Virtual Manufacturing Environment Research Articles

Partnership of Lean Six Sigma and Digital Twin under Type 2 Neutrosophic Mystery Toward Virtual Manufacturing Environment: Real Scenario Application

Partnership of Lean Six Sigma and Digital Twin under Type 2 Neutrosophic Mystery Toward Virtual Manufacturing Environment: Real Scenario Application

Leveraging Blockchain to Support Collaborative Distributed Manufacturing Scheduling

The recent trend in collaborative distributed manufacturing scheduling (CDMS) has gained significant importance in extended, networked, and virtual manufacturing environments due to its adaptability and integration potential. In a distributed manufacturing environment, CDMS can occur within a single factory or across multiple companies in a dynamic and variable extended or virtual organization. For effective collaboration, the CDMS system must be secure, transparent, and trustworthy. This paper proposes a blockchain-based model for CDMS and discusses its implementation in the processing of manufacturing functions, specifically joint process planning and scheduling. An illustrative example is used to demonstrate the application of the proposed approach and its potential to enhance the management processes of CDMS enterprises. The results of the analysis indicate that the proposed blockchain approach can effectively facilitate communication and integration among CDMS enterprises. Additionally, the approach can be expanded to more complex manufacturing environments under different conditions.

Preliminary design of assembly system and operations for large mechanical products using a game engine

High-end commercially available CAD/PLM systems support virtual simulation of assembly procedures using digital avatars. An advanced solution involves real people in virtual manufacturing environment. This work presents development of a Virtual Reality environment based on an open game engine. This is developed in order to test assembly plans executed on a purpose-designed workstation including specially designed fixtures and all necessary tools for manual assembly of a large centrifugal pump. The system allows the engineer to evaluate and suitably modify the fixtures and overall workstation layout as well as perform preliminary checks on productivity and ergonomics of product assembly before any equipment is built or commissioned. Due to its open nature such a system can further evolve in complexity.

A Novel Multi-Agent-Based Collaborative Virtual Manufacturing Environment Integrated with Edge Computing Technique

This paper proposes a multi-agent-based collaborative virtual manufacturing environment (VME) to save energy consumption and improve efficiency in the manufacturing process. In order to achieve the high autonomy of the manufacturing system, a multi-agent system (MAS) is designed to build a collaborative VME. In this new VME environment, edge computing is embedded to strengthen the cyber resource utilization and system economy. Moreover, an efficient communication channel between networks is proposed. The subsequent cooperation and collaboration protocols among agents are designed to ensure flexible and process-oriented operations. Furthermore, the fuzzy resolution algorithm is employed to resolve the competition conflicts among function-similar MASs in the distributed manufacturing scenario. Lastly, a simulation and case study are performed to evaluate the performance of the proposed VME in Internet of Things (IoT)-based manufacturing. The analysis results have demonstrated the feasibility and effectiveness of the proposed VME system.

Accelerated Thermal Simulation for Three-Dimensional Interactive Optimization of Computer Numeric Control Sheet Metal Laser Cutting

In the context of computer numeric control (CNC)-based sheet metal laser cutting, the problem of heat transfer simulation is relevant for the optimization of CNC programs. Current physically based simulation tools use numeric or analytic algorithms which provide accurate but slow solutions due to the underlying mathematical description of the model. This paper presents: (1) an analytic solution to the laser heating problem of rectangular sheet metal for curved laser trajectories and convective cooling, (2) a graphics processing unit (GPU) implementation of the analytic solution for fast simulation of the problem, and (3) an integration within an interactive environment for the simulation of sheet metal CNC laser cutting. This analytic approach sacrifices the material removal effect of the laser cut in the favor of an approximated real-time temperature map on the sheet metal. The articulation of thermal, geometric, and graphic feedback in virtual manufacturing environments enables interactive redefinition of the CNC programs for better product quality, lower safety risks, material waste, and energy usage among others. The error with respect to finite element analysis (FEA) in temperature prediction descends as low as 3.5%.

Knowledge extraction and visualization of digital design process

After digitally designing components of vehicles, a design team creates a virtual manufacturing environment that resembles actual manufacturing facilities. During this digital pre-assembly process, a review team examines each component, and records its problems and requirements in part verification reports. Once these reports are delivered to specific design team responsible for each part, the design team can make appropriate adjustments to their designs. This digital pre-assembly process can evaluate and prevent flaws in design prior to actual manufacturing, improving production quality and reducing manufacturing cost. As these reports are written in free text form, they, however, are not fully utilized for understanding problems arising from the design process. This paper proposes a method of applying text mining techniques on verification reports to extract insights for quality improvement. In this paper, following three text mining approaches are proposed: (1) Extracting n-grams for text preprocessing and constructing domain ontology; (2) Extracting meaningful insights from text preprocessing; (3) Creating intuitive visual tools to understand the extracted insights. The proposed method is applied on approximately 140,000 reports, and is validated through the quality of the answers obtained for the questions posed by the domain experts. The proposed method successfully extracts useful information from the text database, and provides intuitive graphical interface, thereby satisfying the need of the domain experts. This paper proposes a systematic framework of transforming huge amount of raw text data into intuitive visualization. Through this framework, meaningful knowledge can be extracted, analyzed and shared to improve the quality of the products. Main contribution of our paper is that it proposes a framework for knowledge extraction from pre-assembly process. Not only does it systematically arrange the data, but it also combines various data sources and creates a knowledge system to improve efficiency of the design process.

Application of Virtual Reality in Side Clamp Fixture Assembly

Background/Objectives: The main objective of this paper is dealt with the application of virtual reality in side clamp fixture assembly. Methods/Statistical Analysis: The proposed methodology utilized the geometry and assembly details of side clamp assembly and makes the fixture assembly as close as possible to the real one. It includes two stages. The first stage demonstrates the procedure used for creating virtual prototype of an assembly and the second stage includes the creation of virtual fixture assembly. Findings: VRML coding is used to simulate virtual assembly process. Based on interference analysis errors can be rectified. Fixture assembly planning in virtual environment gives better understanding of the design engineer and the virtual assembly planning gives clear detail for virtual manufacturing. It enables intuitive assembly sequences which are then evaluated by Vizard inspector module. Application/Improvement: In this paper fixture assembly sequences are simulated using VIZARD software. Future research will investigate the fixture assembly plan in a complex virtual manufacturing environment.

Holonic control approach for the “green”-tyre manufacturing system using IEC 61499 standard

Traditional tyre-manufacturing systems are characterised by a slow response during optimisation of the manufacturing process and insufficient adaptability to system disturbances. The objective of our research is to develop a distributed and adaptive control approach based on the concept of holonic control and IEC 61499 function blocks. A brief description of the manufacturing modules within the “green”-tyre manufacturing system is given. The architecture of distributed holonic control and implementation environment using IEC 61499 function blocks are then proposed and elaborated. Comprehensive discussion is given thereafter, including an evaluation of the distributed holonic control approach within the virtual manufacturing environment based on simulation tests for various scenarios, whereby system operation in unstable conditions is taken into account. The real-life implementation of this technology in the future is expected to increase productivity, resource utilisation and robustness in a tyre-manufacturing environment.

Towards an experience based collective computational intelligence for manufacturing

Knowledge based support can play a vital role not only in the new fast emerging information and communication technology based industry, but also in traditional manufacturing. In this regard, several domain specific research endeavours have taken place in the past with limited success. Thus, there is a need to develop a flexible domain independent mechanism to capture, store, reuse, and share manufacturing knowledge. Consequently, innovative research to develop knowledge representation models of an engineering object and engineering process called Virtual engineering object (VEO) and Virtual engineering process (VEP) has been carried out and extensively reported. This paper proposes Virtual engineering factory (VEF), the final phase to create complete virtual manufacturing environment which would make use of the experience and knowledge involved in the factory at all levels. VEF is an experience based knowledge representation for a factory encompassing VEP and VEO within it. The novelty of this approach is that it uses manufacturer’s own previous experience and formal decisions to collect and expand intelligence for future production. The experience based collective computational techniques of Set of Experience Knowledge Structure (SOEKS) and Decisional DNA (DDNA) are used to develop aforesaid models. In this article the concept and architecture of VEF is explained as well as the integration of all three levels of virtual manufacturing i.e. VEO, VEP and VEF is presented. Furthermore, a case-study is presented to validate the practical implementation of the proposed concept. The benefits of this approach are manifold as it creates the environment for collective intelligence of a factory and enhances effective decision making. The models and research presented here embody the important first step into developing the future computational setting as required by the emerging next generation of cyber-physical systems.

가상제조환경에서 제품의 표면 거칠기 전달을 위한 촉각 디스플레이

In smart factories, the entire manufacturing process from design to the final product is simulated in a virtual manufacturing environment and optimized before starting production. Suppliers and customers make decisions based on the simulation results. Therefore, effective rendering of the information of the virtual products to suppliers and customers is essential for this manufacturing paradigm. In this study, a method of rendering the surface roughness of the virtual products using a tactile display is presented. A tactile display device comprising a 3 x 3 array of individually controlled piezoelectric stack actuators is constructed. The surface topology of the virtual products is rendered directly by controlling the piezoelectric stack actuators. A series of experiments is performed to evaluate the performance of the tactile display device. An electrical discharge machined surface is rendered using the proposed method.

フィジカル・システムと連動した生産設備シミュレーション（設備シミュレーションを構築するためのコンポーネント標準化の提案）

This paper discusses the effectiveness of manufacturing facility simulation linked with physical systems on value chain activities. The activities on manufacturing preparation and implementation processes of manufacturing systems have been improved by manufacturing facility simulation. This method originates from research on the concept of virtual manufacturing environment in the early 1990s. The equipment or facility simulation layer corresponding with the standard hierarchy model of enterprise and control integration is defined. Facility and control model utilized for whole facility lifecycle and its configuration are proposed as a standardization candidate of the reference model. The model consists of digital data of many components including mechanical and control properties like 3D data of mechanism, kinematics, axis, joint, sensor signal and actuator signal. The model should be the standard because the property information of components is only provided by parts suppliers. The facility simulation is linked with both physical controllers and their simulators by standard communication middleware connecting various communication protocols of Real-time Ethernet and fieldbus. After the detail system configuration is described, the applied case studies of improving engineering chain activities in automobile manufacturing are explained. The case studies indicate these systems are efficient to shorten the development period of flexible manufacturing facilities including robots and fixture jigs and to reduce the development cost.

Interactive Generation of Spatial Solutions for Manufacturing Systems by Means of Virtual Reality

The contribution deals with the generation of interactive spatial solutions to manufacturing systems by means of virtual reality. It characterizes experimental work aimed at creating 3D models of manufacturing systems through technical and software resources of virtual reality. For innovative work is considered an example of data gloves in a virtual manufacturing environment. Data glove is used for placement of models means of production in manufacturing three-dimensional space.

A Publishing Method of Lightweight Three-Dimensional Assembly Instruction for Complex Products

In order to accurately guide on-site workers to quickly accomplish the assembly job of complex products, and reduce the deployment cost of assembly instruction, we propose a publishing method of lightweight 3D assembly instruction for complex products. In this paper, the key frames of assembly motion and the 3D technical annotations in the lightweight model are mapped to the time-based assembly process. Then, the annotated lightweight model and assembly process information are integrated and published into a single 3D assembly instruction document. An assembly instruction publishing example of satellite antenna feed component shows that the lightweight 3D assembly instruction is well instructive and affordable because it provides the interactive simulation of assembly process and time-based display of assembly technical annotations without using expensive computer-aided design (CAD) systems, graphics workstations, or virtual reality equipments. This method gives a full play to the advantages of model-based definition technology and lightweight model, and fills the gap between the process planning and the instruction publishing in the 3D virtual manufacturing environment.

Autonomous Virtual Hand Behavior Construction in Virtual Manufacturing Environment

This paper describes a method for autonomous virtual hand behavior construction in virtual manufacturing environment. The new mechanism is aimed to reduce user’s cognitive and manipulation loads. Based on a realistic and accurate virtual hand model; a strategy and an algorithm for behavior simulation, as well as continuous operation simulation; an intelligent and efficient virtual hand is generated. The experimental results demonstrate the ability of the method, to create an autonomous and reliable virtual hand in virtual manufacturing environment.

A methodology for developing service in virtual manufacturing environment

Developing product related services in the context of virtual manufacturing environment to support manufacturing industry is considered as one of the main challenges for industrialised countries to improve their competiveness in the years to come. This is a complex servitization process that needs supports of appropriate models, methods and tools. This paper presents a methodological approach for the creation of the manufacturing service and service system along the engineering phases of a service life cycle. The proposed approach is developed under the frame of a FP7 European Integrated Project MSEE (Manufacturing Service Ecosystem). The methodology relates and federates a set of models, methods and tools through a structured approach. The experimentations of the methodology in industrial pilots showed that it allows the gain of time and consistency in a complex manufacturing servitization project.

Validating and verifying fixture kinematics for virtual manufacturing

This paper presents a method to validate and verify the kinematics of fixtures for virtual manufacturing. The proposed method exploits the strengths of loop detection and simplified fixture kinematics. The solution to the kinematics problem is acquired by sequentially processing the loops in a structure, starting from the main loop and continuing for the remaining loops. The proposed method incorporates the Newton–Raphson method to solve the inverse kinematics of a closed loop. The proposed method is an alternative and systematic way to simulate fixture kinematics that is simple yet general enough for various fixture kinematics types. The proposed method was implemented in a software module to validate and verify fixture kinematics for a virtual manufacturing environment.

A Methodology for Developing Service in Virtual Manufacturing Environment

Developing services to support manufacturing industry in a context of virtual manufacturing environment and Ecosystem is a complex servitization process that needs support of appropriate models, methods and tools. This paper proposes a methodological approach to follow in the creation of service and service system during the whole service life cycle. The proposed approach is developed under the frame of an ongoing FP7 European Integrated Project MSEE. The methodology relates and integrates a set of frameworks, models, modelling and simulations tools by providing a structured approach. The added value of the approach is the gain of time and consistency in a complex servitization engineering project.

Virtual approach to holonic control of the tyre-manufacturing system

Tyre manufacturers aiming to remain competitive in complex modern markets must promptly adjust to the changes within the production environment. With traditional tyre-manufacturing systems, a slow response during optimization of the manufacturing process and low-level adaptability to system disturbances is evident. The presented approach to virtual holonic control of the tyre-manufacturing system enables dynamic response in the event of new optimization demands, decrease of the impact of disturbances on system productivity and smaller future investments in the manufacturing equipment.The developed virtual manufacturing environment enables analysis of the manufacturing process, visualization of operations, management of simulation parameters of the operations and analysis of the control system behaviour within a virtual manufacturing system prior to the implementation of the suitable control approach into a real-life manufacturing system. This helps to avoid failures in the manufacturing system due to potential disadvantages of the manufacturing system structure or lack of coordination between control parameters.Evaluation of the holonic control approach implementation within the virtual tyre-manufacturing system is performed based on simulation tests for various scenarios, whereby system operation in stable and unstable condition is taken into account. At the end, analysis results are presented. By means of the virtual tyre-manufacturing system, optimization requirements in stable condition of the holonic control system can be achieved in real time compared to the optimization which is applied in the conventional control approach. In the event of a disturbance, the holonic control approach increases productivity compared to the conventional control approach.

Interoperability for virtual manufacturing systems

As manufacturing systems are often costly to develop and operate, simulation technology has been demonstrated to be an effective tool for improving manufacturing system design and the efficiency of manufacturing operations and maintenance. However, effectively and efficiently using simulation remains an important issue in the manufacturing industry. One of the principal reasons is the difficulty in processing, organising, and making use of the production-related information about the manufacturing system to be simulated. The difficulty stemmed from no standard representation for such data, making the effort to input data such as product attributes, processing times, and material quantity requirements into simulations complex, time consuming, and error prone. The core manufacturing simulation data (CMSD) standards, SISO-STD-008-2010 and SISO-STD-008-01-2012, specifically address this data representation issue. CMSD enables the import/export of many different types of factory data into computer simulations and other manufacturing systems. This paper describes the motivation for creating CMSD, standardisation efforts for CMSD, and related research efforts. This paper also describes how CMSD could be used as an integration mechanism in a sustainable manufacturing test-bed being developed at the National Institute of Standards and Technology. The test-bed will be a virtual manufacturing environment to support the testing and validation of sustainability metrics, assessment methods, and tools for use in manufacturing.

Evolutionary optimization of robotic assembly operation sequencing with collision-free paths

Many problems in the lifecycle of product and production development (PPD) can be formulated as optimization problems. But in most of the real-world cases, they are too complex to be solved by analytical models or classical optimization methods. CAx and virtual manufacturing (VM) tools are on the other hand being employed to create virtual representation of products and processes before any physical realization is conducted. Synergy of these two domains is of interest in this paper where planning a process with the minimum cycle-time for assembling a spot welded sheet-metal product is desired. The methodology suggests an extendible virtual manufacturing-based optimization approach using evolutionary algorithms. Accordingly, a novel toolset with integration of evolutionary optimization and a commercial VM environment is developed. More specifically, the latest feature which takes advantage of the collision avoidant segment path planning functionality of the VM tool and integrates it with the sequence optimizer is described.