Showing papers in "Cirp Journal of Manufacturing Science and Technology in 2012"
TL;DR: In this paper, a framework is presented to validate the introduction of energy consumption in the objectives of process planning for CNC machining, where the state of the art in process planning and energy consumption of manufacturing research is utilised as a basis for the framework.
Abstract: Machining is one of the major activities in manufacturing industries and is responsible for a significant portion of the total consumed energy in this sector. Performing machining processes with better energy efficiency will, therefore, significantly reduce the total industrial consumption of energy. In this paper, a framework is presented to validate the introduction of energy consumption in the objectives of process planning for CNC machining. The state of the art in process planning and energy consumption in manufacturing research is utilised as a basis for the framework. A mathematical representation of the logic used is presented followed by two sets of experiments on energy consumption in machining to validate the logic. It is shown that energy consumption can be added to multi-criteria process planning systems as a valid objective and the discussion on using resource models for energy consumption estimation concludes the paper. These experiments represent a part test procedure machining proposal for the new environmental machine standard ISO 14955 Part 3.
264 citations
TL;DR: In this article, technologies used for the generation of functional surface structures for optical applications are reviewed and two novel processes introduced, diamond micro chiseling (DMC) and nano Fast Tool Servo (nFTS) assisted turning, have been developed.
Abstract: In this paper, technologies used for the generation of functional surface structures for optical applications will be reviewed and two novel processes introduced. In many cases, these structures are generated by diamond machining processes into mold inserts for replication purposes or for direct application as metal optics. However, the spectrum of machinable structures is limited by the applied kinematics and tool shapes. For example, the generation of pyramidal prismatic structures with sharp edges is not possible. In order to extend the spectrum of machinable geometries, novel processes like Diamond Micro Chiseling (DMC) or nano Fast Tool Servo (nFTS) assisted turning, have been developed.
118 citations
TL;DR: In this article, the effect of five important parameters such as layer thickness, part build orientation, raster angle and air gap on the sliding wear of test specimen built through fused deposition modelling process (FDM) is investigated.
Abstract: Present work focuses on extensive study to understand the effect of five important parameters such as layer thickness, part build orientation, raster angle, raster width and air gap on the sliding wear of test specimen built through fused deposition modelling process (FDM). The study provides insight into complex dependency of wear on process parameters and proposes a statistically validated predictive equation. Microphotographs are used to explain the mechanism of wear. The equation is used to find optimal parameter setting through quantum-behaved particle swarm optimization (QPSO). As FDM process is highly complex one and process parameters influence the responses in a non linear manner, artificial neural network (ANN) are employed to confirm the results of present study.
117 citations
TL;DR: In this paper, a comprehensive view on a kinematic simulation of the grinding process (KSIM) is given, which is able to compute and evaluate chip parameters of each grain participating in the material removal process.
Abstract: In this paper, a comprehensive view on a kinematic simulation of the grinding process (KSIM) is given. Using detailed modeling of the grinding wheel topography, KSIM is able to compute and evaluate chip parameters of each grain participating in the material removal process. This provides the opportunity to investigate the grinding process in a level of detail impossible to achieve in experiments. Using KSIM, the influence of process parameters and changes in the grinding wheel topography on the chip parameters and hence on the material removal process can be investigated and used for optimization of the process, the tool and for evaluation of process–machine interactions. The paper summarizes the research activities involving KSIM conducted in the last 12 years and presents new insights in the modeling process and the examination of process–machine interactions using this simulation tool.
85 citations
TL;DR: In this article, the quality oriented cutting edge preparation via abrasive brushing is presented, and the influence of the hone design on process forces, wear behavior and tool life of coated inserts is analyzed within a wide range of cutting edge microgeometries and process parameters.
Abstract: The design of the cutting tool microgeometry influences the thermo-mechanical load profile on the wedge. Applying the appropriate hone design stabilizes the cutting edge, leads to improved wear behavior and higher tool life. Higher process forces and temperature, induced by larger hone, can be described as a side effect of cutting edge preparation, which should also be observed. This paper presents the quality oriented cutting edge preparation via abrasive brushing. The influence of the hone design on process forces, wear behavior and tool life of coated inserts will be analyzed within a wide range of cutting edge microgeometries and process parameters.
79 citations
TL;DR: In this article, an integrated approach for the evaluation of machine tools consisting of methodological proposals for the measurement of energy consumption, modeling of energy flows and simulative analysis of the energy saving potentials as well as an energy-oriented life-cycle costing concept is presented.
Abstract: Sustainable machine tools are characterized by less consumption of energy as well as low costs during their life-cycle. In order to design such machine tools an evaluation of the energy-efficiency and the costs incurred is needed. In contrast to this, up to now there has been no fully developed evaluation method relating to both technical and cost efficiency of machine tools. Thus, the paper presents an integrated approach for the evaluation of machine tools consisting of methodological proposals for the measurement of energy consumption, modeling of energy flows and simulative analysis of the energy saving potentials as well as an energy-oriented life-cycle costing concept. Additionally, braking energy storage systems and reactive power compensation are analyzed. Based on the identified energy saving potentials, it is shown that at present only reactive power compensation is economically profitable under given assumptions.
55 citations
TL;DR: It is shown that C–K theory encompasses logical inferences that are more complex than classical abduction, which provides some unexplored issues of engineering design.
Abstract: Concept–Knowledge theory (C–K theory) of design is a relatively new theory for describing reasoning and creative processes in engineering design. This paper describes some unique features of this theory. In particular, it is shown that C–K theory encompasses logical inferences that are more complex than classical abduction. A design process in C–K theory is rather motivation-driven and this motivation can be quantified by the concept called information content (entropy) measured under epistemic uncertainty. Since the Internet-driven information will play a major role in performing engineering design (building concept, acquiring domain knowledge, and alike) in the near future, the scope and limitation of building a C–K map by using the Internet is described. This provides some unexplored issues of engineering design.
49 citations
TL;DR: In this paper, the authors report two case studies which provide the baseline for the identification of good practices and of a reference process model for PSS engineering, which is used in this paper to understand which are the main characteristics (how) and the structure and sequence of the phases (what order) characterising a PSS Engineering process model.
Abstract: The concept of Product–Service System (PSS) prevails as a systemic approach for enabling a strategic and managerial transition from selling physical goods to providing product–service solutions that fulfil customer-specific and changeable needs. Besides the potential strategic and economic relevance, many companies do not know how to provide a PSS in an effective way and often incur in high costs without any expected return. In this context, it is becoming relevant to engineer PSS solutions envisioning and encompassing their whole lifecycle. For this purpose, it is necessary to rely on a well-framed PSS engineering process. The contribution of this paper is mainly addressed to understand which are the main characteristics (how) and the structure and sequence of the phases (what order) characterising a PSS engineering process model. The paper reports two case studies which provide the baseline for the identification of good practices and of a reference process model for PSS engineering.
42 citations
TL;DR: In this article, an experimental investigation was performed on 2 mm sheets of wrought aluminium alloy Al99.7Mg0.5Cu-H24, using 1.6 and 2 mm diameter drills.
Abstract: Optimization of the metal drilling process requires creation of minimum amount of burrs and uniform appearance of the drilled holes. In this paper, an experimental investigation was performed on 2 mm sheets of wrought aluminium alloy Al99.7Mg0.5Cu-H24, using 1.6 and 2 mm diameter drills. Cutting data, clamping conditions, and drill geometry were varied in order to optimize the process and reach the desired quality. The results revealed possible reduction of burr occurrence on both the entry and exit side of the sheet, requiring no additional deburring. The demand on the uniform appearance of drilled holes was fulfilled as well as high productivity achieved. Such optimized process results in a noticeable production cost reduction.
42 citations
TL;DR: In this article, a cutting force model is presented, that takes into account the process damping effect and the geometry of the chamfered cutting edge, and theoretically predicted stability charts are compared to experimental data.
Abstract: High performance milling processes are limited by two dominating factors: the available spindle power and the dynamic stability of the process. When the cutting depth exceeds the stability limit, chatter vibrations arise. These vibrations lead to wavy surfaces, increase of the tool wear, acoustic noise and can even damage the spindle. Cutting edge chamfers are a possible means to avoid such vibrations. In this paper it is shown experimentally and theoretically how such chamfers affect the process damping effect and hence the stability limit. A cutting force model is presented, that takes into account the process damping effect and the geometry of the chamfered cutting edge. Theoretically predicted stability charts are compared to experimental data. The process damping coefficients are identified by a very simple wave-on-wave planing method. It is shown that due to cutting edge chamfers process damping is not restricted to the low speed cutting range anymore but also occurs at higher spindle speeds. It is demonstrated, that the key reason for the high speed process damping effect is a kind of mode interaction of the low frequency modes with the high frequency ones. Due to this effect stable as well as unstable islands can arise in the stability charts.
38 citations
TL;DR: In this article, the spatial localization of the main thermomechanical fields under dynamic loading conditions with high strain rates, high temperature and large inelastic strains is investigated using a complete 2D adaptive numerical methodology together with fully coupled 3D advanced thermo-elasto-viscoplastic-damage constitutive equations.
Abstract: Using a complete 2D adaptive numerical methodology together with fully coupled 3D advanced thermo-elasto-viscoplastic-damage constitutive equations; this paper focusses on the spatial localization of the main thermomechanical fields under dynamic loading conditions with high strain rates, high temperature and large inelastic strains. First, the advanced fully coupled and time dependent (i.e. thermo-elasto-viscoplastic) constitutive equations accounting for mixed nonlinear isotropic and kinematic hardening and ductile isotropic damage are presented. The associated numerical aspects are then briefly discussed in the framework of fully adaptive 2D finite element analysis. The thermomechanical fields’ localization is examined through the typical example of orthogonal cutting. Attention is paid to the localization of the main thermomechanical fields inside intensive shear bands as well as to the macroscopic crack paths through the chip thickness leading to the chip segmentation.
TL;DR: In this paper, the effect of cutting speed and feed rate on cutting forces and cutting temperature determine the type of tool wear in compacted graphite iron (CGI) machining.
Abstract: The characteristic mechanical (and physical) properties of compacted graphite iron (CGI) are contingent upon its unique microstructure. To model and simulate compacted graphite iron (CGI) in machining meaningfully, the metal's microstructure should not be overlooked throughout the process. In this work, modeling the microstructure of CGI in machining is implemented using a commercial general-purpose finite element package; ABAQUS/EXPLICIT (v 6.8). Segmental chip is modeled by the introduction of a new chip formation modeling technique. The cohesive zone elements are used to model the graphite–matrix interface. The methodology pursued to implement the finite element model is based upon an iterative interaction between comprehensive metallurgical investigations and finite element formulation of the problem in hand. Metallurgical examination of fractured and machined chips is not solely performed as a tool of validation, but rather as a tool of modeling. Vital model inputs are based upon metallurgical investigations of fractured CGI samples and machined chips. Subsequent comparisons between (1) simulated chips and (2) cutting forces trends, to experimental findings are used to validate the finite element model. The effects of cutting forces and temperature are comprehensively investigated to elaborate on their effects on tool wear. The effect of cutting speed (and feed rate) on cutting forces and cutting temperature determine the type of tool wear in CGI machining. Variation of the cutting speed triggers the deviation from mechanical to thermal tool wear mechanisms. This behavior is captured through the investigation of the cutting forces and simulated temperature trends in the finite element model. Other important findings are documented to serve as an optimization technique for tool material selection and machining conditions of compacted graphite iron (CGI) for which automotive and locomotive industries are of significant need to date.
TL;DR: In this article, the effect of tool diameter, length and applied frequency on the shape and size of fabricated microholes, machining time, number of short circuits and material removal rate (MRR) was investigated.
Abstract: The electrochemical micromachining is an important nontraditional machining process. Micro electrochemical machining (μECM) utilizes very high frequency pulses for micro to nano scale dissolution. For the study and characterization of the micro electrochemical machining process an experimental setup has been developed. Numerous microtools have been produced by reverse μECM technique and used to investigate the effect of tool diameter, length and applied frequency on the shape and size of the fabricated microholes, machining time, number of short circuits and material removal rate (MRR). The shapes of micro-drilled holes have been measured and compared with tool geometry. It has been observed that MRR and machining time increase and decrease respectively with an increase of tool diameter. On the other hand they decrease and increase respectively with an increase of tool length. It is also been observed that the applied frequency determines the size of the micro-drilled hole.
TL;DR: In this article, an integrated decision-making policy was devised to optimize a customizable objective function that takes into account operation-dependent degradation models and production target, based on the results of discrete-event simulations of operations of the underlying manufacturing system.
Abstract: In highly flexible and highly integrated manufacturing systems such as semiconductor manufacturing, the dynamic interactions between equipment condition, operations executed on the tools and product quality necessitate joint decision-making in maintenance scheduling and production operations. To address these problems, we devise an integrated decision-making policy optimizing a customizable objective function that takes into account operation-dependent degradation models and production target. Optimization was achieved using a metaheuristic method based on the results of discrete-event simulations of operations of the underlying manufacturing system. The method was applied to optimization of maintenance on a generic cluster tool routinely utilized in semiconductor manufacturing. The results show that operation-dependent maintenance decision-making outperforms the case where maintenance decisions are made without considerations of operation-dependent degradation dynamics.
TL;DR: In this article, a comparative study on existing clustering indices to the application of nanoparticle distribution in metal matrix nanocomposites (MMNCs) is conducted through a comprehensive simulation study.
Abstract: A uniform distribution of nanoparticles is the key to ensuring enhanced mechanical properties in metal matrix nanocomposites (MMNCs). Extensive work has been done on developing clustering indices in various areas. This paper conducts a comparative study on existing clustering indices to the application of nanoparticle distribution in MMNCs. Through a comprehensive simulation study, we investigated the detection powers of these methods in different scenarios. Five methods with high detection powers are tested further for their ability to quantify the severity of clustering, which are found to have unsatisfactory differentiating capability despite of their high detection powers.
TL;DR: In this article, the performance, wear mechanism and thermal stability in turning, milling and drilling operations of austenitic steels with coated cemented carbide cutting tools (coating system (Ti,Al)N/γ-Al 2 O 3 ) were investigated.
Abstract: Stainless steels are widely used in several industrial sectors, such as engine production, medical and chemical industry. Their high strength, low thermal conductivity, high ductility and high tendency towards work hardening are the main factors for their poor machinability. In order to improve the cutting tools performance, they are often coated. γ-Al 2 O 3 seems to be one promising candidate as coating material for machining difficult-to-machine materials. The performance, wear mechanism and thermal stability in turning, milling and drilling operations of austenitic steels with coated cemented carbide cutting tools (coating system (Ti,Al)N/γ-Al 2 O 3 ) were investigated. The thermal stability was analysed with TEM/STEM.
TL;DR: In this paper, acidithiobacillus ferrooxidans (At. ferrooxideidans) was used to remove metal from Fe 2+ to Fe 3+.
Abstract: A B S T R A C T This study explores an innovative metal machining process by using bacteria. Acidithiobacillus ferrooxidans (At. ferrooxidans) was used to remove metal. The bacteria first carried out the oxidation of Fe 2+ to Fe 3+ . The produced Fe 3+ then oxidized the metals. The machining of copper, nickel and aluminum was experimentally investigated using both the cells and the culture supernatant of At. ferrooxidans. The material removal rates of these three metals were 2.0, 1.6, 0.55 and 5.5, 4.2 and 0.7 mg/h cm 2 by using cells and culture supernatant, respectively. Higher metal removal rate was achieved for copper by using the culture supernatant. A microbe-based fabrication of micropattern is thus feasible applying the current principle. 2012 CIRP.
TL;DR: In this article, the dynamic interaction of autonomous products and work systems is investigated using a hybrid simulation model and a control-theoretic model and results obtained using both models show that these dynamic interactions can be well behaved and predictable through linearized models of continuous input flows at nominal rates.
Abstract: Autonomous production is characterized by local and autonomous decision making of intelligent logistic objects such as work systems that adjust production rates and parts that decide which products they “want” to become and which orders they will fill It is important to understand and have confidence in dynamic interactions of these objects and their resulting performance In this paper the dynamic interaction of autonomous products and work systems is investigated using a hybrid simulation model and a control-theoretic model Results obtained using both models show that these dynamic interactions can be well behaved and predictable Through linearized models of continuous input flows at nominal rates, tools of control theory are shown to build confidence in complex system dynamic behavior of interacting autonomous logistics objects when decision-making logic is modeled in a way that makes control-theoretic analyses tractable
TL;DR: In this article, a reaming operation had to be performed within given technological and economical constraints, and a statistical engineering project was supported by a comprehensive experimental investigation providing detailed information on single and combined effects of several parameters on key responses.
Abstract: A reaming operation had to be performed within given technological and economical constraints. Process improvement under realistic conditions was the goal of a statistical engineering project, supported by a comprehensive experimental investigation providing detailed information on single and combined effects of several parameters on key responses. Results supported selection of production parameters meeting specified quality and cost targets, as well as substantial improvements.
TL;DR: In this paper, an extended simulation study was conducted to evaluate the performance of adaptive traffic control in a logistic network and showed that the promising findings from traffic control regarding waiting time reduction and the emergence of synchronized behavior can be reproduced for production logistics.
Abstract: Recent publications on traffic control in urban road networks have presented strategies for adaptive flow control under varying network load. Traffic lights are modeled as independent, periodic devices, which take decisions on a local level. Despite the not actively coordinated decisions at single network nodes, such a strategy can perform better in terms of waiting time for the whole system than applying a standard optimization approach. First results from an ongoing simulation study indicate that adaptive control algorithms can also be applied successfully to different network topologies, e.g., logistic networks. This article presents the outcome of an extended simulation study. The simulation experiments have been carried out on artificially generated networks as well as networks derived from real manufacturing environments. We are able to show that the promising findings from traffic control regarding waiting time reduction and the emergence of synchronized behavior can be reproduced for production logistics. Furthermore, we illustrate how the variance of the network degree as an indicator for network connectivity influences the logistic performance.
TL;DR: In this article, a case of flexibility consideration in designing the punching department, in a commercial refrigerator's industry, is analyzed and three alternative technology solutions, defining the volume and products that need to be produced within a time horizon, have been studied, under different sets of market requirements.
Abstract: Flexibility is an important aspect of manufacturing systems, but it is difficult to properly consider during a real system's design. In this paper, a case of flexibility consideration in designing the punching department, in a commercial refrigerator's industry, is analyzed. Three alternative technology solutions, defining the volume and the products that need to be produced within a time horizon, have been studied, under different sets of market requirements. The capability of the alternative system designs to expand and increase their capacity and production range in order to meet the demand, has been studied with the use of the Penalty of Change method.
TL;DR: In this paper, a manufacturing method for structured surfaces by combining microindentation and ultraprecision cutting was proposed, and the effects of indentation depth, indentation load and indentation pitch and indenter vibration on dimple form accuracy and surface property were experimentally investigated.
Abstract: A manufacturing method for structured surfaces by combining microindentation and ultraprecision cutting was proposed. Firstly, microindentation was performed on metal materials, such as oxygen free copper and electroless-plated nickel, to generate micro dimples with curved cross-sectional profiles. Secondly, material pile-ups formed around the micro dimples during microindentation were removed by ultraprecision cutting using diamond tools. Piezo actuated high-speed repetitive microindentation tests were performed, and effects of indentation depth, indentation load, indentation pitch and indenter vibration on dimple form accuracy and surface property were experimentally investigated. Effects of cutting conditions on pile-up removal behavior were examined in the diamond turning process after indentation.
TL;DR: In this paper, the Semi Discretization Method (SDM) is employed to model chatter in peripheral milling using cutters with helical teeth and the process damping is included in the model using the equivalent viscous damper approach.
Abstract: In this paper the Semi Discretization Method, SDM, is employed to model chatter in peripheral milling using cutters with helical teeth. The process damping is included in the model using the equivalent viscous damper approach. The development is demonstrated first in straight cutting of plain surfaces. Stability lobes are established for these surfaces using an effective flank wear that also accounts for tool radial runout. A new approach of presenting the stability of the cut at different locations along the toolpath is developed; it is designated as the Stability Maps. The stability maps are established for 5-axis peripheral milling of three surfaces. Unlike the stability lobes, these maps are toolpath specific. The maps are verified using numerical simulations and cutting experiments.
TL;DR: In this article, a novel concept to investigate the noise level in manufacturing is proposed, where a simulation method and the virtual reality (VR) implementation are involved, and a representation of simulation results in the virtual environment is visualized in a Cave Automatic Virtual Environment (CAVE).
Abstract: Even though the noise issue in manufacturing is widely discussed from legal and health aspects, there is still no comprehensive method to simulate and analyze it. In this paper, a novel concept to investigate the noise level is proposed. Therefore a simulation method and the virtual reality (VR) implementation are involved. Acoustic measurements in real factory provide validation data for a realistic simulation. Furthermore, a representation of simulation results in the virtual environment is visualized in a Cave Automatic Virtual Environment (CAVE). The analysis and evaluation of potential noise reduction are realized by using described methods.
TL;DR: In this article, the variable thickness tube drawing process was studied with a newly developed procedure to evaluate the effect of tools geometries on the maximum possible tube deformation, where the desired variation in the design variables (die angle, mandrel angle, and die fillet radius) and the required adjustments and changes in the geometry with the aid of an in-house code automatically.
Abstract: The application of aluminium tubes, especially with variation of thickness, in the structures of various transportation devices like cars and bicycles makes it a point of interest for various designers. In this paper, the variable thickness tube drawing process was studied with a newly developed procedure to evaluate the effect of tools geometries on the maximum possible tube deformation. The procedure applies the desired variation in the design variables (die angle, mandrel angle, and die fillet radius) and the required adjustments and changes in the geometries with the aid of an in-house code automatically. Based on the optimized results, a die and a mandrel were built to verify numerical results in variable thickness tube drawing. The numerical results were compared with the experiments in the prototype machine, which was designed by this group, and acceptable agreements were observed.
TL;DR: In this paper, the authors proposed an optimized envelope order spectrum for bearing defect diagnosis in rotary machines that operate under non-stationary conditions by integrating wavelet enveloping, computed order tracking and spectral analysis.
Abstract: This paper presents a computational method, termed optimized envelope order spectrum, for bearing defect diagnosis in rotary machines that operate under non-stationary conditions. The method takes a holistic approach to bearing vibration signal analysis by integrating wavelet enveloping, computed order tracking, and spectral analysis. A scale selection criterion based on the maximum relative energy to Renyi entropy ratio is proposed to determine optimal decomposition scale for wavelet analysis. To eliminate the effect of speed variations and facilitate envelope-order spectral analysis, computed order tracking is introduced. The effectiveness of the method for identifying and localizing bearing defect is evaluated numerically and confirmed by experimental studies.
TL;DR: In this article, a method to identify hybrid manufacturing technology concepts for the supplementation of conventional technologies is introduced, and an evaluation of these new technologies in the context of production ramp-up projects is presented.
Abstract: Hybrid manufacturing technologies often provide a high potential for innovation and are not widely used in industries. Therefore the ramp-up of hybrid manufacturing technologies is a special challenge. The aim of this article is to show how hybrid manufacturing technologies can be found and evaluated. In the first part a method to identify hybrid manufacturing technology concepts for the supplementation of conventional technologies is introduced. The second part presents an evaluation of these new technologies in the context of production ramp-up projects. Thus, the optimal hybrid manufacturing technology can be chosen during the production process planning of new products.
TL;DR: In this article, an approach supporting both, tactical as well as strategic decision-making in volatile manufacturing environments is presented, where operating costs and performance figures of manufacturing systems are calculated and a Markovian decision process is solved to find a cost minimal policy over planning horizons.
Abstract: The automotive industry faces major challenges due to volatile markets and expenses for new technologies. The dynamics of markets and future technological variety demand flexibility. A sustainable transformation strategy is indispensable for upcoming decades. The following paper presents an approach supporting both, tactical as well as strategic decision-making in volatile manufacturing environments. At first, operating costs and performance figures of manufacturing systems are calculated. In step two, a Markovian Decision Process is solved to find a cost minimal policy over planning horizons. The optimization of the manufacturing system is based on capacity adaptations and changes in process steps, suppliers, and locations.
TL;DR: In this paper, a method is presented for analyzing the dynamic behavior involved in terms of costs in manufacturing cell, a production line, or an individual machine, making use of both empirical and theoretical distribution functions that apply to functioning times and downtimes.
Abstract: Downtimes in a manufacturing cell, a production line or an individual machine are characterized by a complex statistical behavior that their frequency and duration display. The work reported here concerns likenesses and differences between various statistical distributions that apply to functional times (TBF) and downtimes (DT) in connection with different discrete manufacturing processes. The TBF and DT are viewed as varying over the whole production time for the batch. A method is presented for analyzing the dynamic behavior involved in terms of costs. An important element in this method is the statistical analysis of downtimes, making use of both empirical and theoretical distribution functions that apply to functioning times and downtimes of specific types. For demonstrating how the method is employed, use is made of real data obtained from the Swedish company Alfa Laval.
TL;DR: In this article, the authors presented the results of research toward a more intelligent condition-based maintenance scheme for belt monitoring in a belt driven automated material handling system, and a novel, contact based device was designed to consistently excite belt vibrations in the material handling systems with greatly reduced variations in belt length and initial condition location.
Abstract: The extension of the useful life of manufacturing equipment is one of the keys to sustainable manufacturing. The high uptime requirements of the semiconductor industry result in the need for conservative preventive maintenance schemes, which leads to replacement of key components before the end of their useful life. This paper presents the results of research toward a more intelligent condition based maintenance scheme for belt monitoring in a belt driven automated material handling system. An experimental study of belt dynamics showed that transverse belt vibrations were sensitive to changes in belt length, belt tension, belt misalignment, and excitation location. Based on these findings, a novel, contact based device was designed to consistently excite belt vibrations in the material handling system with greatly reduced variations in belt length and initial condition location. On average, standard deviations of tension estimates using the device were 65% lower than that of a trained technician performing the current standard technique on three different robots. This design was then further adapted to facilitate a non-contact belt excitation and monitoring approach that did not require bringing the material handling system offline in order to obtain sensor readings. Such a procedure greatly eased and accelerated the monitoring process.