Reconfigurable manufacturing system

Last updated

A reconfigurable manufacturing system (RMS) is a system invented in 1998 that is designed for the outset of rapid change in its structure, as well as its hardware and software components, in order to quickly adjust its production capacity and functionality within a part family in response to sudden market changes or intrinsic system change. [1] [2] A reconfigurable machine can have its features and parts machined. [3]

Contents

History

A schematic diagram of Koren's RMS, drawn by Rod Hill RMS schematic.gif
A schematic diagram of Koren's RMS, drawn by Rod Hill

The RMS, as well as one of its components—the reconfigurable machine tool (RMT)—were invented in 1998 in the Engineering Research Center for Reconfigurable Manufacturing Systems (ERC/RMS) at the University of Michigan College of Engineering. [4] [5] [6] The term reconfigurability in manufacturing was likely coined by Kusiak and Lee. [7]

From 1996 to 2007, Yoram Koren received an NSF grant of $32.5 million to develop the RMS science base and its software and hardware tools. [8] RMS technology is based on an approach that consists of key elements, the compilation of which is called the RMS science base.

System operations

Reconfigurable Manufacturing System Architecture by Y. Koren RMS Architecture.png
Reconfigurable Manufacturing System Architecture by Y. Koren

The system is composed of stages: 10, 20, 30, etc. Each stage consists of identical machines, such as CNC milling machines. The system produces one product. The manufactured product moves on the horizontal conveyor. Then Gantry-10 grips the product and brings it to one of CNC-10. When CNC-10 finishes the processing, Gantry-10 moves it back to the conveyor. The conveyor moves the product to Gantry-20, which grips the product and loads it on the RMT-20, and so on. Inspection machines are placed at several stages and at the end of the manufacturing system.

The product may move during its production in many production paths. In practice, there are small variations in the precision of identical machines, which create accumulated errors in the manufactured product; each path has its own "stream-of-variations" (a term coined by Y. Koren). [9] [10]

Characteristics

RMT patent drawing:
.mw-parser-output .citation{word-wrap:break-word}.mw-parser-output .citation:target{background-color:rgba(0,127,255,0.133)}
US 5943750 . A patent of a reconfigurable machine tool with a modular structure, containing spindle modules that can be reconfigured to allow different machining operations. RMT-Patent Drawing.gif
RMT patent drawing: US 5943750  . A patent of a reconfigurable machine tool with a modular structure, containing spindle modules that can be reconfigured to allow different machining operations.

Ideal reconfigurable manufacturing systems, according to professor Yoram Koren in 1995, possess six characteristics: modularity, integrability, customized flexibility, scalability, convertibility, and diagnosability. [5] [11] Characteristics for its components are: reconfigurable machines, controllers, and system control software. An RMS does not necessarily have all of the charateristics. [12] These principles are called Koren's RMS principles. Supposedly, the more of these principles applicable to a given manufacturing system, the more reconfigurable that system is. The RMS principles are:

The components of RMS are CNC machines, [13] reconfigurable tools, [5] [11] reconfigurable inspection machines, [14] and material transport systems (such as gantries and conveyors) that connect the machines to form the system. Different arrangements and configurations of these machines will affect the system's productivity. [15] A collection of mathematical tools, which are defined as the RMS science base, may be used to maximize system productivity with the smallest possible number of machines.

See also

Related Research Articles

<span class="mw-page-title-main">Computer-aided manufacturing</span> Use of software to control industrial processes

Computer-aided manufacturing (CAM) also known as computer-aided modeling or computer-aided machining is the use of software to control machine tools in the manufacturing of work pieces. This is not the only definition for CAM, but it is the most common. It may also refer to the use of a computer to assist in all operations of a manufacturing plant, including planning, management, transportation and storage. Its primary purpose is to create a faster production process and components and tooling with more precise dimensions and material consistency, which in some cases, uses only the required amount of raw material, while simultaneously reducing energy consumption. CAM is now a system used in schools and lower educational purposes. CAM is a subsequent computer-aided process after computer-aided design (CAD) and sometimes computer-aided engineering (CAE), as the model generated in CAD and verified in CAE can be input into CAM software, which then controls the machine tool. CAM is used in many schools alongside CAD to create objects.

<span class="mw-page-title-main">Numerical control</span> Computer control of machine tools

In machining, numerical control, also called computer numerical control (CNC), is the automated control of tools by means of a computer. It is used to operate tools such as drills, lathes, mills, grinders, routers and 3D printers. CNC transforms a piece of material into a specified shape by following coded programmed instructions and without a manual operator directly controlling the machining operation.

<span class="mw-page-title-main">CNC wood router</span> CNC router tool

A CNC wood router is a CNC router tool that creates objects from wood. CNC stands for computer numerical control. The CNC works on the Cartesian coordinate system for 3D motion control. Parts of a project can be designed in the computer with a CAD/CAM program, and then cut automatically using a router or other cutters to produce a finished part. The CNC router is ideal for hobbies, engineering prototyping, product development, art, and production work.

<span class="mw-page-title-main">FANUC</span> Japanese robotics company

FANUC is a Japanese group of companies that provide automation products and services such as robotics and computer numerical control wireless systems. These companies are principally FANUC Corporation of Japan, Fanuc America Corporation of Rochester Hills, Michigan, USA, and FANUC Europe Corporation S.A. of Luxembourg.

<span class="mw-page-title-main">Computer-integrated manufacturing</span> Manufacturing controlled by computers

Computer-integrated manufacturing (CIM) is the manufacturing approach of using computers to control the entire production process. This integration allows individual processes to exchange information with each part. Manufacturing can be faster and less error-prone by the integration of computers. Typically CIM relies on closed-loop control processes based on real-time input from sensors. It is also known as flexible design and manufacturing.

<span class="mw-page-title-main">Modular design</span> Design approach

Modular design, or modularity in design, is a design principle that subdivides a system into smaller parts called modules, which can be independently created, modified, replaced, or exchanged with other modules or between different systems.

<span class="mw-page-title-main">Design for manufacturability</span> Designing products to facilitate manufacturing

Design for manufacturability is the general engineering practice of designing products in such a way that they are easy to manufacture. The concept exists in almost all engineering disciplines, but the implementation differs widely depending on the manufacturing technology. DFM describes the process of designing or engineering a product in order to facilitate the manufacturing process in order to reduce its manufacturing costs. DFM will allow potential problems to be fixed in the design phase which is the least expensive place to address them. Other factors may affect the manufacturability such as the type of raw material, the form of the raw material, dimensional tolerances, and secondary processing such as finishing.

A flexible manufacturing system (FMS) is a manufacturing system in which there is some amount of flexibility that allows the system to react in case of changes, whether predicted or unpredicted.

<span class="mw-page-title-main">Tool and die maker</span> Class of machinist in manufacturing

Tool and die makers are highly skilled crafters working in the manufacturing industries. Tool and die makers work primarily in toolroom environments—sometimes literally in one room but more often in an environment with flexible, semipermeable boundaries from production work. They are skilled artisans (craftspeople) who typically learn their trade through a combination of academic coursework and with substantial period of on-the-job training that is functionally an apprenticeship. They make jigs, fixtures, dies, molds, machine tools, cutting tools, gauges, and other tools used in manufacturing processes.

<span class="mw-page-title-main">Outline of manufacturing</span> Overview of and topical guide to manufacturing

The following outline is provided as an overview of and topical guide to manufacturing:

A microfactory either refers to a capital-light facility used for the local assembly of a complex product or system or a small factory for producing small quantities of products. The term was proposed by the Mechanical Engineer Laboratory (MEL) of Japan in 1990 and has recently been used to describe the approach of manufacturers like Local Motors and Arrival.

Incremental sheet forming is a sheet metal forming technique where a sheet is formed into the final workpiece by a series of small incremental deformations. However, studies have shown that it can be applied to polymer and composite sheets too. Generally, the sheet is formed by a round tipped tool, typically 5 to 20mm in diameter. The tool, which can be attached to a CNC machine, a robot arm or similar, indents into the sheet by about 1 mm and follows a contour for the desired part. It then indents further and draws the next contour for the part into the sheet and continues to do this until the full part is formed. ISF can be divided into variants depending on the number of contact points between tool, sheet and die. The term Single Point Incremental Forming (SPIF) is used when the opposite side of the sheet is supported by a faceplate and Two Point Incremental Forming (TPIF) when a full or partial die supports the sheet.

<span class="mw-page-title-main">Manufacturing engineering</span> Branch of engineering

Manufacturing engineering or production engineering is a branch of professional engineering that shares many common concepts and ideas with other fields of engineering such as mechanical, chemical, electrical, and industrial engineering. Manufacturing engineering requires the ability to plan the practices of manufacturing; to research and to develop tools, processes, machines, and equipment; and to integrate the facilities and systems for producing quality products with the optimum expenditure of capital.

LinuxCNC is a free, open-source Linux software system that implements computer numerical control (CNC) capability using general purpose computers to control CNC machines. It's mainly intended to run on PC AMD x86-64 systems. Designed by various volunteer developers at linuxcnc.org, it is typically bundled as an ISO file with a modified version of Debian Linux which provides the required real-time kernel.

A punching machine is a machine tool for punching and embossing flat sheet-materials to produce form-features needed as mechanical element and/or to extend static stability of a sheet section. According to the file, Richard Walsh, the county of Grayson, and the State of Texas had invented and applied for US patent in 1894.

Industrial and production engineering (IPE) is an interdisciplinary engineering discipline that includes manufacturing technology, engineering sciences, management science, and optimization of complex processes, systems, or organizations. It is concerned with the understanding and application of engineering procedures in manufacturing processes and production methods. Industrial engineering dates back all the way to the industrial revolution, initiated in 1700s by Sir Adam Smith, Henry Ford, Eli Whitney, Frank Gilbreth and Lilian Gilbreth, Henry Gantt, F.W. Taylor, etc. After the 1970s, industrial and production engineering developed worldwide and started to widely use automation and robotics. Industrial and production engineering includes three areas: Mechanical engineering, industrial engineering, and management science.

Virtual machining is the practice of using computers to simulate and model the use of machine tools for part manufacturing. Such activity replicates the behavior and errors of a real environment in virtual reality systems. This can provide useful ways to manufacture products without physical testing on the shop floor. As a result, time and cost of part production can be decreased.

<span class="mw-page-title-main">Yoram Koren</span> Israeli-American engineering academic

Yoram Koren is an Israeli-American academic. He is the James J. Duderstadt Distinguished University Professor Emeritus of Manufacturing and the Paul G. Goebel Professor Emeritus of Engineering at the University of Michigan, Ann Arbor. Since 2014 he is a distinguished visiting professor at the Technion – Israel Institute of Technology.

Learning factories represent a realistic manufacturing environment for education, training, and research. In the last decades, numerous learning factories have been built in academia and industry.

References

  1. Koren, Y., Jovane, F., Heisel, U., Moriwaki,, T., Pritschow G., Ulsoy G., and VanBrussel H.: Reconfigurable Manufacturing Systems. A Keynote paper. CIRP Annals, Vol. 48, No. 2, pp. 6–12, November 1999.
  2. Michigan Engineering | About our ERC
  3. Moon, YM and Kota, S.: Design of reconfigurable machine tools. Journal of Manufacturing Science and Engineering, Trans of the ASME, 124:22, pp. 480–483, May 2002.
  4. Koren Y. and Kota, S.: Reconfigurable Machine Tool. US patent US 5943750 ; issue date: 8/31/1999.
  5. 1 2 3 "Creating the new manufacturing paradigm exactly the functionality and capacity needed, exactly when needed". Engineering Research Center for Reconfigurable Machining Systems. Retrieved September 22, 2024.
  6. Koren, Y. and Ulsoy, G,: Reconfigurable Manufacturing System Having a Method for Changing its Production Capacity. US patent # 6,349,237; issue date: 2/19/2002.
  7. Kusiak, A. and Lee, G.H., Design of Components and Manufacturing Systems for Reconfigurability, Proceedings of the First World Conference on Integrated Design and Process Technology, Austin, TX, pp. 14–20, December 1995.
  8. NSF Grant: Engineering Research Center for Reconfigurable Machining Systems
  9. Jianjun Shi, J. Stream of Variation Modeling and Analysis for Multistage Manufacturing Processes. CRC Press, Taylor & Francis Group, 2006. ISBN   0-8493-2151-4.
  10. Hu,, S. J. and Koren Y.: Stream of Variation Theory for Automotive Body Assembly. Annals of the CIRP, Vol. 46/1, pp.1–6. 1997.
  11. 1 2 Landers, R., Min, B.K., and Koren, Y.: Reconfigurable Machine Tools. CIRP Annals, Vol. 49, No. 1, pp. 269–274, July 2001.
  12. Mehrabi, M. Ulsoy, G. and Koren Y.: Reconfigurable Manufacturing Systems: Key to Future Manufacturing. Journal of Intelligent Manufacturing, Vol. 11, No. 4, pp. 403–419, August 2000.
  13. Koren, Y.: Computer Control of Manufacturing Systems. McGraw-Hill Book Co., New York, 1983. ISBN   0-07-035341-7
  14. Koren, Y. and Katz, R.: Reconfigurable Apparatus for Inspection During a Manufacturing Process. US patent # 6,567,162 Issue date: 5/20/03.
  15. Koren, Y., Hu J., and Weber T.: Impact of Manufacturing System Configuration on Performance. CIRP Annals, Vol. 1, pp. 689–698, August 1998.