposing an incremental inter-agent learning (IIAL) method for the online estimation of the process model in the adaptive control of a class of processes modeled by linear-in-unknown-constant-parameters (LIP) formulae. Each individual process control system makes use of information from its own and other processes incrementally with time and across process. The application of the proposed work to a single layer RBF neural networks adaptive control shows that the speed of tracking error convergence of each process is improved.