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CAD/CAM Robotics and Factories of the Future '90
Suren N. Dwivedi Alak K. Verma J ahn E. Sneckenberger Editors
CADjCAM Robotics and Factories of the Future '90 Volume 2: Flexible Automation
5th International Conference on CAD/CAM, Robotics and Factories of the Future (CARS and FOF'90) Proceedings
International Society for Productivity Enhancement
With 245 Figures
Springer-Verlag Berlin Heidelberg GmbH
Suren N. Dwivedi Department of Mechanical and
Aerospace Engineering West Virginia University Morgantown, WV 26506-6101 USA
lohn E. Sneckenberger Concurrent Engineering Research Center West Virginia University Morgantown, WV 26506 USA
Alok K. Verma Chairman Department of Mechanical Engineering Technology Old Dominion University Norfolk, VA 23508 USA
Library of Congress Cataloging-in-Publication Data International Conference on CAD/CAM, Robotics, and Factories of the
Future (5th: 1990: Norfolk, VA.) CAD/CAM, robotics, and factories of the future: 5th International
Conference on CAD/CAM, Robotics, and Factories ofthe Future (CARS and FOF'90) proceedings /S.N. Dwivedi, Alok Verma, lohn Sneckenberger.
p. cm. "International Society for Productivity Enhancement." Includes bibliographical references. Contents: v. I. Concurrent engineering-v. 2. Flexible
automation. ISBN 978-3-642-63504-5 ISBN 978-3-642-58214-1 (eBook) DOI 10.1007/978-3-642-58214-1
l. CAD/CAM systems-Congresses. 2. Flexible manufacturing systems-Congresses. 3. Robotics-Congresses. 4. Manufacturing processes-Automation-Congresses. I. Dwivedi, Suren N. Ir. Verma, Alok. III. Sneckenberger, lohn. IV. International Society for Productivity Enhancement. V. Title. TSI55.6.I58181990 670.42'7-dc20 90-19478
Printed on acid-free paper.
© 1991 by Springer-Verlag Berlin Heidelberg Originally published by Springer-Verlag Berlin Heidelberg New Y ork in 1991 Softcover reprint of the hardcover 1 st edition 1991 This work is subject to copyright. All rights are reserved, whether the whole or part of the material is concerned, specifically the rights of translation, reprinting, reuse of illustrations, recitation, broadcasting, reproduction on microfilms or in other ways, and storage in data banks. Duplication of this publication or parts thereof is only permitted under the provisions of the German Copyright Law of September 9, 1965, in its version ofJune 24, 1985, and a copyright fee must always be paid. Violations fall under the prosecution act of the German Copyright Law. The use of general descriptive names, trade names, trademarks, etc., in this publication, even if the former are not especially identified, is not to be taken as a sign that such names, as understood by the Trade Marks and Merchandise Act, may accordingly be used freely by anyone.
Camera-ready prepared by the editors.
987654321
ISBN 978-3-642-63504-5
Conference Objective
The last decade has seen the emergence of a unified approach for product design which attempts to combine traditionally distinct tasks like design, management, marketing, analysis, manufacture and materials. Often called "Concurrent Engineering" or "Simultaneous Engineering", this new philosophy aims at improving cost competitiveness by reducing waste of time, money, and other resources inherent in the iterative traditional methods. In view of the importance of this new philosophy, Concurrent Engineering is selected as the theme for this conference.
The main objective of the conference is to bring together researchers and practitioners from government, industries and academia interested in the multidisciplinary and inter-organizational productivity aspects of advanced manufacturing systems utilizing CAD/CAM, CAE, CIM, Parametric Technology, AI, Robotics, AGV Technology, etc.
Conference Organization
Sponsors
International Society for Productivity Enhancement (ISPE), USA
Center for Innovative Technology, Virginia, USA
Old Dominion University, Norfolk, Virginia, USA
Concurrent Engineering Research Center (CERC) West Virginia University, West Virginia, USA
Department of Mechanical and Aerospace Engineering, West Virginia University, West Virginia, USA
Committee Chairpersons
Conference General Chairperson: Alok K. Verma, Old Dominion University, USA.
Conference co-chairs: Suren N. Dwivedi, West Virginia University, USA. Gary Crossman, Old Dominion University, USA.
Program Chairpersons: John Sneckenberger, West Virginia University, USA.
Technical Chairperson: Virendra Kumar, General Electric, USA.
International Chairperson: Jean Marie Proth, INRIA, France.
Reception Chairperson: John. M. Jeffords, Old Dominion University, USA.
Workshop Chairpersons: Stewart Shen, Old Dominion University, USA. Bharat Thacker, Universal Computer Services, USA. Sumitra Reddy, CERC, West Virginia University, USA. Hal Schall, Ford Motor Co., Dearborn, USA.
Printing and Publication Chairperson: Sacha ria Albin, Old Dominion University, USA.
Abstract and Paper Review Chairperson: Jean Hou, Old Dominion University, USA. Resit Unal, Old Dominion University, USA.
University Chairperson: Robert Ash, Old Dominion University, USA.
Industrial Chairpersons: Gary Crossman, Old Dominion University, USA. Larry Richards, Old Dominion University, USA.
Plenary Chairperson: Suren N. Dwivedi, West Virginia University, USA.
Exhibit Chairperson: Thomas Houlihan, Jonathan Corporation, USA.
Student Chairpersons: Drew Landman, Old Dominion University, USA. Francis M. Williams, Old Dominion University, USA.
International Coordinators
H. Bera (U.K.) M. Dominguez (Spain) K. Ghosh (Canada) V.M. Ponomaryov (USSR) J.M. Proth (France) R. Sagar (India) T.-P. Wang (Taiwan) T. Yamashita (Japan)
vii
Committee Rosters
Abstract and Paper Review Committee
Dr. Ralph Wood Dr. John Spears Dr. Cheng Y. Lin Dr. Duc Nguyen Dr. Nageswara Rao
Program Committee
Donald W. Lyons John Sneckenberger Suren N. Dwivedi Sumitra Reddy Larry Banta John Hackworth Bob Creese B. Gopalkrishnan Waeik Iskander Bruce Kang Ken Means Jacky Prucz Nithi Sivaneri Emil Steinhardt
Editorial Board and Publication Committee
Donald W. Lyons Ralph Wood John Spears William Bentley Zenon Kulpa Michael Sobolewski Sati Maharaj Sisir Padhy BinDu Prashanth Murthy Deepak Kohli Dandamudi Venugopal Dhananjay Salunke
Industrial Committee
Thomas Houlihan Moustafa R. Moustafa Ed Wilson Jim Fox Larry Wilson
Reception Committee
Taj Mohieldin Linda Vahala Nancy Short
Professional Relations Committee
John Jurewicz Donald W. Lyons Ramana Reddy Ralph Wood Biren Prasad Kumar Singh John Spears
Conference Coordinators
William Bentley Nancy Short Georgette Ingram
Conference Staff
Sati Maharaj Robin Johnson Joette Claiborne Marylin Host Indira Dwivedi Iva Dwivedi Fern Wood Vicki Grim Pat Logar Jean Shellito
ix
Letter from the President, ISPE The International Society for Productivity Enhancement (ISPE) is
entering its seventh year. The Conference you are attending is our fifth of the international series on CAD/CAM, Robotics and Factories of the Future (CARS & FOF). The fourth conference was held at the Indian Institute of Technology, New Delhi, India in 1989. During the past seven years, we have expanded our activities significantly. The membership interest and international participation are also growing. During the past year alone, the Society has made tremendous progress in the following major frontiers:
J 0 URN A L: The Society now has its own journal entitled The International lournal of Systems automation Research and diJplications (SARA), an international, multidisciplinary research and applications-oriented journal to promote a better understanding of systems considerations in interdisciplinary automation using computers. The Journal contains important reading for design, engineering, and manufacturing persons as well as those with interest in research and development and applications of productivity tools, concepts and strategies to multidisciplinary systems environments. The Journal will only publish original, quality papers. To receive more information about this Journal, write to: Editor-in-Chief, ISPE, SARA Journal Department, P.O. Box 731, Bloomfield Hills, Michigan 48303-0731.
PROCEEDINGS: Starting this year (with the Fifth Conference), the Society is now making the Conference Proceedings available at the Conference. Selected papers from this Proceedings will also be considered for publication in SARA.
CONFERENCES: ISPE's annual conferences are now book until 1994. The Sixth International Conference will take place at South Bank Polytechnic, London from August 19-21, 1991. The Seventh and Eight International Conferences will be held in Leningrad, USSR and France, respectively.
COOPERATIVE PROGRAMS: In 1989, ISPE started a new cooperative program called the Indo-U.S. Forum for Cooperative Research and Technology Transfer (lFCRTT) in cooperation with West Virginia University and the National Science Foundation (NSF). The first joint meeting of the IFCRTT was held from December 17-18, 1989, in New Delhi, India. The meeting attracted a large body of scholars from industry, universities, and research institutions from both the United States and India. Similar cooperative programs are being arranged in the U.K., U.S.S.R. and France.
xii
As you can see, we have made great strides, but significant changes are taking place in the manufacturing sectors due to global competitiveness and economic factors. Productivity enhancement needs are even larger than before, and such needs require us to be more dynamic and resourceful. ISPE is looking for a few good people to take leadership positions in its organization and committees for sponsored events. If you would like to help us build our technical program or if you would like to work on ideas of your own, please write to us. There are openings in the following areas:
* SARA Journal - Readers' Committee * Productivity Directors * Workshop and Tutorial Organizers * CARS & FOF Conferences: University, Industry, International
Representatives, Session Organizers, and Technical and Program Chairpersons.
We are still a very young organization and your leadership can play a significant role. Please do not hesitate to write us with your ideas and opinions.
Biren Prasad, Ph.D. ISPE, P.O. Box 731, Bloomfield Hills, MI 48303-0731, USA.
Acknowledgments
The Fifth International Conference on CAD/CAM, Robotics, and Factories of the Future (Cars & FOF '90) was hosted by the College of Engineering and Technology at Old Dominion University and was endorsed by more than ten societies, associations, and international organizations. The conference was held in Norfolk, Virginia at the Omni International Hotel from December 2-5, 1990. Over 200 presentations organized into 40 specialty sessions, three plenary sessions, and eight workshops were conducted during the four days. Authors, plenary session speakers, and participants from 17 different countries around the world converged in Norfolk for this Conference. In view of the ever-increasing importance for integrating different facets of manufacturing with design process, the organizing committee selected "Concurrent Engineering" as the theme of the Conference.
I wish to acknowledge, with many thanks, the contributions of all the authors who presented their work at the Conference and submitted the manuscripts for publication. It is also my pleasure to acknowledge the role of banquet, luncheon, and plenary session speakers who shared their vision of the manufacturing industry and issues related to productivity. My sincere thanks to the session organizers, session chairs, and members of the Organizing Committee both at Old Dominion University and West Virginia University without whose cooperation this Conference would not be possible. Thanks are due to Ms. Georgette Ingram and other staff members in the MET Department for their patience and hard work. Financial support from the Center for Innovative Technology and industrial sponsors also made this Conference possible.
I acknowledge, with gratitude, the help and support received from Dr. James V. Kock, President, and Dr. Ernest J. Cross, Dean of the College of Engineering and Technology at Old Dominion University. From West Virginia University, I thank Dr. Donald W. Lyons, Chairman, MAE Department, for his support; Drs. Ralph Wood and John Spears for their help in reviewing conference papers and for allowing us to use the facilities of the Concurrent Engineering Research Center; and Ms. Sati Maharaj for her assistance in coordinating the conference. In addition, I extend my deepest gratitude to Dr. Suren N. Dwivedi for providing me with support and encouragement in organizing this conference. Furthermore, I express my sincere thanks to all my colleagues,friends, student volunteers, and family members who extended their help in organizing this conference.
I also acknowledge with great appreciation the excellent work done by Springer-Verlag in publishing both volumes of the proceedings.
Alok K. Verma Conference General Chairperson
Preface
Flexibility is as acceptable an objective for today's industrial community as is automation. Thus, the title of this conference proceedings volume -Flexible Automation - reflects an added emphasis to the usual industrial automation. As with general automation that has impacted every component of the manufacturing office and plant, the identity of flexible automation can possess various forms and functions.
The papers in this volume have been grouped into two main categories. One category deals with implementation of so-called "intelligent manufacturing". This means use of algorithmic methods and artificial intelligence approaches to various problems encountered in practical factory automation tasks. The placement of papers into five chapters of this part cannot be very precise, due to multidisciplinary nature and constant rapid change of the field. The categories are arranged starting from problems of enhancement of current factory settings, and followed by the papers addressing more specific issues of production planning, process technology and product engineering. The fifth chapter contains papers on the very important aspects of factory automation - problems of design, simulation, operation and monitoring of manufacturing cells.
In the second category, papers dealing with practical developments in applied automation, especially robotics, have been grouped. The section starts from a parade of industrial applications of robotics, proceeding then to task performance analysis. The specific problems of robotics, namely motion specification and manipulator mechanics are thoroughly covered by the papers in next two chapters. The final chapter groups four papers addressing the topic of engineering education and training in the field of automated manufacturing - a problem of considerable importance to preapare people so that the idea of "factories of the future" may become a reality.
Suren N. Dwivedi
Contents, Volume 2
Conference Objective ................................................................ v
Conference Organization.............................................. ............. VI
Committee Rosters........................................ ... ......................... VIll
Letter from the President, ISPE................................................. xi
Acknowledgments ..................................................................... xiii
Preface....................................................................................... xv
Section A: Implementation of Intelligent Manufacturing
Chapter I: Factory Enhancements ............................................. 1
Introduction............... .... ...... ............. ......... ......... ... ...... .... ..... ......... .... ....... 1
From the Existing Manufacturing System to CIM D.S. LVOV, E.I. ZAK, and YU.M. ZYBAREV............................................. 3
Flexible Manufacturing System in Manufacture of Precision Engineering Components - Key Issues in Implementation
V.K. GUPTA and R. SAGAR......................................................................... 9
A Survey of CIM Strategic Planning in U.S. Industry MARK D. PARDUE and FREDERICK 1. MICHEL..................................... 19
Modelling and Optimization of a Flexible Manufacturing System R.N. CHAVALI, S. KESWANI, and S.c. BOSE........................................... 25
Computer Based Safety System for the FMS - Management Logic C.F. MARCIOLLI........................................................................................... 31
CIM Repositories H. T. GORANSON.......................................................................................... 45
The Selection and Prospect of CAD/CAM System for Diesel Engine Design and Manufacturing
GU ZE-TONG and HU GANG....................................................................... 56
A Model for the Factory of the Future for Industrialized Housing AHMAD K. ELSHENNAWY, MICHAELA. MULLENS, WILLIAM W. SWART, and SUBRATO CHANDRA .................................. 62
Enabling Automation Technologies for an Automated Mail Facility of the Future
JAY LEE and GARY HERRING.................................................................... 71
Some Optimization Problems of Scheduling in a Flexible Manufacturing System
TOMASZ AMBROZIAK................................................................................ 77
Some Methods of Modeling for Computer Integrated Workshop V.N. KALACHEVand YE.N. KHOBOTOV................................................. 83
Combined Procedures for Simulation of Manufacturing Systems SUREN N. DWIVEDI and YE.N. KHOBOTOV ........................................... 88
Expert Systems in CIM V.M. PONOMARYOV, V.V. IVANISTCHEV, AA LESKIN, and N.N. LYASHENKO................................................................................. 94
:hapter II: Production Planning ........................................ 100
Introduction .............................................................................................. 100
A Taxonomy on Event-Driven Production Systems S.S. IYENGAR, NITIN S. NAIK, and RAJENDRA SHRIVASTAVA........ 105
An Improved Lot Sizing Policy for Variable Demand M.D. SREEKUMAR, e. ESWARA REDDY, and O.V. KRISHNAlAH CHETTY ................................................................ 120
Simulation for Real-Time Control: Advantages, Potential Pitfalls, Opportunities
C.M. HARMONOSKY ................................................................................... 126
Decomposition Approach for the Job-Shop Scheduling Problem H.D. LEMON lAS and Z. BINDER ................................................................ 132
Evaluation of the Impact of Plant and Production Management Automation on Job-Shop Manufacturing Performances
M. PESSINA, A POZZETTI, and A SIANESl............................................. 138
Role of Non-Productive Time in the Evaluation of Computer Generated Process Plans
N.K. MEHTA, P.e. PANDEY, and AV.S.R.K. PRASAD............................ 144
:hapter III: Process Technology........................................ 151
Introduction .............................................................................................. 151
Computer Managed Process Planning for Cylindrical Parts AMY J. KNUTILLA and BOBBY e. PARK................................................. 153
An Application of Non-Linear Goal Programming in Electrodischarge Machining of Composite Material
M. RAMULU, H.-W. SEE, and D.H. WANG ................................................ 166
xix
An Expert System for Metalforming K. HANS RAJ and V.M. KUMAR................................................................. 173
Optimal Process Planning for Robotic Assembly Operations SHY ANGLIN LEE and HSU-PIN WANG .................................................... 179
Effect of Angular Errors in Part Registration for PC Board Assembly T. RADHAKRISHNAN .................................................................................. 185
An Evaluation Framework for AGVS Within FMS P.F. RIEL and M.S. JONES ............................................................................ 191
Computer Aided Machine Loading Technique USHIR SHAH, SAUMIL TRIVEDI, KETAN SHAH, and P.B. POPAT ...... 197
An Optimal Parallel Algorithm for Channel-Assignment STEPHEN OLARIU, JAMES L. SCHWING, and JINGYUAN ZHANG..... 203
Chapter IV: Product Engineering ....................................... 217
Introduction .............................................................................................. 217
Design Using Case-Based Reasoning COSTAS TSATSOULIS................................................................................. 219
An Interactive Programming System for Design of Mechanical Clutches B. SATYANARAYANA, K.V. MOHAN, and M. MALLIKHARJUNARAO 225
An Expert System for the Design and Selection of Ball Bearing Parameters
M.A. PATHAK and R.S. AHLUW ALIA........................................................ 231
Computer-Aided Optimal Design of Gears HUNGLIN WANG and HSU-PIN WANG .................................................... 237
CAD for Underground Structure GU HANLIANG ............................................................................................. 243
A Microcomputer Aided Design of Technical Systems W. PRZYBYLO ............................................................................. _............... 249
Solid Modeling With Tension DA-PAN CHEN .............................................................................................. 259
Integration of Design Optimization in Finite Element Analysis FRED BA.~EZ................................................................................................. 265
Automatic Generation of Finite Element Modeling for Integrated CAD and CAE
TATSUHIKO AlZAWA................................................................................. 273
Three Dimensional Mesh Generation: A New Approach M.H. KADIVAR and H. SHARIFI................................................................. 279
xx
Effective Modeling of Elastic Mechanical System Through Objective-Aimed Finite Element Strategies
V.H. MUCINO, W.G. WANG, and J.E. SMITH............................................ 285
Design and Evaluation of Shock Isolation of Trailer Mounted Electronic Equipments
V. SUNDARARAMAN .................................................................................. 297
Chapter V: Workcell Operations ........................................ 303
Introduction ......... ....... ........... .......... ...... ... ...... ............... ........... .... ............ 303
Group Technology: Cell Formation Using Simulated Annealing J.M. PROTH .................................................................................................... 305
Cost Considerations for Cell Design in Group Technology KENNETH R. CURRIE.................................................................................. 311
Application of CAD/CAM in the Textile Industry P.B. JHALA .................................................................................................... 317
CAD/CAM of Cams for Use in Automatic Lathes P.c. PANDEY, N.K. MEHTA, and AATUL WADEGAONKAR................. 323
An Objective SIMTOOL in FMS C. ESWARA REDDY, O.V. KRISHNAIAH CHETTY, and D. CHAUDHURI ..................................................................................... 329
A Methodology for Automating the Redressing of the Grinding Wheel AC.S. KUMAR and U.R.K. RAO.................................................................. 336
Experimental Investigations on Tool Vibrations in Turning for On-Line Tool Wear Monitoring
D.N. RAO, P.N. RAO, and U.R.K. RAO........................................................ 342
!1p-Based Industrial Grade Multi-Channel Temperature Controller For Sugar and Allied Industries
H. SINGH, S.M. SHARMA, and C.R.K. PRASAD........................................ 348
Use of SenSors for Safety of Personnel in Robotic Installations K. GHOSH, J.-J. PAQUES, and Y. BEAUCHAMP ............................................ 355
Section B: Developments in Applied Robotics and Automation
xxi
Chapter VI: Industrial Applications .......................................... 361
Introduction .............................................................................................. 361
Determining the Workspace Design of Robotized Cells in Pre-Determined Environments
LOUISE CLEROUX....................................................................................... 363
Judicious Selection of a Robot for an Industrial Task - An Expert System Approach
SURENDER KUMAR and ALOK VARMA ................................................. 369
Fixtureless Robotic Assembly Workcell LARRY BANTA and THOMAS BUBNICK................................................. 374
Design of a Wall-Scaling Robot for Inspection and Maintenance BEHNAM BAHR and SAMI MAARI............................................................ 381
A Telemanipulator for Hazardous Mining Operations M.R. UDAYAGIRI, T.R. RANGNATH, K.C.S. MURTY, S. RAGHUNATH, and PRAVEEN DHYANI................................................ 388
Adoption of Robotic System for Inter-Station Handling Operations for Nagpur Milk Scheme, India
J.P. MODAK, R.D. ASKHEDKAR, and A.V. PESHWE............................... 394
Integration and Realtime Monitoring of Robotic Controllers SUDHAKAR R. PAIDY and MICHAEL SHEA............................................ 400
On the Applications of Part Image Reconstruction Systems in Automated Manufacturing
SAEID MOTAVALLI and BOPAYA BIDANDA......................................... 406
Kalman Filter Application to Tridimensional Rigid Body Motion Parameter Estimation from a Sequence of Images
R. VASQUEZ and J. MA YORA..................................................................... 412
Optimization Techniques for Mathematical Routines Available through High-Level Source Code
S. ROY and A. CHAUDHURI ........................................................................ 421
Chapter VII: Task Performance ................................................ 427
Introduction .... ....... .... ......... .......... ... ..... .... .... ..... ..... ..... .... ............. ... ... ... ... 427
Sensing and Analysis of End-Effector Forces for Precision Assembly ANTHONY DE SAM LAZARO, ECHEMPATI RAGHU, and BERAT GUROCAK ................................................................................ 429
xxii
Accuracy Test From Kinematic Parameter Errors in a Closed-Loop Robot
CHENG Y. LIN, ALOK K. VERMA, and LOUIS J. EVEREIT................... 435
The Effect of Robot Kinematic Parameter Errors on Joint Torques JING TIAN and JOHN E. SNECKENBERGER ............................................ 441
Kinematic Error Budgeting to Obtain the Best Feasible Task Performance for a Specified SCARA Manipulator
TONY M. LAMB and JOHN E. SNECKENBERGER .................................. 448
Demonstrating Robot Calibration in a Manufacturing Environment KEN PFEIFFER and LOUIS J. EVERETT .................................................... 454
On-Line Robot Calibration F. TUIJNMAN and G.R. MEIJER .................................................................. 460
Expert System for Robot Hand Design Using Graph Representation M. CHEW, G.F. ISSA, and S.N.T. SHEN ...................................................... 466
Pre Grasp Pose Estimation of Objects Using Local Sensors on Dexterous Hands
V.H. PINTO, L.1. EVERETT, and M. ORIELS ............................................. 472
Chapter VIII: Motion Specification .......................................... 479
Introduction .............................................................................................. 479
Approximate and Hierarchical Path Planning NAGESWARA S.V. RAO, WENCH ENG WU, and PAl-SHAN LEE.......... 481
Bandlimited Trajectory Planning for Continuous Path Industrial Robots J.T. HUANG .................................................................................................... 487
Trajectory Planning and Kinematic Control of a Stewart Platform-Based Manipulator
CHARLES C. NGUYEN, SAMI S. ANTRAZI, and ZHEN-LEI ZHOU....... 493
Planning and Execution of Polynomial Manipulator Trajectories FRED BAREZ................................................................................................. 500
Efficient Trajectory Planning Algorithm for Coordinately Operating Multiple Robots
YUNG-PING CHIEN and QING XUE........................................................... 509
Path Planning for Coordinated Planar Robot Arms Moving in Unknown Environment
YUNG-PING CHIEN and QING XUE........................................................... 515
A Theory of Collision Avoidance on Visual Guidance of Robot Motion in Dynamic Environment
Q. ZHU and J. LIU .......................................................................................... 521
xxiii
A Collision Prediction System for a Robotic Environment NANCY SLIWA, WILLIAM BYNUM, and CHARLES WATLAND ......... 527
Multivalue Coding: Application to the Autonomous Robots A. PRUSKI ...................................................................................................... 533
Information Management for Off-Line Robot Programming H. AFSARMANESH, G.R. MEIJER, and F. TUIJNMAN ............................ 539
Chapter IX: Manipulator Mechanics ......................................... 545
Introduction ......... ..................................... ......... ............................ ..... ...... 545
Computer Aided Analysis of a Planar Robot SHAILESH SHAH and YOGESHWAR HARI.............................................. 547
Computer Aided Analysis of the First Three Links in a Puma Robot DURAISWAMI PALANIVELU and YOGESHWAR HARI ........................ 553
Work-Space Calculation of a Robotic Arm Using the Articulated Total Body Model
XAVIER J.R. A VULA, INTS KALEPS, and LOUISE OBERGEFELL ....... 559
Effect on Flexibility on Manipulator Dynamics H. ASHRAFIUON and C. NATARAJ ............................................................ 565
Dynamics of Flexible Manipulators With Application to Robotic Assembly
E. WEHRLI and P. COIFFET......................................................................... 576
Kineto-Elastodynamic Effect on the Design of Elastic Mechanisms ECHEMPATI RAGHU and A. BALASUBRAMONIAN.............................. 585
Scheme for Active Positional Correction of Robot Arms SAEED B. NIKU ............................................................................................ 590
Feedback Control of Robot End-Effector Probable Position Error Y.c. PAO and L.c. CHANG........................................................................... 594
An Intelligent Signal Recognition System T. HOU and L. LIN ......................................................................................... 600
State Estimation Under Unknown Noises - A Least-Squares Approach CHUNG-WEN CHEN and JEN-KUANG HUANG....................................... 606
Chapter X: Educational Endeavors ........................................... 613
Introduction .............................................................................................. 613
Combined EE-ME Senior Capstone Projects In Robotics at West Virginia University
NIGEL T. MIDDLETON and LARRY BANTA............................................ 615
xxiv
Automated Manufacturing at Western Kentucky University R.I. EVERSOLL, H.T. LEEPER, and L.T. ROSS .......................................... 621
Manufacturing Systems Engineering Education at the University of Pittsburgh
JOHN H. MANLEY ........................................................................................ 626
Human Factors Considerations in the Design of a Teach Pendant ALOK K. VERMA and CHENG Y. LIN........................................................ 632
Contents, Volume 1
xxvi
Conference Objective ................................................................ v
Conference Organization. ... ......... ......... ......... ......... ...... ...... ....... vi
Committee Rosters .................................................................... viii
Letter from the President, ISPE................................................. xi
Acknowledgments ........ ............ ......... ............... ...... ... ... ............. xiii
Preface....................................................................................... xv
Chapter I: General Issues .......................................................... 1
Introduction ........... .................. ... ......................... ......... ........... .......... ......... ....... 1
Concurrent Engineering: An Introduction SUREN N. DWIVEDI and MICHAEL SOBOLEWSKI................................ 3
Quality Design Engineering: The Missing Link in U.S. Competitiveness
H. BARRY BEBB........................................................................................... 17
New Activities in the Manufacturing Domain to Support the Concurrent Engineering Process
KEITH WALL and S.N. DWIVEDI ............................................................... 31
Chapter II: Intelligent Information Networks ........................... 37
Introduction .............................................................................................. 37
Artificial Intelligence in Concurrent Engineering A. KUSIAK and E. SZCZERBICKI ............................................................... 39
An Open Ended Network Architecture for Integrated Control and Manufacturing
K.C.S. MURTY and RAMESH BABU .......................................................... 49
A Data Base Inconsistency Checker for EASIE K.H. JONES, S. OLARIU, L.F. ROWELL, J.L. SCHWING, and A. WILHITE............................................................................................. 55
xxvii
Database Exchange in the CAD/CAM/CIM Arena BRUCE A. HARDING.................................................................................... 61
Formation of Machine Cells: A Fuzzy Set Approach CHUN ZHANG and HSU-PIN WANG.......................................................... 67
Design Assessment Tool DANIEL M. NICHOLS and SUMITRA REDDy.......................................... 73
Support of PCs in Concurrent Engineering NARESH C. MAHESHWARI and BRADLEY S. BENNETT...................... 80
Chapter III: Neural Network ..................................................... 87
Introduction .............................................................................................. 87
Artificial Neural Networks In Manufacturing KENNETH R. CURRIE .................................................................................. 89
Using Artificial Neural Networks For Flexible Manufacturing System Scheduling
LUIS CARLOS RABELO and SEMA ALPTEKIN ....................................... 95
Machine-Part Family Formation Using Neural Networks RAM HUGGAHALLI and CIHAN DAGLI................................................... 102
Neural Networks in Process Diagnostics SOUNDAR R.T. KUMARA and NAJWA S. MERCHA WI.......................... 108
Chapter IV: Knowledge Based Engineering ............................. 115
Introduction .............................................................................................. 115
DICEtalk: An Object-Oriented Knowledge-Based Engineering Environment
M. SOBOLEWSKI .......................................................................................... 117
Data Models of Mechanical Systems for Concurrent Design KIRK J. WU, FOOK CHOONG, and S. TWU ............................................... 123
Manufacturing Knowledge Representation Using an Object Oriented Data Model
RASHPAL S. AHLUWALIA and PING 11 .................................................... 130
Knowledge-Based Evaluation of Manufacturability SIPING LlU, VASILE R. MONTAN, and RAVI S. RAMAN....................... 136
Knowledge-Based Graphic User Interface Management Methodology STEWART N.T. SHEN and 1IH-SHIH HSU ................................................. 142
xxviii
Knowledge Augmentation Via Interactive Learning in a Path Finder Q. ZHU, D. SHI, and S. TANG....................................................................... 148
Graphical User Interface with Object-Oriented Knowledge-Based Engineering Environment
Z. KULPA, M. SOBOLEWSKI, and S.N. DWIVEDI.................................... 154
Knowledge Automation: Unifying Learning Automation and Knowledge Base
A. CHANDRAMOULI and P.S. SATSANGI ................................................ 160
Developing a Knowledge Based System for Progressive Die Design PRATYUSH KUMAR, P.N. RAO, and N.K. TEWARI ................................ 166
An Expert System Model for the Use in Some Aspects of Manufacturing
R.B. MISHRA and SUREN N. DWIVEDI ..................................................... 172
Chapter V: Feature Based Design and Manufacturing.............. 179
Introduction .............................................................................................. 179
Using a Feature Algebra in Concurrent Engineering Design and Manufacturing
RAGHU KARINTHI and DANA NAU.......................................................... 181
Feature Recognition During Design Evolution HYOWON SUH and RASHPAL S. AHLUWALIA ...................................... 187
Extraction of Manufacturing Features from an I-DEAS Universal File JONG-YUN JUNG and RASHPAL S. AHLUWALIA.................................. 193
Feature Based Design Assembly SISIR K. PADHY and SUREN N. DWIVEDI................................................ 199
Feature Based Machining Analysis and Cost Estimation for the Manufacture of Complex Geometries in Concurrent Engineering
B. GOPALAKRISHNAN and V. PANDIARAJAN ....................................... 205
Use of Part Features for Process Planning S.K. GUPTA, P.N. RAO, and N.K. TEWARI ................................................ 211
Chapter VI: CAD and FEM ...................................................... 217
Introduction .............................................................................................. 217
Model Based 3-D Curved Object Recognition Using Quadrics M. HANMANDLU, C. RANGAIAH, and K.K. BISWAS............................. 219
Finite-Element Model for Modal Analysis of Pretwisted Un symmetric Blades
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N.T. SIVANERI and Y.P. XIE....................................................................... 225
Computer Based Life Prediction Methodology for Structural Design T.L. NORMAN, T.S. CIVELEK, and J. PRUCZ............................................ 231
Chapter VII: Process Modeling and ControL........................... 237
Introduction .............................................................................................. 237
Processing of Superalloys in the 1990s F. ROBERT DAX............................................................................................ 239
Application of the Finite Element Method in Metal Forming Process Design
SHANKAR RACHAKONDA and SUREN N. DWIVEDI ............................ 253
Strategic Value of Concurrent Product and Process Engineering EDWIN R. BRAUN and JASON R. LEMON ................................................ 259
The Design Process for Concurrent Engineering NICHOLAS J. YANNOULAKIS, SANJA Y B. JOSHI, and RICHARD A. WYSK............................................................................... 265
Modeling Concurrent Manufacturing Systems Using Petri Nets KELWYN A. D'SOUZA................................................................................. 271
Production Planning and Control in the Factory of the Future W.H. ISKANDER and M. JARAIEDI ............................................................ 281
Expert Control of Turning Process P.S. SUBRAMANYA, V. LATINOVIC, and M.O.M. OSMAN.................... 287
Expert System for Milling Process Selection B. GOPALAKRISHNAN and M.A. PATHAK.............................................. 293
Forging Die Design with Artificial Intelligence S.K. PADHY, R. SHARAN, S.N. DWIVEDI, and D.W. LyONS................. 299
Chapter VIII: Process Simulation and Automation................... 307
Introduction. ...... .... ...................... .............. ......... ......... .... ......... ............. ... 307
Simulation Modeling in CIM Systems Design COLIN O. BENJAMIN, MELINDA L. SMITH, and DEBRA A. HUNKE 309
EXSEMA-An EXpert ~ystem for SElecting Simulation Software for Manufacturing Applications
COLIN O. BENJAMIN and OSSAMA A. HOSNY....................................... 315
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Group Technology Analysis for Manufacturing Data ABDELLAH NADIF, RENE-PIERRE BALLOT, and BERNARD MUTEL 321
Dispatching Mobile Robots in Flexible Manufacturing Systems: The Issues and Problems
HIMANSHU BHATNAGAR and PATRICK D. KROLAK.......................... 327
Automation of Prototype General Aviation Aircraft Development GEORGE BENNETT...................................................................................... 334
Determining Organizational Readiness for Advanced Manufacturing Technology: Development of a Knowledge-Based System to Aid Implementation
DONALD D. DAVIS, ANN MAJCHRZAK, LES GASSER, MURRAY SINCLAIR, and CARYS SIEMIENIUCH ................................... 340
Planning and Realization of Skill Based Flexible Automation for Developing Countries
S. KUMAR and A.K. JHA............................................................................. 346
Chapter IX: PCB Manufacturability and Assembly .................. 353
Introduction .. ............. ....... ... ......... ............. .... ... ...... ......... .... ...... ... ...... ... ... 353
An Expert System Based Concurrent Engineering Approach to PCB Assembly
K. SRIHARI .................................................................................................... 355
Real Time Production Scheduling and Dynamic Parts Routing for Flexible Assembly Lines
J.P. BOURRIERES, O.K. SHIN, and F. LHOTE ........................................... 361
A Knowledge-Based proach for Manufacturability of Printed Wiring Boards
SISIR K. PADHY and S.N. DWIVEDI ......................................................... 369
Design of an IOES Post Processor and Integration with a Robotic Workcell
R.H. WILLISON and G.M. PALMER............................................................ 376
Discrete Optimum Assembly Methods for Automated Workcells KENNETH H. MEANS and JIE JIANG......................................................... 382
Trajectory Planning for Obstacle-Avoided Assembly of Planar Printed Circuit Boards
TAK-LAI LUK and JOHN E. SNECKENBERGER...................................... 388
Development of a Vision Assisted Optimal Part-To-Pad Placement Technique for Printed Circuit Board Assembly
S.H. CHERAGHI, E.A LEHTIHET, and PJ. EGBELU................................ 394
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Chapter X: Quality Control Techniques.................................... 401
Introduction ...... ...................... ..... .......... ...................... ......... ........... ......... 401
Quality Function Deployment, a Technique of Design for Quality CHIA-HAO CHANG ...................................................................................... 403
Quality Value Function and Consumer Quality Loss FU QIANG YANG, MAJID JARAIEDI, and WAFIK ISKANDER ............ 409
Implementation of a Computer Aided Quality System (CAQ) in CIM Environment: Advantages and Disadvantages
M. DOMINGUEZ, M.M. ESPINOSA, J.I. PEDRERO, and J.M. PEREZ..... 415
Computer Aided Quality Assurance Systems V.K. GUPTA and R. SAGAR......................................................................... 421
Quality Consideration During DFA Analysis SUDERSHAN L. CHHABRA and RASHPAL S. AHLUWALIA ................ 436
Selection of Acceptance Sampling Plans Through Knowledge Based Approach
S.S.N. MURTY and D. CHANDRA REDDy................................................ 443
Chapter XI: Cost Analysis Concept .......................................... 451
Introduction .............................................................................................. 451
Analysis of Quality Costs: A Critical Element in CIM RES IT UNAL and EDWIN B. DEAN ............................................................ 453
A Databased Time and Cost Estimation Algorithm for Piece Part Design and Manufacturing
K.W.-N. LAU and M. RAMULU.................................................................... 458
Improvement Curves in Manufacturing R.C. CREESE and MADHU SUD HAN ......................................................... 466
Chapter XII: Materials: Composite ........................................... 473
Introduction .............................................................................................. 473
The Payoffs of Concurrent Engineering in Advanced Materials Development
JACKY C. PRUCZ.......................................................................................... 475
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A Practical Engineering Approach for Predicting Interlaminar Stresses in Composites
JACKY PRUCZ and MARIOS LAMBI ......................................................... 487
Interactive Optimum Parametric Design of Laminated Composite Flange
B.S.-J. KANG, JACKY PRUCZ, and F.K. HSIEH ........................................ 506
Computer Aided Dynamic Analysis of Laminated Composite Plates ALEXANDER E. BOGDANOVICH, ENDEL V. IARVE, and SUREN N. DWIVEDI.............................................................................. 519
Integration of Rigid-Plastic Simulation Engines into Engineering Database System for Advanced Forging
T ATSUHIKO AIZA WA and JUNJI KIHARA............................................... 528
Chapter XIII: Implementation .................................................. 535
Introduction ............ ....... ...... ......... ........ ......... ... ...... .... ......... ... ........... .... ... 535
Transitioning CE Technology to Industry S.N. DWIVEDI, RAV! PRASAD, and D.W. LYONS ................................... 537
Integrated Models of FMS in Concurrent Engineering Environment A.A. LESKIN and S.N. DWIVEDI................................................................. 553
Implementing QFD at the Ford Motor Company HAROLD F. SCHAAL and WILLIAM R. SLABEY .................................... 563