Control applications in other industries
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An interesting feature of Audi's new TT vehicle is its semi-active primary suspension system enabled by magneto-rheological (MR) fluid technology that allows continuously variable real-time suspension damping control. The suspension system is supplied by Delphi Corp. and is based on technology from Lord Corp. Although it can be used for other applications including seismic damping in buildings, damping of bridges against strong winds, and controlled dampers in prosthetic devices designed to provide users with tactile feedback, MR fluid technology's main market is the auto suspension system. MR-based components are now operating in hundreds of thousands of vehicles all over the world.
Connecting the information 'gap' between production level machines and processes with the management level is the goal of many manufacturing companies. Why? Because achieving this kind of visibility of key production data enables managers to make better, more informed decisions at the right times, in response to fast-changing conditions out on the shop floor and from customers. In this article, we look at how Ethernet converter devices are helping to solve production planning and data visualisation problems for one of Europe's largest tobacco manufacturers.
Daimler Chrysler has introduced a new type of automotive production technology that enables precisely coordinated teamwork between robots and makes them faster, more versatile and more precise. Known as "cooperating robot" technologies, the innovative manufacturing system was developed in close cooperation with the KUKA Robot Group and is being used for the first time within manufacturing of the Mercedes-Benz premium brand. Cooperating robots has helped Daimler Chrysler make great progress in all areas of manufacturing including ergonomics and safety as well as quality and efficiency.
The recent installation of a new floor pan assembly line, the first of its kind in Europe at Nissan's Sunderland plant, has effectively removed the need for framing jigs on initial spot welding operations. Core to the line's effectiveness is the use of three Fanuc robots with intelligent control and integrated 3D laser vision systems. Each robot is a Fanuc R2000iA, a six axes 200 kg load capacity arm, fitted with a Fanuc V500iA 3DL vision system to locate the panel position. The robots enable the production of variants without lengthy tool change times. Variants are programmed into the robots and the NC tooling controllers, making conventional tooling and fixtures unnecessary.
Variable valve technique can significantly improve the performance of the automobile engine and reduce pollution emission by varying valve timing, valve duration and valve lift. Variable valve system which is based on electro-hydraulic drive has the advantages of better stability, low noise and simple structure. In this paper, a variable valve system which is based on electro-hydraulic drive is introduced. In this system, a fast response proportional pressure reducing valve is used to throttle the high-pressure and low-pressure fluid. The fluid discharged from the proportional pressure reducing valve drives the piston of the single-acting cylinder and the piston drives the valve. One valve spring is used to close the valve. Valve timing and valve lift can be controlled by varying the input signal of the proportional pressure reducing valve. The component, structure and working principle of electro-hydraulic control system are discussed in this paper respectively. The key system parameters are studied through the simulation. Finally, we carried out some experiments on the established test rig. The results of the experiment show that the system can meet the need of the engine whose maximal speed is 1500 rpm.
The visual inspection system for leather surfaces was developed to quality control and raw material cut, an important component of automatic CAD/CAM cutting systems. The industrial detection of leather defects is difficult because of the large dimensions of the leather hides (3m×2.5 m), and the small dimensions of the defects (200μm×200μm). An efficient approach, using wavelet packets, is presented for the detection of defects embedded in leather surface images. Every inspection leather image is decomposed with a family of real orthonormal wavelet bases. The wavelet packet coefficients from a set of dominant frequency channels containing significant information are used for the characterization of leather images. A fixed number of shift invariant measures from the wavelet packet coefficients are computed. The magnitude and position of these shift invariant measures in a quadtree representation forms the feature set for a two-layer neural network classifier. The neural network classifier classifies these feature vectors into either of defect or defect-free classes. The experimental results suggest that this proposed scheme can successfully identify the defects, and can be used for automated visual leather inspection.
To meet the NC program design of mechanical parts for mass customization, this paper puts forward the systematic structure and information model of NC program design. On the basis of the NC program intelligent design system, Product Data Management (PDM) and CAD are integrated as the platform, then, the main NC program of part is obtained through putting the parameter document into the NC program intelligent design system from SML (Tabular Layouts of Article Characteristics). NC Meta-model program stock is founded by adopting the Meta-model idea, which is seen as the resource-stock for NC design. According to the customization need, the parameters are changed in SML, then, the Meta-model program stock is searched, the configuration and variant design are realized through distilling, increasing, deleting and modifying the sub-program. Finally, the customized NC code is obtained. The T6436 rotor-circulating part is applied to validate the theory in the paper. Results show the NC program design for mass customization improves the design efficiency and meets product customization.
Large or medium scale machine manufacturing companies are generally in possession of a mass of NC machine tools. The cutting tools are mostly dispersed over workshops and branch factories, where self-government is carried out. Because of the comparatively independent management, resources are difficult to share and the level of resources utilization is low. It is necessary to study digitized configuration and automated management of cutting tools, thereby effective and unified management can be realized. Concept of virtual tool, logical tool and physical tool are presented in this paper, and digitized configuration model of cutting tools based on technics is defined. The selection process of tools can be divided into confirmation of virtual tools and matching of logical tools. Tools' automated selection is actualized in the process, the tool information in automated tool warehouse are well considered as well, which can optimize the selection of tools and confirm physical tools. Finally, content of specialized management of tools is stated. Application of the research findings to Zhengzhou textile machinery Inc. is introduced, and the next research direction is pointed out.
In a production process, good measurement systems are important for successful quality improvement or statistical process control. The assessment of a measurement system is known as a gauge repeatability and reproducibility (R&R) analysis. In this paper, the traditional method, analysis of variance (ANOVA), is reviewed and some drawbacks are pointed. Then a new method is introduced to estimate R&R, which is based on a two-way random effects model. After that a method to monitor the measurement process is proposed. Towards the end, a case from an aeronautical manufacturing company is presented, which is used to analyze and monitor the measurement process by our proposal method.
Fine micro structure and high mechanical properties are requested in vehicle using sheet. But the quality of sheet is very difficult to control given many influencing factors in the manufacturing process. In this article, a microstructure control system applied to vehicle using sheet was established with the theory of Ultrafine Grain and Artificial Intelligence. The method of optimal discrimination plane (ODP) was employed to analyse the key factors and weigh of the parameters influencing the microstructure and mechanical properties of the sheet, such as component and deformation process parameters. According to the analysis, the partial least-squares (PLS) method is applied to set up the mapping relationship between influencing parameters and microstructure, performance. Then an optimized process scheme is obtained. The results showed that the key factors influencing the microstructure and mechanical properties were respectively the temperature and deformation amount of the first pass and the first interval. An optimized process scheme was below: t1800; eI25%, τ14, and the finest microstructure and highest mechanical properties of the sheet were obtained: Ffine%=87%.
