New Publications are available for Control applications in other industries
http://dl-live.theiet.org
New Publications are available now online for this publication.
Please follow the links to view the publication.Portable test platform for evaluating voltage dip immunity of industrial robots and components in the automotive industry
http://dl-live.theiet.org/content/conferences/10.1049/cp.2012.0358
Power quality disturbances like voltage sags and harmonics are an important cause of many ill effects and economic losses in industrial productive processes. Among others problems, production down times, equipment malfunctions and/or destruction of devices and even quality defects in final products can be originated by voltage dips. Power quality surveys and electromechanical device testing are previous steps for achieving an effective mitigation solution. This paper discusses a power quality survey conducted in an automotive company. In addition, a portable test platform for evaluating voltage dip immunity of industrial robots and components is presented. The results obtained from this survey and the immunity test may be useful for improving the power quality of this type of installation [3,4,6]. (4 pages)Welding multi-robot task allocation for BIW based on hill climbing genetic algorithm
http://dl-live.theiet.org/content/conferences/10.1049/cp.2009.1485
To study the problem of welding robot task allocation for car Body-in-White (BIW) product line, built the mathematic model of the problem with the strategy of thinking about reasonable abstract and process decision in different stages. Associating strong points of hill climbing algorithm (HCA) local search and genetic algorithm (GA) global search, added directed hill climbing operator to genetic algorithm so as to speed up the search for optimal solution while produce every generation population. After primary allocation results were obtained, reconsidered process restrictions and expert knowledge to revise. A side-panel of some car BIW as model presentation, programmed with MatLab and Visual C++ to realize welding multi-robot task allocation. As result, obtain the suitable allocation results and the distribution of welding spots allocated to each robot on car BIW, the efficiency and rationality of welding robot task allocation are dramatically increased, and also realizes CAPP on welding robot task allocation. On the other hand, the results of welding robots task allocation can provide reference and dependence for welding robot path optimization and welding product line balance design. (8 pages)The design and application of microstructure control system applied to vehicles using sheet
http://dl-live.theiet.org/content/conferences/10.1049/cp_20060913
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: t<sub xmlns="http://pub2web.metastore.ingenta.com/ns/">1</sub>800; eI25%, τ<sub xmlns="http://pub2web.metastore.ingenta.com/ns/">1</sub>4, and the finest microstructure and highest mechanical properties of the sheet were obtained: F<sub xmlns="http://pub2web.metastore.ingenta.com/ns/">fine</sub>%=87%.A new method for analyzing and monitoring measurement process
http://dl-live.theiet.org/content/conferences/10.1049/cp_20060970
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.Research on digitized configuration and automated management of cutting tools for CNC machine
http://dl-live.theiet.org/content/conferences/10.1049/cp_20060959
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.Research on NC program design for mass customization
http://dl-live.theiet.org/content/conferences/10.1049/cp_20060756
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.Automatic defects detection based on adaptive wavelet packets for leather manufacture
http://dl-live.theiet.org/content/conferences/10.1049/cp_20061102
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.Research on variable valve system based on electro-hydraulic drive
http://dl-live.theiet.org/content/conferences/10.1049/cp_20061137
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.SMART-plan: a new message scheduler for real-time control networks
http://dl-live.theiet.org/content/conferences/10.1049/cp_20050328
The CAN (controller area network) is an established automotive control network. CAN is used in many applications outside of the automotive domain, in particular in the industrial automation space. CAN is used in real-time applications, but the scheduling of messages on CAN is not fully deterministic. In recent years a session layer has been developed for CAN so that a 'time-triggered' scheduling approach could be applied to the protocol. The time-triggered solution is referred to as TTCAN (time-triggered CAN). TTCAN supports a simple, time-based, static message schedule where each message has a precise transmit or receive time based on a global network clock. This paper outlines the development of a new tool that automatically generates the schedule for a set of messages running on TTCAN.Hardware in the loop for automotive vehicle control systems development
http://dl-live.theiet.org/content/conferences/10.1049/ic_20040651
There is an increasing requirement to develop vehicles within a shorter time frame. Achieving a rapid vehicle development program reduces cost and maximises the impact of a new vehicle in an extremely competitive market place. Electronic systems form a key aspect of modern vehicles that contain increasingly more electronic control units (1998 Mercedes S-Class 40 and 2002 BMW 7-Series 47). The increased use of electronic control systems requires that a smarter and more efficient means of development and testing be deployed. Hardware in the loop (HIL) systems are an important technology enabling integrated electronic control systems to be developed within the time frame defined by the vehicle development process and with a reduced reliance on expensive prototype vehicles. Such HIL systems provide a flexible test environment that can be updated and modified as the vehicle and corresponding systems develop throughout the duration of a vehicle programme.Neural network applications in the water industry
http://dl-live.theiet.org/content/conferences/10.1049/ic_20010111
The operation of water treatment plants is significantly different from most manufacturing industrial operations because raw water sources are often subject to natural perturbations like flood and drought, both of which significantly affect the characteristics of the abstracted water. More recently, improved sensor technology has enabled the successful regulation of variables such as pH and chlorine residual. Without a precise knowledge of the characteristics of the material to be removed, most chemical dosage requirements for primary water treatment are determined from laboratory measurements which are conducted (usually) not less than once a day. This paper gives a brief explanation of water treatment plant operation, and outlines a number of case studies where system knowledge contained within artificial neural networks has been used to provide solutions to operational problems within the water industry. (6 pages)“How to improve customer service whilst eliminating waste and implementing lean manufacturing”
http://dl-live.theiet.org/content/conferences/10.1049/ic_20000587
Giving customers what they want, when they want it, at a reasonable price is the theme of this paper. Traditional manufacturing businesses have often failed to deliver this and are often characterised by long lead-times, many changes of ownership, large batches, and poor process capability. With these constraints often the only way to deliver an acceptable level of customer service has been to hold large inventories and buffer stocks to cover waste in the operations process. The theme of this talk is to describe how TRW Aeronautical Systems, Lucas Aerospace has been responding to increasingly intense competitive pressures in the aerospace industry to deliver ever improving customer service levels whilst at the same time reducing cost. The company undertook a make-versus-buy review. It then identified customer-focussed value streams. Key approaches were change projects, kaizen breakthrough (monthly week-long efforts focussed on one area of the value stream), and daily continuous improvement. Key points are to maintain a value stream focus; to review the change programme weekly at the executive level; to involve senior management in kaizen events; to focus on sustaining what comes out of the events; and to use external change agents to help challenge traditions that are not readily relinquished. (4 pages)Automotive B2B - the drive for collaboration
http://dl-live.theiet.org/content/conferences/10.1049/ic_20000588
As customers grow more powerful, the automotive industry is forming new relationships with its suppliers. Business-to-business (B2B) commerce over the Internet is breaking down the traditional hierarchical relationships. The supply chain is being transformed into a supply network or a supply community, with the potential for a seamless flow of information between customers, manufacturers, suppliers and partners in the automotive supply chain. Already, hundreds of B2B Exchanges are in operation. The largest vertical exchange, COVISINT, an Internet marketplace for the automotive industry, recently received approval from the US Federal Trade Commission and the German Bundeskartellamt. It seeks to develop a community of trading partners that focuses on the acceleration of the build-to-order and the product development processes of its customers as well as reducing the costs of doing business. The exchange is building a progression of services: procurement, supply community management, and collaborative engineering. The article focusses on the management aspects of this. Some companies may need to rethink their business models. (3 pages)Integrating the supply chain through Web-enabled CAx systems
http://dl-live.theiet.org/content/conferences/10.1049/ic_19990441
The Internet and Web technology are transforming the way many manufacturing and engineering companies do business today. Much of the focus of `e-business' has been on providing new ways of accessing existing markets, or accessing new markets through the Internet. For aerospace companies, however, these new technologies also offer an important and exciting means to improve the integration of the supply chain in the product development process. Leading Web based CAx viewing solutions such as CATweb provide a high level of functionality today and an attractive complement to existing means of extending CAx systems in the supply chain. Integrated access to CAD and other CAx data is enabled with relatively inexpensive and easy to use `standard' desktop products, thus extending the reach of the data to many more users both within the company and the extended enterprise. By using the native data in a `pull based' access mode, access to the current valid level of data is assured. Full function CAD systems will still be required, however, where users require full design capability on the data. (3 pages)A novel sensor for monitoring oilfield fouling in near-real time
http://dl-live.theiet.org/content/conferences/10.1049/ic_19990722
The goal of our research was to improve the control of process fouling by developing new monitors that could be used to measure and predict fouling in real time. Such monitors could be used to assure the application of the proper chemical treatment at the proper dosage. Operation of these monitors in real time will provide a direct condition-based assessment of fouling and a means for optimizing the response. One approach to direct fouling measurement taken by Nalco/Exxon is the use of the quartz crystal microbalance (QCM) technique. A QCM is a device that uses a piezoelectric quartz crystal wafer with electrodes bonded to the crystal as a frequency control device, or resonator. We have developed our QCM-based instrumentation, referred to as a thickness-shear mode resonator (TSMR), using an oscillator circuit that minimizes the effects of resonator loss over a wide dynamic range of liquid viscosity and density. Results demonstrate the sensitivity and versatility of the TSMR technique for monitoring both rigid and visco-elastic fouling events in both lab and field environments. The TSMR voltage response to changes in the sample's visco-elastic properties is more sensitive than a standard oscillator circuit design using only frequency measurements. This response characteristic of the TSMR has enabled us to develop a highly sensitive monitor for both rigid and visco-elastic deposits. (4 pages)Integrate or die! The IT integration challenge in achieving responsiveness
http://dl-live.theiet.org/content/conferences/10.1049/ic_19980095
Outlines the market environment on which British Aerospace is operating. It reviews the legacy of the 1980's and early 1990's from an IT and process perspective and describes how the development from `cost plus' to agile and responsive is an evolutionary journey rather than a revolution. It also considers the challenge of integration and how this is the key to becoming the benchmark for the industry. (3 pages)Guidance on automotive software development in relationship to EMC
http://dl-live.theiet.org/content/conferences/10.1049/ic_19980842
Achieving EMC of vehicle electronics, and indeed of electronics in other applications, has to be regarded from a “total system“ viewpoint. Development issues including hardware design and embedded software cannot proceed in isolation. Whilst hardware measures will remain the front line defence against EMI, software design can play an important part in mitigating the effects of EMI and in ensuring the correct and safe operation of systems in hostile environments. (5 pages)PACTS 21 - defining the systems engineering process, tools and metrics for IMA systems development
http://dl-live.theiet.org/content/conferences/10.1049/ic_19980283
PACTS-21 is a collaborative research programme co-funded by the DTI and a number of aerospace companies. One of its aims is to develop the technologies, infra-structure and standards that will be needed to develop the civil aircraft of the future, viz. those entering service in the 21st century. The next generation of systems may include highly integrated digital avionics under software control, a concept known as integrated modular avionics (IMA). To date the activities of the PACTS systems engineering (SE) working group have included a top level review of existing system engineering processes, tools and metrics to determine their relevance to the aerospace industry, and the provisional definition of an SE process model that better reflects the specific requirements of IMA systems development. This paper reports the work undertaken by the group, outlines the process model, and summarises the group's findings and conclusions. (7 pages)Integrated control system design for the automotive industry using modern robust control methods
http://dl-live.theiet.org/content/conferences/10.1049/ic_19971345
A trend towards the integration of systems in high-technology industry is noted. The authors describe integrated control systems based on modern robust control techniques. They have been applied sucessfully in the aerospace industry, and it is argued that they can readily be applied to the problem of integrated optimal control system design in the automotive industry. 2 approaches are considered, one centralised and one decentralised. (6 pages)Jaguar's approach to dimensional control in product development
http://dl-live.theiet.org/content/conferences/10.1049/ic_19971167
Ask the chief executive of any car company you care to mention “What is your greatest priority?” and the chances are the reply will be “Quality”. This will almost certainly be the reply if the company has had a poor reputation for quality in the past. The reasoning is fairly simple, bad quality hits the bottom line. It reduces current and future sales revenues and leads to high warranty costs which eat straight into any profit the company might make. For this reason, serious effort has been applied over the past 10-15 years to improve the quality of car production. One element of producing a quality vehicle is control of dimensional variation. This paper outlines how Jaguar is addressing this issue from concept though to production and beyond. (2 pages)Rover's approach to the control of dimensional variation
http://dl-live.theiet.org/content/conferences/10.1049/ic_19971169
In order to understand how Rover approach this subject today, it's necessary to appreciate how Rover has emerged as the company it is today, from the myriad of different companies and from its associations with others, i.e. Honda, British Aerospace and more recently how it has become influenced by its new owners, BMW. The author also looks at the role of dimensional specification management in product development. (4 pages)Neural network technique for real-time classification automotive problem
http://dl-live.theiet.org/content/conferences/10.1049/ic_19970737
Although a large number of neural architectures exist and are applied to a wide range of problems, there continues to be a need for fast real time neural network classifiers, especially in the area of sensor interpretation. Moreover, a need currently exists for cost efficient neural network solutions for automotive applications. An algorithm suitable for this task should be fast and dependable and its hardware platform should be able to operate reliably under challenging conditions such as found in the engine compartment of a vehicle (e.g. temperature, humidity and motion). Work in this area has lead to the idea of neural networks implemented on multiple microprocessor systems (R.J. Howlett and D.H. Lawrence, 1995). The paper describes a novel neural network architecture and implementation, which has the potential to eventually lead to a system that will be able to satisfy the above needs. (4 pages)The change to simultaneous engineering
http://dl-live.theiet.org/content/conferences/10.1049/ic_19960767
Describes the changes which have taken place, at the Fordhouses Wolverhampton site of Lucas Aerospace, since the late 1980's. The business provides flight control systems for a wide range of aircraft types in both the military and civil markets. The predicted decline of the military market and a relatively high cost base of the business, amplified the need for a radical change. A small executive level team (known as the Business Development Group) worked together, on a full time basis, for a period of 2 months in order to determine the overall organisational strategy for the business. This group laid the foundation for a number of major changes ranging from the introduction of product based manufacturing cells, operator self inspection and the introduction of a multi-disciplinary project team structure for product introduction. This paper focuses on changes to the product introduction process at the Fordhouses site. (3 pages)Development of a variable density flowmeter for an industrial application using tomographic imaging
http://dl-live.theiet.org/content/conferences/10.1049/ic_19960842
A variable density flowmeter enables the mass flow of plastic nibs to be measured. The flowmeter is situated between the bunker discharge outlet valve and tanker. Measurement of the density distribution across the pipe using process tomography enables the mass flow into the tankers to be determined. A high frequency (1 MHz), eight electrode serial capacitance sensing system was developed. This was used primarily for imaging static objects and real time imaging up to 2-3 frames per second. To increase the imaging speed a parallel system (PT II) was developed. The PT II system consists of an eight electrode parallel capacitance sensing system, using a low frequency AC amplifier detector circuit. The use of a low frequency source has made the capacitance detector circuit stray immune and less sensitive to high frequency noise. A PC based, Texas TMS C40 parallel processing system is used to process data and provide the tomographic images. (3 pages)Improving machine performance using the controller area network - the automation of a high-speed can production line
http://dl-live.theiet.org/content/conferences/10.1049/ic_19960904
This paper describes the introduction of new concepts into a tin can manufacturing line and its re-engineering with the aim of doubling the production speed. The design of the control system played an important part in matching the dynamics of the machinery to the production processes, and also in reducing costs and improving reliability. (7 pages)Customising bicycles through the integration of best practices
http://dl-live.theiet.org/content/conferences/10.1049/ic_19961042
A mass customisation capability is developing at Raleigh Industries. This enables customers to buy a bicycle tailored to their own specification at a competitive price and have it delivered in 1-2 weeks. A range of business drivers are discussed which prompted the adoption of this emerging competitive strategy, and it is hoped that parallels can be drawn in other sectors. The report follows the evolution of the service and gives an overview of the order fulfilment process, together with indications of its future potential. It will be demonstrated that the elements of mass customisation are not new-it is an exciting opportunity for many companies that can be realised through the integration of best-practices. (6 pages)Automatic material handling, illustrated by an aerospace small parts FMS application
http://dl-live.theiet.org/content/conferences/10.1049/ic_19960907
An aerospace small parts FMS is described. Upon receiving an order, a billet is cut, bar coded and scanned. In the billet preparation cell, the billets are stored and delivered by robot on demand to one of two machines. Four wire-guided AGVs bring new tools when necessary, and the old ones go for regrind or disposal. The machine tools' operations are monitored. After processing the parts at manually unloaded and sent to a finished parts store by AGV. Prepared aluminum parts are sent to a conveyor by the robot. The pallets for each type of these billets are processed by a gantry robot. Then the pallet is manually loaded by the aluminum part and sent to a store where it remains until required by one of six Automax machines. It is then taken by AGV for its first of two operations on an Automax machine, returned to the store, and later sent for its second operation. After these operations the billets go for inspection. The control VAX software is modular and machine programs are downloaded. The AGV local control unit receives transport orders and performs optical handshakes for interfacing. (5 pages)Application of adaptive control in stone processing industries
http://dl-live.theiet.org/content/conferences/10.1049/ic_19951176
The stone processing industries produce different types of material for use in the construction industries. Two major types are stone aggregates used for production of asphalt and concrete, and polished stone slabs used for a range of products including floor and wall tiles. Traditionally, the stone processing industries have relied on manual and subjective methods of plant set up, monitoring and control. The increasing demand for better quality products and lower costs is creating a trend towards process optimization and automatic control. Due to the nonlinear nature of the involved processes, the introduction of automation in these industries is often problematic. Variation in stone properties, in particular, presents a major problem which causes a drift in plant performance in terms of tool wear, system efficiency, and product characteristics. The paper describes the use of adaptive and intelligent control strategies to overcome this problem in both stone polishing and aggregate industries. (4 pages)PLCs and SCADA - a water industry experience
http://dl-live.theiet.org/content/conferences/10.1049/ic_19950742
This paper reviews the experiences of Bechtel Water Technology in the application of programmable logic controllers. The paper outlines how experience of industrial disputes followed by the introduction of EC Drinking Water Directives during the 1980's generated a requirement to build a substantial number of unmanned automated plants. This resulted in a substantial increase in the number and sophistication of process control solutions produced. It outlines the challenges encountered during the life cycle of these sophisticated solutions and continues by considering how, in addition to the control requirements other factors such as the investment regime, operational constraints, and manpower skill levels influence the design of PLC control systems and led to different solutions being proposed for the water and wastewater treatment plants. It identifies how by the use of dynamic modelling techniques the company has been able to focus the application of advanced technology only to the areas where it is specifically needed. The paper reviews the adoption of PLC systems with SCADA interfaces, in preference to DCS packages. (10 pages)Aubergenville treatment plant, a fully automated waterworks in Paris western suburb
http://dl-live.theiet.org/content/conferences/10.1049/ic_19950737
Since 1970, Lyonnaise des Eaux has developed a policy of automation at its water treatment plants. Originally based on solid logic modules, the technology used was upgraded and improved in the late seventies by the progressive and extensive use of programmable logical controllers (PLC). Since 2nd of May 1984, the potable water production of the western suburb of Paris (1 million inhabitants) has been fully automated (with around 100 PLCs), and unmanned after hours. Over the years, PLC has been progressively used for supervisory control and data acquisition (SCADA), for chemical treatment closed loop regulation and for more sophisticated hydraulic balance regulation of waterworks. In most process control and SCADA systems, PLCs are mainly used for real time process control and data collection when remote terminal units (RTU) are used for stamp dated data communication protocol and monitoring purposes on distribution networks. SCADA systems are now built as patchworks of various brands and types of equipment (when necessary). (6 pages)Modelling the design process within the aerospace industry
http://dl-live.theiet.org/content/conferences/10.1049/cp_19940928
The objective of this work is to develop a management tool that is capable of modelling the dynamics of the design process in far greater detail than traditional project management methods. A specific design task, namely the structural design of an aircraft wing will be used to demonstrate the proposed system. The co-operation of BAe Airbus Ltd. will enable realistic data such as target design parameters, activity durations and precedence relationships to be used.Automatic computer control of the manufacture of thin-film optical devices
http://dl-live.theiet.org/content/journals/10.1049/piee.1976.0099
This paper describes a project to investigate the feasibility of using a small digital computer to automatically control the manufacture of multilayer thin film optical interference devices. The manufacturing process and the computer control systems are described in detail and the results from a particular case study are presented. These results relate to the manufacture of a 5-layer antireflectance coating. The computer is shown to be able to control the process with precision and to have the potential for manufacturing devices toa consistent high quality.Modular engineering speeds drugs to market
http://dl-live.theiet.org/content/journals/10.1049/cce_20030309
In the drug industry, the speed that a product is brought to the market is decisive. The "time window" a company has to market its product is shorter than in most industries, because, at one end of the window, extended periods are required for clinical approval to satisfy regulatory requirements, and at the other end, patent expiries allow competitors to share their business. Thus, for economic reasons, it is important for pharmaceutical companies to build production units quickly. To improve speed of construction, Novo Nordisk Engineering (NNE), the engineering contracting subsidiary of Danish pharmaceutical manufacturer Novo Nordisk, developed a new approach called "Modular Engineering".Block exemptions and the new automotive supply chains
http://dl-live.theiet.org/content/journals/10.1049/me_20040104
Following concern by consumer groups over "cosy cartels" and price-fixing in the UK, new rules were implemented to remove car manufacturers from block exemptions to EU Competition Law (BER). Cutting the cord between manufacturers and dealerships who can retail and service vehicles, they expose the automotive market place to the full force of the consumer and allow new and potentially more competitive distribution channels to emerge. BER introduces seven fundamental changes to the distribution of new vehicles, aftersales service and parts. These changes include: (1) dealers and repair centers can set up networks across the UK, (2) dealers can sell more than one brand, (3) dealers and repair centers can expand networks across Europe, (4) intermediaries can enter, (5) sales and service are separated, (6) independent repairers can set up multi-franchised and European repair chains, and lastly (7) repairers have the freedom in where they source parts. With this move, BER is opening up the market for multi-branded franchises and separate sales and service. It also provides scope for networks to develop across Europe, which are free to take advantage of synergies in markets and logistics arrangements.Innovation hotbed [control automation]
http://dl-live.theiet.org/content/journals/10.1049/et_20080806
The automotive sector has always pushed the envelope when it comes to automation and control.Painting a new dawn [robot for automotive painting]
http://dl-live.theiet.org/content/journals/10.1049/cce_20070606
ABB's new, enhanced high-flow atomiser series, the FlexPainter IRB 5500, together with StayOn and NoPatch, offers reduced equipment costs by moving from the historical nine bell gate and four robot paint cell to a two-robot high performance paint cell. The smaller robotic painting booth footprint and the significantly reduced amount of air handled in the ventilation systems also have less impact on the environment. So, it's a win/win situation and proves that, in this case at least, 'less is more'.CADCAM for medallion production
http://dl-live.theiet.org/content/journals/10.1049/cce_19960111
Currently, the mint industry is using some of the conventional manufacturing processes that usually require specialised skills like engraving. This kind of skill is beginning to lose its attractiveness to the younger generations as it takes many years to be trained as an apprentice before one can be a qualified craftsman. This article highlights how CAD/CAM and CNC technologies can be used effectively to computerise some of the conventional medallion design and production processes. Some industrial case studies are described and an evaluation performed. A comparison based on the time required by the current practice and the proposed method is presented in one of the case studies. It is found that the proposed method is able to cut down the time for manufacturing the working and master dies by more than 50%.Waste not, want not [EU End-of-Life Vehicle Directive]
http://dl-live.theiet.org/content/journals/10.1049/me_20020202
The European Union's "End-of-Life Vehicle Directive", which will impact upon all manufacturers that supply the European automotive market, is due to be adopted by the UK Government in July 2002. The actual legislation that each country will introduce will vary, but BMW has been an early pioneer of vehicle recycling and is ready for the Directive.The search for a safer driver interface: a review of gesture recognition human machine interface
http://dl-live.theiet.org/content/journals/10.1049/cce_20050109
Gesture based HMI offers the possibility of substantial safety benefits, but there is conflicting evidence on user acceptance, most researchers concluding that users prefer gesture controls. An alternative system is being developed that an automotive gesture recognition system using electric field sensors can achieve the same safety benefits as vision-based systems, at lower cost, without the same technical difficulties.Holistic approach to control [automotive industry]
http://dl-live.theiet.org/content/journals/10.1049/cce_20070207
GM's Shanghai facility is designed from the ground up with a control system built from scratch. Not every facility has the luxury of designing a production control system from the ground up. The majority of automotive OEMs and suppliers have plants with legacy production and control systems that are upgraded piecemeal. Outmoded controllers running on proprietary networks mean that production control is often carried out in islands of automation rather than adopting a holistic view. So, when presented with the opportunity to build a control system from scratch, GE ensured that the system it implemented at its production facility in the Pudong area of Shanghai was as integrated as the market could offer.The team that changed the world
http://dl-live.theiet.org/content/journals/10.1049/me_20060407
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.Big cat habitat [factory redevelopment]
http://dl-live.theiet.org/content/journals/10.1049/me_20020208
The end of production of the Escort allowed Ford to redevelop its Halewood plant as the home of the new Jaguar X-TYPE. The author describes how the opportunity was taken to integrate environmental objectives.Theatre lighting control for Beauty and the Beast
http://dl-live.theiet.org/content/journals/10.1049/pe_19980210
Theatre Projects is one of the world leaders in the supply of theatre lighting equipment, and its lighting services subsidiary plans, installs and commissions complete systems for musicals, rock concerts, major corporate presentations and public events. This paper describes how one of its recent assignments was for Disney's `Beauty and the Beast' which opened at the Dominion Theatre in London, UK, last year.Developments in control in the water industry
http://dl-live.theiet.org/content/journals/10.1049/cce_20040108
The water industry in the UK has become one of the most efficient and technically advanced in the world, through its use of telemetry and SCADA systems for remote monitoring and process control. Extensive deployment of telemetry and local automation has enabled significant reductions in manpower costs and been one of the most significant drivers of increased operational efficiency. Telemetry systems have the potential to provide data to support a wide range of business planning functions such as energy management and asset condition management.The case for solid-state switching
http://dl-live.theiet.org/content/journals/10.1049/cce_20070202
In harsh manufacturing environment, the twin goals of minimising downtime and maximising productivity are vital for all companies. Not only is it necessary to maximise returns for shareholders, for many companies it is as simple as whether they stay in business or not. As part of this quest for improved productivity, OEMs and systems integrators are looking to push their machines and processes to ever-increasing speeds. In modern machinery applications (such as packaging, palletising or conveying), it would not be considered unusual to switch three-phase electric motors every second or so. Even under almost ideal operating conditions, and specifying high-quality products, the electrical life of an electromechanical contactor is typically exceeded in fewer than two million operations. At this point, the contactor would have to be replaced, resulting in lost production time and increased costs with respect to labour and replacement devices. The whole life cost, including machine downtime and repair, needs to be included in any calculations when it comes to making the decision between the solid state and the more traditional electro-mechanical contactor.Cruise control of automated manual transmission vehicles
http://dl-live.theiet.org/content/journals/10.1049/cce_20030203
A cruise control algorithm has been developed for vehicles with automated manual transmission (AMT). The algorithm is based on fuzzy logic and is embedded in the control program of the AMT.Orchestrating the airbus
http://dl-live.theiet.org/content/journals/10.1049/me_19970610
The paper reports on the task of managing the interrelationships and interdependencies between a set of projects supporting different parts of the British Aerospace Airbus design and manufacturing process. The programme office manager monitors progress across 60 live plans to ensure not only that they stay on time and within budget, but that they all deliver optimum business benefits. A continuous improvement programme has been adopted to constantly reassess the project progress against a changing environment.Let intelligent robots take the strain [automobile industry]
http://dl-live.theiet.org/content/journals/10.1049/me_20060206
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.Smart ecology [automobile manufacture]
http://dl-live.theiet.org/content/journals/10.1049/me_20020201
In 1993, Daimler-Benz embarked upon a feasibility study for the Smart town car. The ecologistics challenge was to create a modular production facility and develop a networked industrial complex to meet the demanding environmental, logistical and constructional requirements. The author gives an overview of production of the Smart facility at Hambach, Germany.Driver distraction trends and issues
http://dl-live.theiet.org/content/journals/10.1049/cce_20050107
Developing a safer HMI for secondary controls without compromising the primary function of driving has become a major challenge for automobile manufacturers. Most automotive manufacturers designed menu-based secondary control interfaces to reduce the number of individual controls. Three main technologies that have been developed to input commands into these menu-based interfaces; touch screens, central controllers, and speech recognition. The reduction in individual controls is achieved by the touch screen often means an increase in the number of steps needed via the menus to operate a simple control.