scholarly journals A simulation-based approach to identify bottlenecks in the bearing manufacturing process

2021 ◽  
Vol 12 (9) ◽  
pp. s843-s855
Author(s):  
Larissa Moreira Alves de Souza Souza ◽  
Adriano Maniçoba da Silva ◽  
Julio Maria de Souza ◽  
Regis Cortez Bueno ◽  
Sivanilza Teixeira Machado ◽  
...  
Keyword(s):  
Physical Environment ◽  
Manufacturing Process ◽  
Flexible Manufacturing ◽  
Simulation Models ◽  
Manufacturing Processes ◽  
Modeling Simulation ◽  
Simulation Based ◽  
Low Costs ◽  
Short Time

Flexible manufacturing processes improve profitability and competitiveness for the company through an efficient process, with quality in a short time, and contribute to achieving low costs. One of the approaches that have been currently developed to improve the flexible manufacturing process is simulation. Simulation models consist of an assertive and powerful tool in strategic planning.  It permits a controlled way of the company's reality so that it was possible to study and analyze the organization's current situation under several circumstances without altering the production's physical environment and involving low costs. Accordingly, this study's primary purpose was to develop a simulation model to verify bottlenecks' existence in the bearing manufacturing process. For this, a case study is presented, and it was used modeling/simulation with Arena Software as a research method. The results showed no bottlenecks in the manufacturing process.

scholarly journals Investigations on Temperature Fields during Laser Beam Melting by Means of Process Monitoring and Multiscale Process Modelling

2014 ◽  
Vol 6 ◽  
pp. 217584 ◽  
Author(s):  
J. Schilp ◽  
C. Seidel ◽  
H. Krauss ◽  
J. Weirather
Keyword(s):  
Process Monitoring ◽  
Manufacturing Process ◽  
Computation Time ◽  
Simulation Models ◽  
Process Models ◽  
Temperature Fields ◽  
Transient Temperature ◽  
Transient Temperature Field ◽  
Laser Beam Melting ◽  
Simulation Based

Process monitoring and modelling can contribute to fostering the industrial relevance of additive manufacturing. Process related temperature gradients and thermal inhomogeneities cause residual stresses, and distortions and influence the microstructure. Variations in wall thickness can cause heat accumulations. These occur predominantly in filigree part areas and can be detected by utilizing off-axis thermographic monitoring during the manufacturing process. In addition, numerical simulation models on the scale of whole parts can enable an analysis of temperature fields upstream to the build process. In a microscale domain, modelling of several exposed single hatches allows temperature investigations at a high spatial and temporal resolution. Within this paper, FEM-based micro- and macroscale modelling approaches as well as an experimental setup for thermographic monitoring are introduced. By discussing and comparing experimental data with simulation results in terms of temperature distributions both the potential of numerical approaches and the complexity of determining suitable computation time efficient process models are demonstrated. This paper contributes to the vision of adjusting the transient temperature field during manufacturing in order to improve the resulting part's quality by simulation based process design upstream to the build process and the inline process monitoring.

scholarly journals Formalizing Manufacturing Process Modeling Using Composition Trees

2011 ◽  
Vol 399-401 ◽  
pp. 1852-1855 ◽  
Author(s):  
Lian Wen ◽  
David Tuffley
Keyword(s):  
Process Modeling ◽  
Manufacturing Process ◽  
Good Effect ◽  
Software Systems ◽  
Manufacturing Processes ◽  
Modeling Languages ◽  
Tree Model ◽  
Short Period

Optimizing manufacturing process modeling is critical to improving the efficiency and quality of manufacturing. However, manufacturing processes in general can be very complicated. A manufacturing process may involve (a) transforming a material into a new form, (b) combining different materials to form a new object, and (c) retrieving a certain part from a material as a new entity. All those activities could be confusing because many intermediate objects that exist only for a short period during the manufacturing process may have no formal names. To solve this problem, this paper proposes that composition trees (CT) can be successfully used to model manufacturing processes. Composition trees are parts of the formal notation in behavior engineering (BE), which is an innovative approach to the development of large software systems. For a composition tree, its characteristics of being intuitive, expressive and formal give it many advantages over other formal and informal modeling languages in software engineering. This paper uses a cooking case study to demonstrate how to use a composition tree model manufacturing processes. It is argued that the method could be applied to process engineering to good effect.

scholarly journals A Simulation-Based Dynamic Programming Method for Interchange Scheduling of Port Collecting and Distributing Network

2018 ◽  
Vol 2018 ◽  
pp. 1-17 ◽  
Author(s):  
Yun Peng ◽  
Wenyuan Wang ◽  
Xinglu Xu ◽  
Modi Chen ◽  
Xiangqun Song ◽  
...  
Keyword(s):  
Dynamic Programming ◽  
Storage Period ◽  
Simulation Models ◽  
Northern China ◽  
Dynamic Programming Method ◽  
Simulation Based ◽  
Random Events ◽  
Dalian Port ◽  
And Storage

As one of the effective methods to reduce congestion, grade intersection has already been changed to interchange in port collecting and distributing network (PCDN) of many Chinese ports, since the first interchange was built in the PCDN of Dalian port in 1924. Due to the growing demand for port freight transportation, congestion in PCDN is becoming one of the inevitable problems that need to be solved. This paper addresses the best interchange scheduling multistage decision problem in PCDN at a network level. The main challenges are how to estimate the delay time and cope with high uncertainties in port network and PCDN. Therefore, a simulation-based dynamic programming (DP) model is proposed with the purpose of minimizing total cost in lifetime period by combining a DP model and two nested simulation models together. Two simulation models are built to figure out the delay cost in the optimization model, which cannot be calculated by mathematical analysis due to complex vehicle travel patterns and irregular traffic volume caused by random events, such as the arrival pattern of ships’, natural conditions, and storage period of cargos. Finally, a real project in northern China is presented as a case study. The proposed method can be applied in similar cases and can help solve analogous complicated multistage problems.

A simulation-based case study for powertrain efficiency improvement by automated driving functions

2018 ◽  
Vol 233 (5) ◽  
pp. 1320-1330 ◽  
Author(s):  
Thorsten Plum ◽  
Marius Wegener ◽  
Markus Eisenbarth ◽  
Ziqi Ye ◽  
Konstantin Etzold ◽  
...  
Keyword(s):  
Energy Demand ◽  
Simulation Models ◽  
Pollutant Emissions ◽  
Traffic Light ◽  
Automated Driving ◽  
Virtual Testing ◽  
Vehicle Simulation ◽  
Simulation Based ◽  
Testing Environments

An increasing level of driving automation and a successive electrification of modern powertrains enable a higher degree of freedom to improve vehicle fuel efficiency and reduce pollutant emissions. Currently, both domains themselves, driving automation as well as powertrain electrification, face the challenge of a rising development complexity with extensive use of virtual testing environments. However, state-of-the-art virtual testing environments typically strictly focus on just one domain and neglect the other. This paper shows the results of a simulation-based case study considering both domains simultaneously. The influence of energy saving automated functionalities on a conventional, a hybrid, and a pure electric powertrain is investigated for a carefully selected inner-city driving scenario. The vehicle simulation models for the different powertrain configurations are calibrated using test bench results and vehicle measurements. A model predictive acceleration controller is developed for realizing the speed optimization function. By considering traffic conditions such as traffic light schedules and a preceding vehicle as the boundary conditions, unnecessary accelerations and decelerations are avoided to reduce the energy demand. The case study is realized by applying this function to the three powertrains variants. As a final result, a clear difference in energy demand is observed: the hybrid powertrain benefits the most in terms of energy demand reduction in the given use case. The results clearly underscore that in future vehicle development programs, the powertrain and the real-world driving functionalities have to be optimized simultaneously to minimize the energy demand during everyday vehicle operation.

scholarly journals Flexible Process Planning Design and Resource Optimization

2021 ◽  
Vol 8 (S1-Feb) ◽  
pp. 38-48
Author(s):  
V Thamaraiselvan ◽  
N Ramakrishnan
Keyword(s):  
Process Planning ◽  
Manufacturing Process ◽  
Flexible Manufacturing ◽  
Capital Investment ◽  
Industrial Revolution ◽  
Manufacturing Processes ◽  
Planning Model ◽  
Human Capabilities ◽  
Flexible Process Planning ◽  
Start Ups

Manufacturing processes undergo various transformations based on technological advancements and industry expectations. At initial times, during the period of first Industrial revolution, products were getting manufactured using human capabilities and skills. Then, electrically-driven motors, machines and conveyors were used. Now in the fourth Industrial revolution, Industries are equipped with automation, robots and cyber-physical systems. But adopting such technologies requires a high capital investment which cannot be accommodated by some start-ups. In this research paper, a case of a start-up which manufactures straws and vessel scrubbers in an eco-friendly manner as an initiative towards sustainability has been discussed. The key product of the company is biodegradable straws which are manufactured from coconut leaves through a set of processes. The scope of the research is to develop a labour-intensive process planning model. Managing contemporary issues is a big task for the company because of the dynamic nature of the environment. In this case, the demand for straws changes based on customer preference and accordingly, the manufacturing processes need to be revised. Hence, developing a rigid planning model is not an effective solution, so that, flexible manufacturing process needs to be developed. There is always a scope of improvement towards betterment and optimization in a manufacturing process. It is not necessary that the improvements should lead to drastic results. Japanese manufactures who bring the Toyota Production System (TPS) believe that small improvements in a continual basis will fetch better results in terms of quality, efficiency and lead time reduction. Once the model is developed, areas of improvement to optimize the resources are found out and iterations of process planning model were carried over to improve the efficiency. Through the study, it is found that the development of a flexible process plan is required to compete with the changing business scenarios.

Lean service system design: a simulation-based VSM case study

2019 ◽  
Vol 25 (7) ◽  
pp. 1802-1821 ◽  
Author(s):  
Fatih Cavdur ◽  
Betul Yagmahan ◽  
Ece Oguzcan ◽  
Nazli Arslan ◽  
Nurbanu Sahan
Keyword(s):  
Design Methodology ◽  
Simulation Models ◽  
Public University ◽  
Decision Makers ◽  
Value Stream Mapping ◽  
Content Type ◽  
Value Stream ◽  
Future State ◽  
Simulation Based

Purpose The purpose of this paper is to present a methodology for using simulation models together with value stream mapping (VSM) for designing lean service systems and illustrate it with a case study. Design/methodology/approach The authors propose a methodology combining simulation and VSM. Simulation models for both current and future states are developed to validate the results of the corresponding maps of current and future states, respectively. Findings The results illustrate the advantages of the suggested design represented by the future state map. Additionally, using simulation models together with VSM for validating current and future states also allows decision makers to perform comprehensive analyses on the system and draw statistical conclusions. Originality/value Although some lean applications in educational services exist in previous studies, according to the best of the authors’ knowledge, this study is the first one combining VSM and simulation for the implementation of the lean concepts in the construction and technical services of a public university.

The Nonlinear Contact Simulation for Manufacturing Process by Using ANSYS Program as Case study with Cylindrical rolling contact

2013 ◽  
Vol 1 (1) ◽  
pp. 60-80
Author(s):  
Ammar Dawood Ghali
Keyword(s):  
Nonlinear Analysis ◽  
Contact Surface ◽  
Manufacturing Process ◽  
Rolling Contact ◽  
Material Behavior ◽  
Manufacturing Processes ◽  
Production Operation ◽  
Nonlinear Simulation ◽  
Analysis And Design

       Numerical simulation plays an indispensable role in the modern manufacturing process, especially in production operation and metal forming by using different of forming Dies Because it give perfect product design to improving quality and performance and reduce the time and cost .Because of the most of forming operation include contact option between the product surface (contact surface) and Die surface (Target surface) then the determination of the contact surface nature and material behavior ( uniform linear ) or ( not uniform nonlinear) that very effect on the carryout of forming process with required product .To improving simulation accuracy, approximations of linear behavior have become less  acceptable, while it is possible to perform nonlinear analysis and design more often  while minimizing approximations, the nonlinear analysis capabilities in general-purpose   programs such as ANSYS Mechanical.The significance of the research is into linear simulation analysis and its limitation and development to nonlinear simulation  where interest with the development manufacturing processes that including change in the geometry , properties and material behavior  through forming ,the search give an example of Case study with Cylindrical rolling contact that very important for wide application to manufacturing processes such as drawing ,Rolling ,Forging , Extrusion, Bending and other .The structural nonlinearities can be classified as geometric nonlinearity, material nonlinearity, and contact or boundary nonlinearity Numerical results indicate the success of ANSYS contact technologies in solving very large scale engineering problems especially large deformation frictional contact problems with the  new surface based contact elements have many advantages over the node based contact  elements .

A simulation-based approach to develop a holonic robotic cell

2019 ◽  
Vol 46 (1) ◽  
pp. 128-134
Author(s):  
Clint Alex Steed
Keyword(s):  
Simulation Models ◽  
Simulation Software ◽  
Robotic Cell ◽  
Communication Interface ◽  
Smart Cameras ◽  
Content Type ◽  
Simulation Tools ◽  
Simulation Based ◽  
Cell Controller

Purpose This paper aims to present an approach for the simulation of a heterogeneous robotic cell. The simulation enables the cell’s developers to conveniently compare the performance of alternative cell configurations. The approach combines the use of multiple available simulation tools, with a custom holonic cell controller. This overcomes the limitation of currently available robot simulation packages by allowing integration of multiple simulation tools including multiple vendor simulation packages. Design/methodology/approach A feeding cell was developed as a case study representing a typical robotic application. The case study would compare two configurations of the cell, namely, eye-in-hand vision and fixed-camera vision. The authors developed the physical cell in parallel with the simulated cell to validate its performance. Then they used simulation to scale the models (by adding subsystems) and shortlist suitable cell configurations based on initial capital investment and throughput rate per unit cost. The feeding cell consisted of a six-degree of freedom industrial robot (KUKA KR16), two smart cameras (Cognex ism-1100 and DVT Legend 500), an industrial PC (Beckhoff) and custom reconfigurable singulation units. Findings The approach presented here allows the combination of dissimilar simulation models constructed for the above mentioned case study. Experiments showed the model developed in this approach could reasonably predict various eye-in-hand and fixed-camera systems’ performance. Combining the holonic controller with the simulation allows developers to easily compare the performance of a variety of configurations. The use of a common communication platform allowed the communication between multiple simulation packages, allowing multi-vendor simulation, thereby overcoming current limitation in simulation software. Research limitations/implications The case study developed here is considered a typical feeding and assembly application. This is however very different from other robotic applications which should be explored in separate case studies. Simulation packages with the same communication interface as the physical resource can be integrated. If the communication interface is not available, other means of simulation can be used. The case study findings are limited to the specific products being used and their simulation packages. However, these are indicative of typical industry technologies available. Only real-time simulations were considered. Practical implications This simulation-based approach allows designers to quickly quantify the performance of alternative system configurations (eye-in-hand or fixed camera in this case) and scale, thereby enabling them to better optimize robotic cell designs. In addition, the holonic control system’s modular control interface allows for the development of the higher-level controller without hardware and easy replacement of the lower level components with other hardware or simulation models. Originality/value The combination of a holonic control system with a simulation to replace hardware is shown to be a useful tool. The inherent modularity of holonic control systems allows that multiple simulation components be connected, thereby overcoming the limitation of vendor-specific simulation packages.

Probabilistic Modeling and Analysis of Fused Deposition Modeling Process Using Surrogate Models

2016 ◽  
Author(s):  
Yi Liu ◽  
Pingfeng Wang
Keyword(s):  
Manufacturing Process ◽  
Composite Structures ◽  
Fused Deposition Modeling ◽  
Probabilistic Modeling ◽  
Surrogate Models ◽  
Manufacturing Processes ◽  
Modeling And Analysis ◽  
Fused Deposition ◽  
Deposition Modeling

Various sources of uncertain parameters at multiple levels, from design steps to manufacturing processes, are often involved in composite structures. Probabilistic modeling and analysis of the composite structure and its manufacturing processes can provide underlying information to assess uncertainties and improve the quality of the developed composite structures. This paper presents a stochastic multi-level modeling framework considering material, structural, modeling parameters as well as the manufacturing process based on a surrogate model. An enhanced laminate theory is employed to determine the elastic constants of the composite materials considering imperfect bonding among filaments in the manufacturing process. To improve the computational efficiency in simulation-based reliability approach, the evaluation of the structure properties is approximated by employing surrogate models based upon the physics model. To apply the present framework, a case study with a composite laminate beam under three-point bending, which is made through fused deposition modeling, is conducted, and the case study results demonstrate the efficacy of the presented modeling scheme and analysis methodology.

Optimales Layout einer Walderschliessung

2016 ◽  
Vol 167 (5) ◽  
pp. 294-301
Author(s):  
Leo Bont
Keyword(s):  
Road Network ◽  
Spatial Arrangement ◽  
Problem Situation ◽  
Optimal Layout ◽  
Forest Road ◽  
The Road ◽  
Network Cost ◽  
User Friendly ◽  
Short Time

Optimal layout of a forest road network The road network is the backbone of forest management. When creating or redesigning a forest road network, one important question is how to shape the layout, this means to fix the spatial arrangement and the dimensioning standard of the roads. We consider two kinds of layout problems. First, new forest road network in an area without any such development yet, and second, redesign of existing road network for actual requirements. For each problem situation, we will present a method that allows to detect automatically the optimal road and harvesting layout. The method aims to identify a road network that concurrently minimizes the harvesting cost, the road network cost (construction and maintenance) and the hauling cost over the entire life cycle. Ecological issues can be considered as well. The method will be presented and discussed with the help of two case studies. The main benefit of the application of optimization tools consists in an objective-based planning, which allows to check and compare different scenarios and objectives within a short time. The responses coming from the case study regions were highly positive: practitioners suggest to make those methods a standard practice and to further develop the prototype to a user-friendly expert software.

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