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Reconfigurable manufacturing systems: Principles, design, and future trends

Yoram KOREN, Xi GU, Weihong GUO

《机械工程前沿（英文）》 2018年第13卷第2期页码 121-136 doi: 10.1007/s11465-018-0483-0

摘要：

Reconfigurable manufacturing systems (RMSs), which possess the advantages of both dedicated serial lines and flexible manufacturing systems, were introduced in the mid-1990s to address the challenges initiated by globalization. The principal goal of an RMS is to enhance the responsiveness of manufacturing systems to unforeseen changes in product demand. RMSs are cost-effective because they boost productivity, and increase the lifetime of the manufacturing system. Because of the many streams in which a product may be produced on an RMS, maintaining product precision in an RMS is a challenge. But the experience with RMS in the last 20 years indicates that product quality can be definitely maintained by inserting in-line inspection stations. In this paper, we formulate the design and operational principles for RMSs, and provide a state-of-the-art review of the design and operations methodologies of RMSs according to these principles. Finally, we propose future research directions, and deliberate on how recent intelligent manufacturing technologies may advance the design and operations of RMSs.

关键词： reconfigurable manufacturing systems responsiveness intelligent manufacturing

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A zone-layered trimming method for ceramic core of aero-engine blade based on an advanced reconfigurable

《机械工程前沿（英文）》 2022年第17卷第2期 doi: 10.1007/s11465-022-0675-5

摘要： Ceramic structural parts are one of the most widely utilized structural parts in the industry. However, they usually contain defects following the pressing process, such as burrs. Therefore, additional trimming is usually required, despite the deformation challenges and difficulty in positioning. This paper proposes an ultrafast laser processing system for trimming complex ceramic structural parts. Opto-electromechanical cooperative control software is developed to control the laser processing system. The trimming problem of the ceramic cores used in aero engines is studied. The regional registration method is introduced based on the iterative closest point algorithm to register the path extracted from the computer-aided design model with the deformed ceramic core. A zonal and layering processing method for three-dimensional contours on complex surfaces is proposed to generate the working data of high-speed scanning galvanometer and the computer numerical control machine tool, respectively. The results show that the laser system and the method proposed in this paper are suitable for trimming complex non-datum parts such as ceramic cores. Compared with the results of manual trimming, the method proposed in this paper has higher accuracy, efficiency, and yield. The method mentioned above has been used in practical application with satisfactory results.

关键词： ceramic parts trimming computer-aided laser manufacturing 3D vision reconfigurable laser processing system

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Service-oriented manufacturing: A literature review and future research directions

《工程管理前沿（英文）》 2022年第9卷第1期页码 71-88 doi: 10.1007/s42524-021-0171-3

摘要： This study presents a systematic review of the literature on service-oriented manufacturing (SOM). Specifically, we focus on the impact of SOM on firm operating decisions, which distinguishes this work from previous reviews. This study proposes a classification framework for SOM research based on product flow, from its design to its final disposal. Although SOM has been studied for many years, most related research remains conceptual. Our criterion for choosing papers is that they must be relevant to practical problems. This review aims to provide readers a guide that will facilitate their search for papers in their field of interest. More importantly, we hope that this review can provide insightful managerial implications for SOM.

关键词： service-oriented manufacturing product– service systems servitization servicing operations mana- gement

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Smart manufacturing systems for Industry 4.0: Conceptual framework, scenarios, and future perspectives

Pai ZHENG, Honghui WANG, Zhiqian SANG, Ray Y. ZHONG, Yongkui LIU, Chao LIU, Khamdi MUBAROK, Shiqiang YU, Xun XU

《机械工程前沿（英文）》 2018年第13卷第2期页码 137-150 doi: 10.1007/s11465-018-0499-5

摘要：

Information and communication technology is undergoing rapid development, and many disruptive technologies, such as cloud computing, Internet of Things, big data, and artificial intelligence, have emerged. These technologies are permeating the manufacturing industry and enable the fusion of physical and virtual worlds through cyber-physical systems (CPS), which mark the advent of the fourth stage of industrial production (i.e., Industry 4.0). The widespread application of CPS in manufacturing environments renders manufacturing systems increasingly smart. To advance research on the implementation of Industry 4.0, this study examines smart manufacturing systems for Industry 4.0. First, a conceptual framework of smart manufacturing systems for Industry 4.0 is presented. Second, demonstrative scenarios that pertain to smart design, smart machining, smart control, smart monitoring, and smart scheduling, are presented. Key technologies and their possible applications to Industry 4.0 smart manufacturing systems are reviewed based on these demonstrative scenarios. Finally, challenges and future perspectives are identified and discussed.

关键词： Industry 4.0 smart manufacturing systems Internet of Things cyber-physical systems big data analytics framework

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Gain-enhanced reconfigurable radiation array with mechanically driven system and directive elements

《机械工程前沿（英文）》 2022年第17卷第4期 doi: 10.1007/s11465-022-0716-0

摘要： In the artificial intelligence-driven modern wireless communication system, antennas are required to be reconfigurable in terms of size according to changing application scenarios. However, conventional antennas with constant phase distributions cannot achieve enhanced gains in different reconfigurable sizes. In this paper, we propose a mechanically reconfigurable radiation array (RRA) based on miniaturized elements and a mechanically reconfigurable system to obtain gain-enhanced antennas in compact and deployed states. A five-element RRA with a phase-reconfigurable center element is designed and analyzed theoretically. The experimental sample has been fabricated, driven by a deployable frame with only one degree of freedom to realize the size and phase distribution reconfiguration simultaneously to validate the enhanced gains of RRA. The proposed RRA can be tessellated into larger arrays to achieve higher gains in other frequency regimes, such as terahertz or photonics applications with nanometer fabrication technology.

关键词： mechanism reconfigurable radiation array (RRA) compact state deployed state enhanced gain

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Recent development on innovation design of reconfigurable mechanisms in China

Wuxiang ZHANG, Shengnan LU, Xilun DING

《机械工程前沿（英文）》 2019年第14卷第1期页码 15-20 doi: 10.1007/s11465-018-0517-7

摘要： Reconfigurable mechanisms can deliberately reconfigure themselves by rearranging the connectivity of components to meet the different requirements of tasks. Metamorphic and origami-derived mechanisms are two kinds of typical reconfigurable mechanisms, which have attracted increasing attention in the field of mechanisms since they were proposed. Improving the independent design level, innovation, and international competitive powers of reconfigurable mechanical products is important. Summarizing related significant innovation research and application achievements periodically will shed light on research directions and promote academic exchanges. This paper presents an overview of recent developments in innovation design of reconfigurable mechanisms in China, including metamorphic and origami mechanisms and their typical applications. The future development trends are analyzed and forecasted.

关键词： innovation design reconfigurable mechanisms metamorphic mechanisms origami-derived mechanisms development trends

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Distributed flexible reconfigurable condition monitoring and diagnosis technology

HU You-min, YANG Shu-zi, DU Run-sheng

《机械工程前沿（英文）》 2006年第1卷第3期页码 276-281 doi: 10.1007/s11465-006-0025-z

摘要： As manufacturing becomes increasingly decentralized, flexible and reconfigurable, more research needs to be done on monitoring and diagnosis technology that accommodate these new trends. The distributed condition monitoring and diagnosis technology based on the flexible and reconfigurable concept is studied here. A condition monitoring diagnosis model based on the distributed flexible and reconfigurable idea is proposed in this paper. The component makeup and functions of this model are discussed in detail. The model can fulfill in most instances the manufacturing system requirements for changing the configuration of the monitoring diagnosis system according to different manufacturing system configurations. This model also realizes the flexibility and reconfigurability of the monitoring diagnosis system in some degree. The model has already spawned a successful prototype for monitoring a chemical plant in accomplishing monitoring and control of the production process and equipment. Finally, some future research work is pointed out.

关键词： chemical diagnosis system configuration monitoring equipment

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Modular structure of a self-reconfigurable robot

FEI Yanqiong, DONG Qinglei, ZHAO Xifang

《机械工程前沿（英文）》 2007年第2卷第1期页码 116-119 doi: 10.1007/s11465-007-0020-z

摘要： This paper proposes a novel, hermaphroditic, and lattice self-reconfigurable modular robot. Each module is composed of a center body a cubic part and six sides that can rotate independently. There are two holes and two extensible pegs on each side. The rotary motion of each side and the extensible motion of the pegs are generated by a motor connected to a reducer, using a cone-shaped gear, belt, clutch, etc. The structure of the module is compact, and has space to extend further.

关键词： compact self-reconfigurable modular hermaphroditic cone-shaped clutch

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Exploring self-organization and self-adaption for smart manufacturing complex networks

《工程管理前沿（英文）》 2023年第10卷第2期页码 206-222 doi: 10.1007/s42524-022-0225-1

摘要： Trends toward the globalization of the manufacturing industry and the increasing demands for small-batch, short-cycle, and highly customized products result in complexities and fluctuations in both external and internal manufacturing environments, which poses great challenges to manufacturing enterprises. Fortunately, recent advances in the Industrial Internet of Things (IIoT) and the widespread use of embedded processors and sensors in factories enable collecting real-time manufacturing status data and building cyber–physical systems for smart, flexible, and resilient manufacturing systems. In this context, this paper investigates the mechanisms and methodology of self-organization and self-adaption to tackle exceptions and disturbances in discrete manufacturing processes. Specifically, a general model of smart manufacturing complex networks is constructed using scale-free networks to interconnect heterogeneous manufacturing resources represented by network vertices at multiple levels. Moreover, the capabilities of physical manufacturing resources are encapsulated into virtual manufacturing services using cloud technology, which can be added to or removed from the networks in a plug-and-play manner. Materials, information, and financial assets are passed through interactive links across the networks. Subsequently, analytical target cascading is used to formulate the processes of self-organizing optimal configuration and self-adaptive collaborative control for multilevel key manufacturing resources while particle swarm optimization is used to solve local problems on network vertices. Consequently, an industrial case based on a Chinese engine factory demonstrates the feasibility and efficiency of the proposed model and method in handling typical exceptions. The simulation results show that the proposed mechanism and method outperform the event-triggered rescheduling method, reducing manufacturing cost, manufacturing time, waiting time, and energy consumption, with reasonable computational time. This work potentially enables managers and practitioners to implement active perception, active response, self-organization, and self-adaption solutions in discrete manufacturing enterprises.

关键词： cyber–physical systems Industrial Internet of Things smart manufacturing complex networks self-organization and self-adaption analytical target cascading collaborative optimization

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Module-based method for design and analysis of reconfigurable parallel robots

Fengfeng XI, Yuwen LI, Hongbo WANG

《机械工程前沿（英文）》 2011年第6卷第2期页码 151-159 doi: 10.1007/s11465-011-0121-6

摘要：

This paper presents a method for the design and analysis of reconfigurable parallel robots. The inherent modularity in a parallel robot lends itself as a natural candidate for reconfiguration. By taking the branches as building blocks, many modular parallel robots can be constructed, from which a reconfigurable parallel robot can be realized. Among three types of reconfigurations, namely, geometry morphing, topology morphing, and group morphing, the method presented here is for the last two reconfigurations, thereby advancing the current research that is mainly limited to geometry morphing. It is shown that the module-based method not only provides a systematic way of designing a reconfigurable parallel robot, but also offers a unified modeling for robot analysis. Two examples are provided, one showing the topology morphing and the other showing the group morphing.

关键词： reconfigurable parallel robot topology morphing group morphing

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Generation of closed-form inverse kinematics for reconfigurable robots

ZHAO Jie, WANG Weizhong, GAO Yongsheng, CAI Hegao

《机械工程前沿（英文）》 2008年第3卷第1期页码 91-96 doi: 10.1007/s11465-008-0013-6

摘要： For reconfigurable robots, the automatic generation of inverse kinematics is a key problem, because such robots may assume various configurations. In this paper, the screw and product-of-exponentials (POE) formula are used to model the kinematics of reconfigurable robots. The POE formula can be converted to canonical subproblems through decomposition and adjoint transformation. Three classes and 28 types of subproblems containing geometric or algebraic solutions are identified and solved, which can be reused in different configurations. A generalized, decomposable, and reusable approach for close-form inverse kinematics of reconfigurable robots is developed based on POE and subproblems. The effectiveness of this method is shown in an example.

关键词： different effectiveness generation reconfigurable algebraic

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流程工业制造系统智能化——人工智能与流程制造深度融合

钱锋

《工程（英文）》 2019年第5卷第6期页码 981-981 doi: 10.1016/j.eng.2019.10.002

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流程工业智能制造展望：过程系统工程师面临的挑战

Lockhart Bogle Ian David

《工程（英文）》 2017年第3卷第2期页码 161-165 doi: 10.1016/J.ENG.2017.02.003

摘要：

本文讨论了流程工业智能制造对过程系统工程(PSE) 研究人员提出的挑战。现有的研究在实现全厂和全站点优化方面已经取得了很大进展，进行基准化测试能够增加说服力。本文进一步讨论了过程系统工程师在开发可用工具和技术时遇到的技术性挑战，包括灵活性和不确定性，响应性和敏捷性，鲁棒性和安全性，混合物性质和功能的预测，以及新的建模和数学范式。利用大数据进行智能化开发来驱动系统灵活性需要面对新的挑战，例如，如何在漫长又复杂的供应链中确保数据的一致性和机密性。建模方面也存在很多挑战，涉及如何对所有的关键技术进行恰当的建模，特别是健康、安全和环境方面，需要在特定地点对微小却关键的量进行准确预测。对环境方面的关注要求我们紧密跟踪所有的分子种类，以便于它们能被最佳地用于创造可持续的解决方案。而源自于新型个性化产品的破坏性商业模式对环境的影响则难以预测。

关键词：智能制造过程系统工程不确定性灵活性优化基于模型的控制

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Dimensional synthesis of a novel 5-DOF reconfigurable hybrid perfusion manipulator for large-scale spherical

Hui YANG, Hairong FANG, Yuefa FANG, Xiangyun LI

《机械工程前沿（英文）》 2021年第16卷第1期页码 46-60 doi: 10.1007/s11465-020-0606-2

摘要： A novel hybrid perfusion manipulator (HPM) with five degrees of freedom (DOFs) is introduced by combining the 5PUS-PRPU (P, R, U and S represent prismatic, revolute, universal and spherical joint, respectively) parallel mechanism with the 5PRR reconfigurable base to enhance the perfusion efficiency of the large-scale spherical honeycomb thermal protection layer. This study mainly presents the dimensional synthesis of the proposed HPM. First, the inverse kinematics, including the analytic expression of the rotation angles of the U joint in the PUS limb, is obtained, and mobility analysis is conducted based on screw theory. The Jacobian matrix of 5PUS-PRPU is also determined with screw theory and used for the establishment of the objective function. Second, a global and comprehensive objective function (GCOF) is proposed to represent the Jacobian matrix’s condition number. With the genetic algorithm, dimensional synthesis is conducted by minimizing GCOF subject to the given variable constraints. The values of the designed variables corresponding to different configurations of the reconfigurable base are then obtained. Lastly, the optimal structure parameters of the proposed 5-DOF HPM are determined. Results show that the HPM with the optimized parameters has an enlarged orientation workspace, and the maximum angle of the reconfigurable base is decreased, which is conducive to improving the overall stiffness of HPM.

关键词： 5-DOF hybrid manipulator reconfigurable base large workspace dimensional synthesis optimal design

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对工业4.0背景下的智能制造的回顾

钟润阳, 徐旬, Eberhard Klotz, Stephen T. Newman

《工程（英文）》 2017年第3卷第5期页码 616-630 doi: 10.1016/J.ENG.2017.05.015

摘要：

作为新一代工业模式的工业4.0旨在提升生产灵活性，也将继续提高企业生产效率，保证更高的产品质量以及培养承担大规模定制的能力。因此，它能够使企业在短时间内生产出更高质量的产品，以应对日益个性化的产品带来的挑战。在工业4.0模式中，智能制造发挥着重要的作用。典型的资源被转换成智能实体，以便它们能够在智能环境中感知、行动和行为。为了能充分理解在在工业4.0背景下的智能制造，本文对智能制造、物联网（IoT）支持制造和云制造等相关课题进行了综合评述，在我们已有的分析基础上对其中的相似之处和不同点进行了重点探讨。在文中我们还回顾了一些用于实现智能制造的关键技术，如物联网、网络物理系统（CPS)、云计算、大数据分析（BDA）以及信息和通信技术（ICT）。之后我们将介绍全球智能制造业的发展动向，包括来自不同国家的政府战略计划以及来自欧盟、美国、日本和中国的主要跨国公司的战略计划。最后，我们提出其当前所面临的挑战和未来的研究方向。本文所讨论的概念将为实现备受期待的第四次工业革命带来新的思路。

关键词：智能制造工业4.0 物联网制造系统物理信息系统