Development of a modular reconfigurable machine for reconfigurable manufacturing systems.
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Date
2010
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Abstract
The Reconfigurable Manufacturing Systems (RMSs) paradigm has been formulated to
encapsulate methodologies that enable manufacturing systems to effectively cope with changes in
markets and products. RMSs are systems which are envisioned to be capable of a rapid change in
manufacturing layouts, process configurations, machines and control components to provide a
quick response to changes in the master production schedule. This research was initiated due to
the necessity for new forms of production machinery to be design for RMSs, which can aid
manufacturers in the adjustment of system capacity and functionality at lower costs.
This thesis presents the development of Modular Reconfigurable Machines (MRMs), as a novel
machining solution within the scope of RMSs. MRMs are characterized by modular mechanical
structures that enable the flexibility of the machine to be adjusted in response to changes in
products. The concept of adjustable flexibility implies that the flexibility of the machines may be
balanced to exactly match the requirements of the system when changes in production plans
occur. Product changes are managed by a variation of machining processes and Degrees of
Freedom (DOF) on a platform. The modular nature of these machines permits this to be done
easily and cost effectively. MRMs therefore possess an advantage over traditional machining
systems, where an adjustment of system functionality would require the procurement of new
machinery. Manufacturers will also have the option to purchase machines with flexibility that
may be increased as needed, instead of investing in highly flexible and expensive CNC systems,
with features that are often excessive and unused.
Main points of this research included the development of mechanical modules for assembly into
complete machines. The number and types modules used in an assembly could be changed to
provide the kinematic and process optimization of the mechanical hardware according to
production requirements. In conjunction to the mechanical development, a suitable Mechatronic
control system will be presented. The focus of control development was the facilitation of
seamless system integration between modular mechanical hardware and the controller at both
hardware and software levels. The control system is modular and distributed and characterised by
a “plug-in” approach to control scalability. This is complimented by a software architecture that
has been developed with a focus on hardware abstraction for the management of a reconfigurable
mechanical and electronic architecture.
A static and dynamic analysis of the MRM system is performed for a selected mechanical
configuration. The performance of the mechanical and control system is also evaluated for static
and dynamic positioning accuracy for different modes of motion control. The implications for
MRMs are then analysed, which include system functionality and capacity scaling, manufacturing
expansion flexibility and system life spans. The research was concluded with an analysis of the
challenges and problems that must be addressed before MRMs become industrially acceptable
machines.
Description
M. Sc. Eng. University of KwaZulu-Natal, Durban 2010.
Keywords
Production engineering--Technological innovations., Computer integrated manufacturing systems., Manufacturing processes., Theses--Mechanical engineering., Modular reconfigurable machine., Reconfigurable manufacturing systems.