A review on stress determination and control in metal-based additive manufacturing

Metal additive manufacturing(MAM)is an emerging and disruptive technology that builds three-dimensional(3D)components by adding layer-upon-layer of metallic materials.The complex cyclic thermal history and highly localized energy can produce large temperature gradients,which will,in turn,lead to compressive and tensile stress during the MAM process and eventually result in residual stress.Being an issue of great concern,residual stress,which can cause distortion,delamination,cracking,etc.,is considered a key mechanical quantity that affects the manufacturing quality and service performance of MAM parts.In this review paper,the ongoing work in the field of residual stress determination and control for MAM is described with a particular emphasis on the experimental measurement/control methods and numerical models.We also provide insight on what still requires to be achieved and the research opportunities and challenges.

A HybridManufacturing ProcessMonitoringMethod Using Stacked Gated Recurrent Unit and Random Forest

This study proposed a new real-time manufacturing process monitoring method to monitor and detect process shifts in manufacturing operations.Since real-time production process monitoring is critical in today’s smart manufacturing.The more robust the monitoring model,the more reliable a process is to be under control.In the past,many researchers have developed real-time monitoring methods to detect process shifts early.However,thesemethods have limitations in detecting process shifts as quickly as possible and handling various data volumes and varieties.In this paper,a robust monitoring model combining Gated Recurrent Unit(GRU)and Random Forest(RF)with Real-Time Contrast(RTC)called GRU-RF-RTC was proposed to detect process shifts rapidly.The effectiveness of the proposed GRU-RF-RTC model is first evaluated using multivariate normal and nonnormal distribution datasets.Then,to prove the applicability of the proposed model in a realmanufacturing setting,the model was evaluated using real-world normal and non-normal problems.The results demonstrate that the proposed GRU-RF-RTC outperforms other methods in detecting process shifts quickly with the lowest average out-of-control run length(ARL1)in all synthesis and real-world problems under normal and non-normal cases.The experiment results on real-world problems highlight the significance of the proposed GRU-RF-RTC model in modern manufacturing process monitoring applications.The result reveals that the proposed method improves the shift detection capability by 42.14%in normal and 43.64%in gamma distribution problems.

Advances in Compact Manufacturing for Shape and Performance Controllability of Large-scale Components-A Review

Research on compact manufacturing technology for shape and performance controllability of metallic components can reanze the simplification and high-reliability of manufacturing process on the premise of satisfying the requirement of macro/micro-structure. It is not only the key paths in improving performance, saving material and energy, and green manufacturing of components used in major equipments, but also the challenging subjects in frontiers of advanced plastic forming. To provide a novel horizon for the manufacturing in the critical components is significant. Focused on the high-performance large-scale components such as bearing rings, flanges, railway wheels, thick-walled pipes, etc, the conventional processes and their developing situations are summarized. The existing problems including multi-pass heating, wasting material and energy, high cost and high-emission are discussed, and the present study unable to meet the manufacturing in high-quality components is also pointed out. Thus, the new techniques related to casting-rolling compound precise forming of rings, compact manufacturing for duplex-metal composite rings, compact manufacturing for railway wheels, and casting-extruding continuous forming of thick-walled pipes are introduced in detail, respectively. The corresponding research contents, such as casting ring blank, hot ring rolling, near solid-state pressure forming, hot extruding, are elaborated. Some findings in through-thickness microstructure evolution and mechanical properties are also presented. The components produced by the new techniques are mainly characterized by fine and homogeneous grains. Moreover, the possible directions for fin＇ther development of those techniques are suggested. Finally, the key scientific problems are first proposed. All of these results and conclusions have reference value and guiding significance for the integrated control of shape and performance in advanced compact manufacturing.

Role of laser scan strategies in defect control,microstructural evolution and mechanical properties of steel matrix composites prepared by laser additive manufacturing

Steel matrix composites(SMCs)reinforced with WC particles were fabricated via selective laser melting(SLM)by employing various laser scan strategies.A detailed relationship between the SLM strategies,defect formation,microstructural evolution,and mechanical properties of SMCs was established.The laser scan strategies can be manipulated to deliberately alter the thermal history of SMC during SLM processing.Particularly,the involved thermal cycling,which encompassed multiple layers,strongly affected the processing quality of SMCs.Sshaped scan sequence combined with interlayer offset and orthogonal stagger mode can effectively eliminate the metallurgical defects and retained austenite within the produced SMCs.However,due to large thermal stress,microcracks that were perpendicular to the building direction formed within the SMCs.By employing the checkerboard filling(CBF)hatching mode,the thermal stress arising during SLM can be significantly reduced,thus preventing the evolution of interlayer microcracks.The compressive properties of fabricated SMCs can be tailored at a high compressive strength(~3031.5 MPa)and fracture strain(~24.8%)by adopting the CBF hatching mode combined with the optimized scan sequence and stagger mode.This study demonstrates great feasibility in tuning the mechanical properties of SLM-fabricated SMCs without varying the set energy input,e.g.,laser power and scanning speed.

Research on Technological Process Control Model of Reverse Logistics in Manufacturing System

This paper has found out some important input factors of reverse logistics in manufacturing system throuth analysis and summary,and established four kinds of technological process control models of reverse logistics in manufacturing system according to different processing methods. These models embed each other that form a cubic control system of reverse logistics.

Deadlock-free Supervisor Design for Robotic Manufacturing Cells With Uncontrollable and Unobservable Events

In this paper,a deadlock prevention policy for robotic manufacturing cells with uncontrollable and unobservable events is proposed based on a Petri net formalism.First,a Petri net for the deadlock control of such systems is defined.Its admissible markings and first-met inadmissible markings(FIMs)are introduced.Next,place invariants are designed via an integer linear program(ILP)to survive all admissible markings and prohibit all FIMs,keeping the underlying system from reaching deadlocks,livelocks,bad markings,and the markings that may evolve into them by firing uncontrollable transitions.ILP also ensures that the obtained deadlock-free supervisor does not observe any unobservable transition.In addition,the supervisor is guaranteed to be admissible and structurally minimal in terms of both control places and added arcs.The condition under which the supervisor is maximally permissive in behavior is given.Finally,experimental results with the proposed method and existing ones are given to show its effectiveness.

Fluid-driven artificialmuscles: bio-design, manufacturing, sensing, control, and applications

Developing artificial muscles that can replace biological muscles to accomplish various tasks iswhat we have long been aiming for.Recent advances in flexible materials and 3D printing technology greatly promote the development of artificial muscle technology.A variety of flexible material-based artificial muscles that are driven by different external stimuli,including pressure,voltage,light,magnetism,temperature,etc.,have been developed.Among these,fluid-driven artificial muscles(FAMs),which can convert the power of fluid(gas or liquid)into the force output and displacement of flexible materials,are the most widely used actuation methods for industrial robots,medical instruments,and human-assisted devices due to their simplicity,excellent safety,large actuation force,high energy efficiency,and low cost.Herein,the bio-design,manufacturing,sensing,control,and applications of FAMs are introduced,including conventional pneumatic/hydraulic artificial muscles and several innovative artificial muscles driven by functional fluids.What’s more,the challenges and future directions of FAMs are discussed.

Regulations for the Manufacture and Control of Live Poliovirus Vaccine: International Experience and China’s Path

The eradication of poliomyelitis is a landmark achievement in the history of public health, providing strong protection for children’s health. The introduction of the Chinese Regulations for the Manufacture and Control of Live Poliovirus Vaccine is a prerequisite and safeguard for the large-scale production and use of domestically produced live poliovirus vaccines, serving as an indispensable component of vaccine safety. This article, based on archival documents, letters, collections of essays, and oral interviews, examines the historical experience of the development of Chinese Regulations for the Manufacture and Control of Live Poliovirus Vaccine. It contends that the emphasis on localization and the active engagement in international cooperation are critical factors in the swift introduction of Chinese Regulations for the Manufacture and Control of Live Poliovirus Vaccine.

Optimal Production Control of Hybrid Manufacturing/Remanufacturing Failure-Prone Systems under Diffusion-Type Demand

The problem of production control for a hybrid manufacturing/remanufacturing system under uncertainty is analyzed. Two sources of uncertainty are considered: machines are subject to random breakdowns and repairs, and demand level is modeled as a diffusion type stochastic process. Contrary to most of studies where the demand level is considered constant and fewer results where the demand is modeled as a Poisson process with few discrete levels and exponentially distributed switching time, the demand is modeled here as a diffusion type process. In particular Wiener and Ornstein-Uhlenbeck processes for cumulative demands are analyzed. We formulate the stochastic control problem and develop optimality conditions for it in the form of Hamilton-Jacobi-Bellman (HJB) partial differential equations (PDEs). We demonstrate that HJB equations are of the second order contrary to the case of constant demand rate (corresponding to the average demand in our case), where HJB equations are linear PDEs. We apply the Kushner-type finite difference scheme and the policy improvement procedure to solve HJB equations numerically and show that the optimal production policy is of hedging-point type for both demand models we have introduced, similarly to the known case of a constant demand. Obtained results allow to compute numerically the optimal production policy in hybrid manufacturing/ remanufacturing systems taking into account the demand variability, and also show that Kushner-type discrete scheme can be successfully applied for solving underlying second order HJB equations.

Development of a Simulation-Based Intelligent Decision Support System for the Adaptive Real-Time Control of Flexible Manufacturing Systems

This paper describes a simulation-based intelligent decision support system (IDSS) for real time control of a flexible manufacturing system (FMS) with machine and tool flexibility. The manufacturing processes involved in FMS are complicated since each operation may be done by several machining centers. The system design approach is built around the theory of dynamic supervisory control based on a rule-based expert system. The paper considers flexibility in operation assignment and scheduling of multi-purpose machining centers which have different tools with their own efficiency. The architecture of the proposed controller consists of a simulator module coordinated with an IDSS via a real time event handler for implementing inter-process synchronization. The controller’s performance is validated by benchmark test problem.

Control for Intelligent Manufacturing： A Multiscale Challenge

《中国制造2025》计划要求从顾客到产品等全部环节的全面自动化。这将为生产制造系统的各个环节带来巨大挑战。在未来的加工制造领域中,全部的设备和系统应当具有对控制性和适应性的感知能力和基础智能化处理的能力。在研究中,经过关于多尺度动力学在现代加工制造系统中应用的讨论后,一个五层的功能结构被用于不确定的加工制造过程。多尺度力学包括:多时间尺度、多时空尺度以及多尺度的动力学标准。随着快速与慢速的时间尺度对设计的更多要求,不同的尺度所对应的不同控制行为也将呈现区分化。低速时间尺度下的操作需要更多的定量化手段,与此同时,高速时间尺度下的监管也需要更多高质量的手段。智能生产系统应当拥有灵活应变的能力、较好的适应能力及足够的智能化程度。这些能力需要我们通过控制性手段进行区分化处理并应用在不同方面,如智能感知、优化设计、智能学习等。最后,将一个典型的喷射点胶系统模型用于多尺度建模和控制。

Integrated Product and Process Control for Sustainable Semiconductor Manufacturing

半导体制造是有几百复杂单位操作和它的一个生产序列被策略开发总是为保证没有缺点的产品的收益质问。在这份报纸，通过集成产品和过程控制的先进控制策略被建立。建议多尺度的计划为协调设备控制，进程控制和产品质量控制包含三层。在上面的层，联机控制表演评价被使用减少优秀变化并且最大化全面产品表演(OPP ) 。它用作监督控制在中间的层更新进程控制器的配方。过程控制器作为指数地加权的移动一般水准(EWMA ) 被设计拒绝骚乱的 run-to-run 控制器那例如用坏的过程移动，飘移和工具，被施加到操作。在这个过程的设备个别地被控制维持它的最佳的运作的地位并且最大化全面设备有效性(OEE ) ，基于过程控制器给的集合点。建议综合控制计划的功效通过案例研究被表明，在的地方两 OPP (为产品) 并且 OEE (为设备) 被提高。

Component-based Control Software Design for Flexible Manufacturing System

A new method that designs and implements the component-based distributed & hierarchical flexible manufacturing control software is described with a component concept in this paper. The proposed method takes aim at improving the flexibility and reliability of the control system. On the basis of describing the concepts of component-based software and the distributed object technology, the architecture of the component-based software of the control system is suggested with the Common Object Request Broker Architecture (CORBA). And then, we propose a design method for component-based distributed & hierarchical flexible manufacturing control system. Finally, to verify the software design method, a prototype flexible manufacturing control system software has been implemented in Orbix 2. 3c, VC++6.0 and has been tested in connection with the physical flexible ranufacturing shop at the WuXi Professional Institute.

Study on the Architecture of Control System for Manufacturing Cells

The depiction of the agile manufacturing cell includes a synopsis of some of the change proficiencies obtained by the configuration. To achieve agile configuration, the cell control system for agile manufacturing must be rapidly and efficiently generated or modified. In this paper, the object oriented architecture is defined that supports design and implementation of highly reconfigurable control systems for agile manufacturing cells, which is composed of database objects, control objects, and resource objects, so as to reduce costs and to increase the control system's agility with respect to changing environment.

Carbon Emission Modeling and Analysis in Manufacturing Process for Numerical Control Machine Tools

Reducing carbon emissions( CEs) is the urgent demand all over the world. In order to realize the low-carbon numerical control( NC) machining, the evaluation model of a part's manufacturing carbon emission with NC machine tools was built by considering the influences of the cutting tool geometrical parameters.The manufacturing CEs were produced by electric power,cutting tools,and cutting fluid consumed in manufacturing process. The parameters of cutting tools affected not only the CEs,but also the machining quality. Then the actual constraint models of the machine performance,machining quality were given in order to optimize the cutting parameters and achieve the low-CEs. Finally,a case was given to analyze the influences of the cutting tool angles on the manufacturing CEs. The results show that the CEs decrease as the rake angle and edge angle increase under the constraints of the machine specifications and machining quality.

Management and Control of Outsourcing in Dispersed Network Manufacturing Systems

The trend of economic globalisation and advances in i nformation technology has led to the emergence of dispersed manufacturing system s as a form of the virtual organisation. New manufacturing strategy pays more at tention to the management of the total value chain and therefore puts emphasis o n outsourcing. In fact, outsourcing is an efficient way of utilizing available r esources and has become one key aspect of the manufacturing strategy. Improved d ecision and organization on outsourcing will result in cost production and short er lead-times. However, most concepts and practice of traditional outsourcing do not adapt to t he changing environment and meet increasing performance requirements. On the oth er hand, virtual organisations might display instability between pure outsourcin g and establishing alliance. Balance and trade-off between independent agents a nd creating alliance are thus required. Therefore, the purpose of this paper is to develop a model to support decision-making, management and control on outsou rcing in a dispersed network manufacturing system and to discuss several key iss ues that are relevant to the relationship between the agents of the network. Dev elopment of the model will deploy Applied System Theory and will be built on fou ndations of earlier research on industrial management such the theories of Outso urcing, Order Entry Points, Design of Organisations and Logistic Control. The is sues that will be addressed in this paper are: · The selection of suppliers and co-makers; · Communication between suppliers and clients; · The mechanisms for profit-sharing between agents; · The product data management to integrate the knowledge of the different agent s into product design. Industrial companies will benefit from this research by the practical methods an d implementation extending their business models beyond concepts for outsourcing and alliances. Additionally, the exploration will lead to proactive contributio n of manufacturing during engineering, which would improve management and contro l of dispersed manufacturing systems.

Agent-Based Synthesis of Distributed Controllers for Discrete Manufacturing Systems

A method for designing real-time distributed controllers of discrete manufacturing systems is presented. The approach held is agent based;the controller strategy is distributed into several interacting agents that operate each one on a part of the manufacturing process;these agents may be distributed into several interconnected processors. The proposed method consists of a modelling methodology and software development framework that provides a generic agent architecture and communication facilities supporting the interaction among agents.

Implementation of Hierarchical and Distributed Control for Discrete Event Robotic Manufacturing Systems

The large scale and complex manufacturing systems have a hierarchical structure where a system is composed several lines with some stations and each station also have several machines and so on. In such a hierarchical structure, the controllers are geographically distributed according to their physical structure. So it is desirable to realize the hierarchical and distributed control. In this paper, a methodology is presented using Petri nets for hierarchical and distributed control. The Petri net representation of discrete event manufacturing processes is decomposed and distributed into the machine controllers, which are coordinated through communication between the coordinator and machine controllers so that the decomposed transitions fire at the same time. Implementation of a hierarchical and distributed control system is described for an example robotic manufacturing system. The demonstrations show that the proposed system can be used as an effective tool for consistent modeling and control of large and complex manufacturing systems.

APPLICATION OF IMPROVED PRODUCTION ACTIVITY CONTROL ARCHITECTURE FOR SHOP FLOOR INFORMATION SYSTEM IN DIGITAL MANUFACTURING

Shop floor control （SFC） is responsible for the coordination and control of the manufacturing physical and information flow within the shop floor in the manufacturing system. Weaknesses of the production activity control （PAC） architecture of the shop floor are addressed by the Maglica＇s new system architecture. This architecture gives rise to unlimited number of movers and producers thus evolving more complex but decentralized architecture. Beijing Institute of Technology - production activity control （BIT-PAC） architecture introduces an idea of sub-producars and sub-movers thus reducing the complexity of the architecture. All the equipments including sub-producars and sub-movers are considered to be passive in the proposed shop floor information system. The dissemination of information from sub-producers and sub-movers is done manually through a PC. Proposed BIT-PAC SFC architecture facilitates the information flow from shop floor to the other area of the organization. Effective use of interact information services （IIS） and SQL2000 is done along with the ASP.NET technology to implement the application logic. Applicability of the software based on BIT-PAC architecture is checked by running application software on a network PC that supports the dynamic flow of information from sub-producers and sub-movers to the other parts of the organization. Use of software is also shown at the end for BIT training workshop thus supporting the use of SFC architecture for similar kind of environments.

Investigation on Occupational Disease Inductive Factors ofA utomobile Manufacturing Enterprises and Evaluation of Control Effect

The automobile manufacturing industry has a complex process and various processes,so it has buried many occupational-disease-related safety hazards and is the industry of high incidence of occupational diseases.Accurate identification and effective control of hazards in automobile manufacturing are an important guarantee for effective prevention of occupational disease.In order to investigate the types and status of occupational-disease-inductive factors of a car manufacturer,and evaluate the control effect,the general situation of the enterprise is collected from August 2016 to October 2017.And then the targeted treatment,including management measures,engineering protection and personal protection.The occupational-disease-inductive factors that are mainly produced in automobile manufacturing are productive dust,chemical substance and physical factors.