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Currently, inaccuracies in machine tools are often not detected until after they have produced nonconforming parts, causing reworking or scrap. For high-value aerospace parts, a single rejected part is a significant cost. Low-value parts are often inspected less frequently, allowing many nonconforming parts to be produced before the issue is detected, also resulting in high cost. The alternative to relying on part inspection is to run frequent tests on the machine itself, but established calibration and health-check processes take between 20 minutes and several days. Emerging rapid and automated verification (RAV) processes enable machine tools to check their performance automatically in just a few minutes. These RAV processes can be performed frequently throughout the day, allowing machines to operate without human intervention for long periods of time. When an issue is detected, the machine may be able to recalibrate and then continue automatically. Where this is not possible, the machine stops and provides diagnostic information enabling the operator to efficiently get the machine back into production. For many machines, especially smaller ones, artifact probing is the most cost-effective and easily implemented method. Combined with probing of roughing cuts, it can also verify spindle and dynamic errors at the micrometer level. Inertial measurement has a lot of potential to provide continuous monitoring during operations, and significant research efforts are therefore justified to validate and improve diagnostic capability. Noncontact triple-probing of spheres can provide highly accurate RAV while also enabling some compensation to be achieved in a very rapid way. This equipment is costly when dedicated to each machine for RAV but may be justified for very high-value machines and processes. NOTE: SAE EDGE™ Research Reports are intended to identify and illuminate key issues in emerging, but still unsettled, technologies of interest to the mobility industry. The goal of SAE EDGE™ Research Reports is to stimulate discussion and work in the hope of promoting and speeding resolution of identified issues. SAE EDGE™ Research Reports are not intended to resolve the issues they identify or close any topic to further scrutiny. https://doi.org/10.4271/EPR2020019
This book is devoted to intelligent models and algorithms as the core components of cyber-physical systems. The complexity of cyber-physical systems developing and deploying requires new approaches to its modelling and design. Presents results in the field of modelling technologies that leverage the exploitation of artificial intelligence, including artificial general intelligence (AGI) and weak artificial intelligence. Provides scientific, practical, and methodological approaches based on bio-inspired methods, fuzzy models and algorithms, predictive modelling, computer vision and image processing. The target audience of the book are practitioners, enterprises representatives, scientists, PhD and Master students who perform scientific research or applications of intelligent models and algorithms in cyber-physical systems for various domains.
This open access book summarizes the results of the European research project “Twin-model based virtual manufacturing for machine tool-process simulation and control” (Twin-Control). The first part reviews the applications of ICTs in machine tools and manufacturing, from a scientific and industrial point of view, and introduces the Twin-Control approach, while Part 2 discusses the development of a digital twin of machine tools. The third part addresses the monitoring and data management infrastructure of machines and manufacturing processes and numerous applications of energy monitoring. Part 4 then highlights various features developed in the project by combining the developments covered in Parts 3 and 4 to control the manufacturing processes applying the so-called CPSs. Lastly, Part 5 presents a complete validation of Twin-Control features in two key industrial sectors: aerospace and automotive. The book offers a representative overview of the latest trends in the manufacturing industry, with a focus on machine tools.
There is a need to optimise the maintenance of nuclear power plants, both to improve reliability and increase competitiveness. The tendency is to move from preventative (time based) maintenance to one dependent on the condition of plant and its components. This publication collects and analyses proven condition based maintenance strategies and techniques in Member States as well as selected papers on maintenance optimisation.
Hard machining is a relatively recent technology that can be defined as a machining operation, using tools with geometrically defined cutting edges, of a work piece that has hardness values typically in the 45-70HRc range. This operation always presents the challenge of selecting a cutting tool insert that facilitates high-precision machining of the component, but it presents several advantages when compared with the traditional methodology based in finish grinding operations after heat treatment of work pieces. Machining of Hard Materials aims to provide the reader with the fundamentals and recent advances in the field of hard machining of materials. All the chapters are written by international experts in this important field of research. They cover topics such as: • advanced cutting tools for the machining of hard materials; • the mechanics of cutting and chip formation; • surface integrity; • modelling and simulation; and • computational methods and optimization. Machining of Hard Materials can serve as a useful reference for academics, manufacturing and materials researchers, manufacturing and mechanical engineers, and professionals in machining and related industries. It can also be used as a text for advanced undergraduate or postgraduate students studying mechanical engineering, manufacturing, or materials.
Artificial intelligence (AI) is taking an increasingly important role in our society. From cars, smartphones, airplanes, consumer applications, and even medical equipment, the impact of AI is changing the world around us. The ability of machines to demonstrate advanced cognitive skills in taking decisions, learn and perceive the environment, predict certain behavior, and process written or spoken languages, among other skills, makes this discipline of paramount importance in today's world. Although AI is changing the world for the better in many applications, it also comes with its challenges. This book encompasses many applications as well as new techniques, challenges, and opportunities in this fascinating area.
This second edition of An Introduction to Predictive Maintenance helps plant, process, maintenance and reliability managers and engineers to develop and implement a comprehensive maintenance management program, providing proven strategies for regularly monitoring critical process equipment and systems, predicting machine failures, and scheduling maintenance accordingly. Since the publication of the first edition in 1990, there have been many changes in both technology and methodology, including financial implications, the role of a maintenance organization, predictive maintenance techniques, various analyses, and maintenance of the program itself. This revision includes a complete update of the applicable chapters from the first edition as well as six additional chapters outlining the most recent information available. Having already been implemented and maintained successfully in hundreds of manufacturing and process plants worldwide, the practices detailed in this second edition of An Introduction to Predictive Maintenance will save plants and corporations, as well as U.S. industry as a whole, billions of dollars by minimizing unexpected equipment failures and its resultant high maintenance cost while increasing productivity. - A comprehensive introduction to a system of monitoring critical industrial equipment - Optimize the availability of process machinery and greatly reduce the cost of maintenance - Provides the means to improve product quality, productivity and profitability of manufacturing and production plants
The Springer Reference Work Handbook of Manufacturing Engineering and Technology provides overviews and in-depth and authoritative analyses on the basic and cutting-edge manufacturing technologies and sciences across a broad spectrum of areas. These topics are commonly encountered in industries as well as in academia. Manufacturing engineering curricula across universities are now essential topics covered in major universities worldwide.
The essential introduction to the principles and applications of feedback systems—now fully revised and expanded This textbook covers the mathematics needed to model, analyze, and design feedback systems. Now more user-friendly than ever, this revised and expanded edition of Feedback Systems is a one-volume resource for students and researchers in mathematics and engineering. It has applications across a range of disciplines that utilize feedback in physical, biological, information, and economic systems. Karl Åström and Richard Murray use techniques from physics, computer science, and operations research to introduce control-oriented modeling. They begin with state space tools for analysis and design, including stability of solutions, Lyapunov functions, reachability, state feedback observability, and estimators. The matrix exponential plays a central role in the analysis of linear control systems, allowing a concise development of many of the key concepts for this class of models. Åström and Murray then develop and explain tools in the frequency domain, including transfer functions, Nyquist analysis, PID control, frequency domain design, and robustness. Features a new chapter on design principles and tools, illustrating the types of problems that can be solved using feedback Includes a new chapter on fundamental limits and new material on the Routh-Hurwitz criterion and root locus plots Provides exercises at the end of every chapter Comes with an electronic solutions manual An ideal textbook for undergraduate and graduate students Indispensable for researchers seeking a self-contained resource on control theory