© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2010, Poland

PROCEDURE TO IMPROVE THE UNDERSTANDING OF THE ROTATING STRAIGHTENING PROCESS

Graziella KREISELER¹, Jörg SIEGERT¹, Engelbert WESTKÄMPER^1
1University of Stuttgart, Institute of Industrial Manufacturing and Management

Abstract

In industry wire is used for great variety of applications, such as cables, springs or nails. For many applications straight wires are necessary, e.g. shopping trolleys, dishwasher baskets or construction steel. Besides straightness these products demand specific characteristics such as the structure of the metal or the residual stress.After being produced, wire is normally coiled up for better handling. For the following production process the wire has to be straightened and cut into pieces. Therefore, different technical processes such as roll straightening, straightening by stretching or rotating straightening are possible.Rotating straightening with its special characteristics is one of the least known straightening processes in science. At the time being, skilled experienced workers are necessary to adjust and control the process. For a scientific description of rotating straightening, parameters have to be identified. After defining such parameters, they are then used to assess the different settings of a rotating straightening machine in order to explain the physics of the process. Another possibility to describe the physics of the process would be through a model. All of this should make it possible to predict the quality of wire after straightening, reduce waste wire and accelerate the ramp up.

Author Keywords :

straightening modelling with FEM

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2010, Poland

SUSTAINABLE INCREASES OF ENERGY EFFICIENCY BY HOLISTICALLY CONSIDERED STRUCTURES OF FACTORY SYSTEMS

Carsten RICHTER¹, Stephan FISCHER², Reinmund NEUGEBAUER¹, Egon MÜLLER², Klaus SCHÄDLICH^3
1Chemnitz University of Technology, Institute for Machine Tools and Production Processes IWP, German, e-mail: carsten.richter@mb.tu-chemnitz.de
²Chemnitz University of Technology, Department of Factory Planning and Factory Management
³Fraunhofer Institute for Machine Tools and Forming Technology IWU, Department Maschine Tools

Abstract

A number of efficient solutions are already in existence today for reducing specific energy and raw material needs, and they are continuously being improved. Since the competition between individual solutions for sustained energy efficiency may prove to be an obstacle to the system as a whole, the interaction of individual elements and sub-systems in complex domains must be considered in an integrated way with an eye to their reciprocal energy effects. What will be the impact of energy savings resulting from innovative approaches and intelligent solutions at a single systemic level on the system as a whole? Do they serve to reduce overall energy costs? What kinds of energy-related information are necessary to answer these questions? This article examines the issue of how dedicated energy savings in the production sector impact on the total energy requirement in factory systems. In one example, process and building are examined together in order to thereby recognize energy relationships. It was demonstrate that waste heat from machine tools has a significant impact on the factory hall climate and therefore on the heating needs of factory buildings. A model calculation demonstrated that energy savings at individual system levels are transferable to the entire system in direct proportion to the energy efficiency of the building.

Author Keywords :

factory building,process, energy interaction

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2010, Poland

MODEL BASED ENTERPRISE MANUFACTURING CAPACITY DEFINITION AND PRODUCT COST ESTIMATION FOR SME

Jevgeni SAHNO¹, Igor POLYANTCHIKOV¹, Marina PRIBYTKOVA¹, Eduard SHEVTSHENKO^2
1Tallinn Technical University, Doctoral Student at Dept. of Machinery Tallinn, Estonia
²Tallinn Technical University, Researcher, Dept. of Machinery, Tallinn, Estonia, eduard.shevtshenko@ttu.ee

Abstract

In today's business environment enterprises are trying to establish reorganization changes in their work and organization. It is necessary to structure the existing business to understand all enterprise functions, and change them in order to achieve the main enterprise objectives. To stay competitive under new conditions the external and internal factors should be assessed before restructuring of existing practices. The goal of this paper is to show how to put into practice the process of transition from Small-sized enterprise to Medium-sized enterprise category. For this purpose the existing company data that is stored in the ERP system should be transformed into knowledge. In this paper we consider the conditional "Metal Service" enterprise that produces various metal constructions and plans to produce load lifting equipment (jib cranes, overhead cranes, and additional equipment for existing cranes) for manufacturing enterprises that produce heavy products. The manufacturing capacities of enterprise are defined based on IDEF0 functional model created for each type of product. The simulation results received from these models enables to analyse new production processes, to estimate production time and route for all type of unit and yearly product release. In addition, after the Systematic Layout Planning (SLP) methodology and Relationship Matrix (RM) was applied to simulation results it became possible to calculate new manufacturing area, facilities layout and to assess the new production capacities.

Author Keywords :

Enterprise Resource Planning (ERP) IDEF0, Systematic Layout Planning (SLP), Relationship Matrix (RM)

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2010, Poland

MODEL OF A FACTORY STRUCTURE UNDER CHANGEABILITY ASPECTS IN AUTOMOTIVE MANUFACTURING

Carina LÖFFLER¹, Engelbert WESTKÄMPER², Karl UNGER^3
1GSaME, Universität Stuttgart, AUDI AG, Ingolstadt, Germany
²GSaME, Universität Stuttgart, Fraunhofer IPA, Stuttgart, IFF, Universität Stuttgart, Germany
³AUDI AG, Ingolstadt, Germany

Abstract

The complexity in automotive manufacturing increased enormously in the last couple of years. Reasons therefore are due to a widened product portfolio, enlarged manufacturing capacities distributed over several manufacturing sites and a large number of suppliers feeding the manufacturing network around the world. The factories are under permanent change and must be planned, configured and adapted in a permanent way. Consequently, planning tasks go along with a comparable degree of complexity as the manufacturing itself and must stand the continuous change manufacturing is faced with. Therefore, a factory model representing the essential information about the products, the technological resources and their interdependencies must be built for planning purposes. In context of long-term strategic planning tasks, structural changes are in specific focus and must be considered in the model. In this paper, a model of a factory structure, which can be used for the strategic planning of a manufacturing network is proposed. The factory structure model is based on a current configuration and has the architecture to consider future change within forecasts and scenarios.

Author Keywords :

model of a factory structure, changeability, manufacturing

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2010, Poland

INTEGRATION OF PRODUCT DESIGN AND MANUFACTURING WITH THE USE OF ARTIFICIAL INTELLIGENT METHODS

Izabela KUTSCHENREITER-PRASZKIEWICZ^1
1University of Bielsko-Biała Bielsko-Biała, 43-300, ul. Willowa 2, ipraszkiewicz@ath.bielsko.pl http://www.ath.bielsko.pl

Abstract

Product and process design is time- and cost consuming [15]. To reduce the cost of product development, it is necessary to integrate product and process design. The proposed product planning approach integrates activities involved in product design and manufacturing process. The aim of this paper is to develop a method of knowledge integration about customer needs, product and process characteristics. The range of analyses is limited to mechanical product type manufacturing for institutional customers. Customer needs are focused on functional characteristics of the product and the trade characteristics include product price, timing and warranty. Integration of functional requirements, product and process characteristics is needed to select the best product from a catalogue and adapt it to particular customer needs. From the given set of products, where a product is described by a set of attributes, the subset is chosen which roughly satisfies customer needs. Basing on artificial intelligent (AI) methods, data related to redesign and production processes is estimated.

Author Keywords :

product design, manufacturing, artificial intelligence

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2010, Poland

PREDICTIVE SCHEDULING BASED ON KNOWLEDGE ACQUIRED FROM FREQUENCY OF MACHINE WORK DISTURBANCES

Iwona WOSIK¹, Bozena SKOLUD^1
1Silesian University of Technology, Faculty of Mechanical Engineering, Institute of Engineering Processes Automation and Integrated Manufacturing Systems, Poland

Abstract

During execution of a schedule some uncertain events may take place for example: resources may become unavailable, machine can be broken. Uncertainty should be included in the process of job scheduling. In the paper the problem to generate a workable, proactive baseline schedule under production constraints and unexpected event occurrence conditions is considered. The proactive baseline schedule protects against anticipated occurrences that may appear during the schedule execution. The machine breaking time is searched and the information is used to generate a robust schedule. In the paper the method of data acquisition basing on probability theory is proposed. The time of machine breaking is acquired from historical data of frequency of machine failure. A numerical example of building a hypothesis H:{the cumulative distribution function of the failure time is a normal distribution}, verification of the hypothesis, and predictive scheduling is presented. The normal distribution is proposed to describe failure time of machine as it gives consideration to a gradual wear process of the machine. The paper is proposition of improving simulation systems such as the Enterprise Dynamics or Taylor and scheduling systems such as Knowledge based Rescheduling System and Multi Objective Immune Scheduling Algorithm.

Author Keywords :

predictive and reactive scheduling, mathematical statistics, Mean Time To Failure (MTTF)

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2010, Poland

DECISION MAKING STAGES IN PRODUCTION SCHEDULING OF COMPLEX PRODUCTS

Krzysztof KALINOWSKI^1
1Silesian University of Technology, Faculty of Mechanical Engineering, Institute of Engineering Processes Automation and Integrated Manufacturing Systems

Abstract

In this article the issue of production scheduling in manufacturing systems characterized by discrete production flow is presented. A decision making stages taken in production scheduling of complex products as a part of the project N R03 0073 06/2009 - "Integrated, Centre for Research and Development are shown. Complex product is understood as product, which can be a composition of other products, it means that in its structure assembly operations are allowed. There are following decision-making stages in proposed method that should be performed while creating a schedule: order sequencing, scheduling strategy selection, subprocesses and operations sequencing, selecting of operation variants, schedule evaluation. The "order sequencing" stage is associated with organizing the processes according to established priorities. The "choice of scheduling strategy" stage determines the way of operations introduction into a schedule. The "subprocesses and operations sequencing " stage refers to the issue of sequencing parallel operations in the structure of the process. The "selecting variants of operation" stage shows how to select alternative variants for the operation. Scoring method for assessing schedules allows carrying out the assessment process using multiple criteria and experts.

Author Keywords :

scheduling, complex products, decision making

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2010, Poland

SELECTED ASPECTS OF METHODOLOGY OF A CAPP SYSTEM DESIGN

Cezary GRABOWIK^1
1Silesian University of Technology, Faculty of Mechanical Engineering, Institute of Engineering Processes Automation and Integrated Manufacturing Systems, Poland

Abstract

In this paper the selected aspects of the methodology of a CAPP system design are presented. The special emphasis was put on problems of design features identification and method of design representation. Based on the carried out design features identification process the open structure of design features was worked out. This open structure was the base in the process of elaboration of the CAD application which was thought as a source of design data for a CAPP system. Moreover on the basis of the open structure of design features the formal FMCAD model was elaborated. This formal model is use for design representation purpose. Based on this model the AXI-CAD application was elaborated. The purpose of this application is to model a design of rotational products. The paper is finished with a short example of practical application of AXI-CAD module and some further direction of software development.

Author Keywords :

CAD, CAPP, design features, object techniques

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2010, Poland

ON A SYSTEMATIC APPROACH TO DEVELOPMENT OF MAINTENANCE PLANS FOR PRODUCTION EQUIPMENT

Jerzy MIKLER¹, Constantinos FRANGOUDIS², Bengt LINDBERG^3
1Jerzy MIKLER, The Royal Institute of Technology, Stockholm, Sweden
²Constantinous FRANGOUDIS, The Royal Institute of Technology, Stockholm, Sweden
³Bengt LINDBERG, The Royal Institute of Technology, Stockholm, Sweden

Abstract

Reliability is a collective term covering several abilities of the technical system: to deliver required functions, to uphold quality of products and services, to assure that the safety requirements associated with the system are properly fulfilled with regards both to the users and the environment and finally to uphold the durability of the technical system during its whole life cycle. All this has to be performed at acceptable risks, optimal cost, and correspond to operational needs of the business. Even though there is an advanced, well thought-out concept for this purpose - reliability centred maintenance (RCM) - that correctly applied might result in very good quality maintenance programs, it is not broadly used in the industry due to the vast efforts required for its implementation. An appropriate methodology supporting systematic functional break down of a studied systems, and guidelines how to couple functional failures to failure modes, integrated with RCM, would greatly speed up generating of effective maintenance programs. In this paper we present our research towards development of such a methodology, and show a pilot implementation to analysis of machine tool spindle. The methodology is based on Hubka's theory of design and AFD/TRIZ.

Author Keywords :

reliability,maintenance, RCM, TRIZ

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2010, Poland

ARTIFICIAL INTELLIGENCE AND VIRTUAL ENVIRONMENT APPLICATION FOR MATERIALS DESIGN METHODOLOGY

Leszek Adam DOBRZAŃSKI¹, Rafał HONYSZ^1
1Institute of Engineering Materials and Biomaterials, Silesian University of Technology, ul. Konarskiego 18a, 44-100 Gliwice, Poland

Abstract

The purpose of this study is to develop a methodology for material design. This methogology will enabling the selection of production descriptors to ensure the required mechanical properties of structural steels specified by the designer of machinery and equipment. The selection is performed by using a computational model developed with use of artificial intelligence methods and virtual environment. The model is designed to provide impact examinations of these factors on the mechanical properties of steel only in the computing environment. Virtual computing environment allows full usage of the developed intelligent model of non-alloy and alloy structural steel properties and provides an easy, intuitive and user-friendly way to designate these properties for products after heat and plastic treatment. Also, very easy is the determination of chemical composition, treatment conditions and geometric dimensions on the basis of the steels mechanical properties. The proposed solutions allow the usage of developed virtual environment as a new medium in both, the scientific work performed remotely, as well as in education during classes. It is also possible the extension of this model to other groups of materials, not just for steel.

Author Keywords :

materials design, mechanical properties, virtual environment, modellin

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2010, Poland

OPTIMISATION OF HIGH-SPEED STEELS CHEMICAL COMPOSITION USING THE ARTIFICIAL INTELLIGENCE METHODS

Wojciech SITEK^1
1Politechnika Śląska, ul. Konarskiego 18a, 44-100 Gliwice, Poland

Abstract

The main goal of the research carried out was developing the design methodology for the new high-speed steels with the required properties, including hardness and fracture toughness, as the main properties guaranteeing the high durability and quality of tools made from them. It was decided that hardness and fracture toughness KIc are the criteria used during the high-speed steels design. In case of hardness, the statistical and neural netw chemical composition and its heat treatment parameters, i.e., austenitizing- and tempering temperatures. In the second case - high-speed steels fracture toughness, the neural network model was developed, makin it possible to compute the KIc factor based on the steel chemical composition and its heat treatment parameters. The developed material models were used for designing the chemical compositions if the new high-speed steel, demonstrating the desired properties, i.e., hardness and fracture toughness. Methodology was developed to this end, employing the evolutionary algorithms, multicriteria optimisation of the high-speed steels chemical composition.

Author Keywords :

tool steel, materials design, artificial intelligence methods

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2010, Poland

STRUCTURE, PHYSICAL PROPERTIES AND FRACTAL CHARACTER OF SURFACE TOPOGRAPHY OF CVD COATINGS

Waldemar KWAŚNY^1
1Institute of Engineering Materials and Biomaterials, Silesian University of Technology, ul. Konarskiego 18a, 44-100 Gliwice, Poland

Abstract

The aim of the presented study is to establish a methodology elaboration, giving a possibility to predict properties of coatings reached in CVD process on tool materials, based on fractal quantities describing their surface. Coatings' topography and its structure which has an impact on a shape of analysed objects' surface were characterised in a comprehensive way. Influence of a type of process and conditions of deposition over structure and shape of topography as well as mechanical and operational properties of the acquired coatings were determined.

Author Keywords :

CVD coatings, fractal and multifractal geometry, X-ray analyses

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2010, Poland

MODELLING HYBRID POWERTRAIN OPERATION OF A WHEELED VEHICLE INCLUDING DUAL POWER SOURCE

Wacław BANAŚ¹, Gabriel KOST¹, Andrzej NIERYCHLOK^1
1Institute of Engineering Processes Automation and Integrated Manufacturing Systems, Silesian University of Technology, Poland

Abstract

The paper presents a way of modeling hybrid drive system with a dual source of electricity. The use of such solution is to use better used and flow of energy in hybrid vehicle. Describes the sizing of electrochemical batteries per unit weight of a wheeled vehicle and the system was adopted to supporting the super-capacitor batteries. Presents a concept of switching multiple units in a hybrid system, which adopted the criterion of engine rotational speed and linear speed of the vehicle.

Author Keywords :

hybrid powertrain, dual source, wheeled wehicle

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2010, Poland

MODELING AND SELECTION OF THE WORK OF A POWERTRAIN HYBRID WHEELED VEHICLE

Wacław BANAŚ¹, Gabriel KOST¹, Andrzej NIERYCHLOK^1
1Institute of Engineering Processes Automation and Integrated Manufacturing Systems, Silesian University of Technology, Poland

Abstract

The paper presents the main issues of control the combustion engine by stabilizing power. Algorithms work, certain flue units for which the work of the internal combustion engine is most effective. A method of modeling the flow of energy between an engine and an electric generator as a function of engine speed and load of the specific fuel consumption - the greatest efficiency. Presented a stabilization system diagram under the internal combustion engine and generator for hybrid vehicle. Described to adopted algorithm the stabilization of power for the engine and generator exhaust in the rotational speed to stabilize at a point and stability in the area.

Author Keywords :

hybrid vehicle, concept of control, stabilization process

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2010, Poland

DATA TRANSFORMATION FOR PRODUCTION PLANNING AND CONTROL SYSTEMS INTEGRATION

Damian KRENCZYK^1
1Silesian University of Technology, Faculty of Mechanical Engineering, Institute of Engineering Processes Automation and Integrated Manufacturing Systems, Poland

Abstract

In this paper the method of production planning and control systems (PROEDIMS and SWZ) integration is presented. Both systems are parts of a distributed system which is thought as a replacement of large MRP / ERP systems for SMEs. This idea derived from the needs of several small and medium enterprises. In these kind of enterprises the larger stress is applied rather on technical preparation of production than tackling business problems. Integration is achieved by methods of data transformation and data mapping. The proposed data transformation interface uses neutral data formats like XML, XML schema, Extensible Stylesheet Language Transformations XSLT and XML Path Language. The functional scheme of the module for data exchange which is necessary for the interaction between the production planning module of PROEDIMS system and production orders verification system for a multiassortment, concurrent production (SWZ) has been proposed and various stages of data transformation have been discussed.

Author Keywords :

data transformation, data mapping, PPC systems integration

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2012, Poland

STUDY ON REDUCING ENERGY CONSUMPTION IN MANUFACTURING SYSTEMS

Jerzy JEDRZEJEWSKI¹,Wojciech KWASNY¹,
¹Institute of Production Engineering and Automation, Wroclaw University of Technology, Poland

Abstract

The paper presents the complexity and importance of energy saving in industry, manufacturing facilities, machine tools and machining processes. The increasing energy demand and the necessity of conscious energy use are highlighted. Problems relating to the reduction of energy consumption by machine tools and manufacturing facilities, the necessity of basing new energy-efficient designs on knowledge, the accurate modelling of power losses and the use of intelligent energy consumption control with special regard to the drives of controllable axes are discussed. of reducing energy consumption by machine tools and manufacturing processes is indicated.

Author Keywords :

machine tool, processes,energy consumption

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2012, Poland

A PROPOSAL OF MODULAR DESIGN FOR LOCALIZED GLOBALIZATION ERA

Yoshimi ITO^1
1Tokyo Institute of Technology, Japan
elite.wdi.pwr.edu.pl

Abstract

In localized globalization era, it appears that the modular design enables something new to be played, and thus at burning issue is the reconsideration of to what extent the modular design is applicable. To delve into a desirable modular design in not distant future, this paper describes first the present perspective including some facing problems and milestones in the developing history of the modular design. Then, the paper shows some applications of the modular design to other industrial spheres, ranging from automobile, through food processing plant, to submarine. On the strength of such awareness and also in consideration of characteristic features of the manufacturing environment in future, proposed is a new concept for modular design, in which primary concerns are two leading attributes, i.e., functionality-related, and also culture- and mindset-related attributes. These two should be duly converted into the quantified design specifications, and we must conduct the " One-to-One " conversion from functionality to structural configuration, and also conversion from the uncertain attribute to the quantified factor. Of note, the forerunning research is reviewed.

Author Keywords :

modular design, manufacturing culture,localized globalization,conversion methodology

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2012, Poland

A CULTURE-BASED VIEW ON INNOVATION COMMUNITIES WITH SOME MARGINAL NOTES ON THE POSSIBLE FUTURE OF OPEN INNOVATION

Klaus RUTH^1
1Institute Technology and Education, University Bremen, Germany

Abstract

During the last years changes in innovation styles have occurred. The most recent development was the advent of a concept labeled as 'open innovation'. The meaning of open innovation ranges from the opening of the involved actors' basis, e.g. by including suppliers and customers to opening the understanding of innovation, e.g. by opening to new themes. The paper outlines an approach into innovation competence, which is a synthesis of knowledge, experience, skills and intuition. The synthesis or fusion is embedded into an innovation discourse among the relevant innovation actors. Innovation competence in its perfected form goes beyond carrying out high-level innovations, but rather can be understood as the involved actors' ability to transcend the boundaries of innovation, its premises, and the given goals. Thus innovation competence can be seen as contributing to an enhanced understanding of open innovation. Innovation communities are suggested as the preferred form to develop a high level of innovation competence.

Author Keywords :

innovation, culture, competence

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2012, Poland

A MANUFACTURING NETWORK FOR GENERATING ADDED VALUE FROM A GEOGRAPHICAL DISTANCE FOR THE NEXT GENERATION

Keiko YUKAWA¹, Takashi KAWAKAMI¹,
¹Hokkaido Institute of Technology, Japan

Abstract

In this study, we suggested a manufacturing network for generating added value from a geographical distance in terms of value creation from various management resources. Until today, most researchers focused on the Real Concentration of Production Base, which provides certain manufacturing benefits in these domains. However, "the Virtual Concentration of Production Bases" is realized by overcoming large physical distances and time differences between production bases, and creates greater added value for products. We attempted the simulation of the manufacturing network of creating the added value after having shown the new framework of network analysis in the manufacturing system.

Author Keywords :

virtual concentration,optimization problems,value-added network

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2012, Poland

COMPARATIVE RESEARCH INTO MARKETABILITY REINFORCEMENT IN CONVENTIONAL MACHINING CENTER OF CHINA, INDIA, JAPAN, KOREA AND TAIWAN-MAKES

Puneet TANDON¹, Yoshimi ITO^2
1PDPM-IIITDM Jabalpur, India
²Tokyo Institute of Technology, Japan

Abstract

This paper describes the results of a comparative research into the marketing and product strategies for the conventional MCs of China, India, Japan, Korea and Taiwan-makes. In this work, information from conventional MC manufacturers of these countries is collected on the spot and with the help of a questionnaire to identify the relevant strategies for differentiation. The parameters considered are the target customers, date of delivery, sale price, features of operability, design attributes, after sales service, motivation to purchase, target market segment. Based on these parameters, mind maps are drawn. The differences in the strategies among Japan, Korea and Taiwan manufacturers is that although most of the manufacturers in these countries have employed in-house design and assembly systems, and strongly rely on supply chain management, still the Korean manufacturers maintain the competitiveness through cheaper sales price and shorter delivery time, the Taiwanese manufacturers focus on current customers through cheap pricings but do not pay proper attention to business-oriented-enterprise management; while the Japanese manufacturers are capable of introducing directly opposite attributes in the product design. The Chinese and Indian manufacturers produce machines that are cost effective and focus on the inland market. The delivery time is long due to obsolete manufacturing facilities and sparse competition.

Author Keywords :

conventional machining center, marketing and product strategies,technological qualification, mind map

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2012, Poland

A COMPARATIVE STUDY OF JAPANESE AND US AMERICAN MEDICAL DEVICE INDUSTRIES

Etsuko TSUTSUMI^1
1Hokkai School of Commerce, Japan

Abstract

Japan has an unfavorable balance of trade in medical devices, and large Japanese companies hesitate to enter the medical device industry. This paper investigates the process of the expansion of the American medical device industry. It was concluded that the propensity for risk in the U.S.A. and Japan is different; both countries have different industries and ways of thought which construct their manufacturing cultures. A system called Investigational Device Exemption (IDE) indicates that US Medical Industries are in a stronger position than their Japanese counterparts. The American system allows purchasing of developing medical devices before pharmaceutical acquisition. Japan has no foster policy for medical venture, nor are medical devices tested strictly before pharmaceutical approval. It is predicted that the Japanese economy will no longer be able to grow in a stable manner just by relying on the large corporation-led export of manufactured goods, whereas those SMEs with the sophisticated technology, by accommodating the needs of the medical institutions, will be highly competitive internationally in a narrow and specialized market. The author points out that promotion for the medical device industry may help Japanese economic revitalization. Japanese companies and their government will have to support developing "diversity" of the players.

Author Keywords :

diversity, medical device, risks,endoscope development, competitiveness, IDE; Investigational Device Exemption

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2012, Poland

THE FOUR RATIONALES OF TECHNOLOGY TRANSFER~IDENTIFYING TECHNOLOGY TRANSFER RISKS~

Iris Ann Galarosa MARTINEZ^1
1Department of Industrial Engineering and Operations Research, College of Engineering, University of the Philippines Diliman, Diliman, Quezon City, 1101 Philippines

Abstrakct

Up until now, most technology transfer activities have been carried out on trial-and-error basis. However, recent studies have emerged to provide scientifically-based guides for technology transfer in recognition of the fact that technology transfer is important for global advancement. Along with these studies, this research aims to present a systematic methodology, called the Four Rationales of Technology Transfer, for identifying the risks of technology transfer. This methodology is derived from an empirical study conducted on 50 recently-implemented technology transfer projects. With the proposal of the methodology of Four Rationales of Technology Transfer and the presentation of the results of the empirical study, it is the hope of this research that future activities of technology transfer will become more successful.

Author Keywords :

technology transfer,four rationales, 5Ps

© Copyright by Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2012, Poland

DIFFERENCES IN TECHNOLOGY TRANSFERS TO CHINA BETWEEN EUROPE AND JAPAN

Junko MIZUNO^1
1Dr. Econ., Executive Senior Research Fellow, Inter-Disciplinary Studies Center, IDE-JETRO, Japan

Abstract

This report analyzes technology transfers and education for local engineers within overseas subsidiaries of Japanese and European companies that have advanced into China, and examines differences among them. The local engineers nurtured in overseas subsidiaries of Japanese companies have mid-level skills similar to those of Japanese engineers at a holding company. When Japanese holding companies succeed in fostering local engineers, of course, there is a beneficial effect both for the overseas subsidiary and for the technical enlightenment of local engineers. However, these benefits may also help rivals. In comparison, overseas subsidiaries of European companies foster low-level engineers, and the division of labor with engineers at a holding company is a complementary relation, without duplication.

Author Keywords :

technology transfers, human resources development,international division of labor

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2012, Poland

STUDY ON EUROPEAN MARKET-ORIENTED PASSENGER CAR DESIGN BASED ON QUANTITATIVE REPRESENTATION OF SHAPE CHARACTERISTICS

Shin'ichi WARISAWA^1
1The University of Tokyo, 7-3-1 Hongo, Bunkyo-ku, Tokyo 113-8656, Japan

Abstract

Due to the poor evaluation of the design of Japanese cars in the European market, this study proposes an evaluation to improve the rating of Japanese cars by Europeans. First, the concept of passenger car design evaluation is defined. Based on this definition, the appearance of a front image of a passenger car is decomposed into primitive components, and each component is analyzed in terms of shape, size, and position information. The shape information can be evaluated by two quantitative methods: Fourier series expression and aspect ratio calculation. To validate the evaluation method, five Volkswagen, four Peugeot, and three Toyota cars are sampled. The analysis indicates obvious differences in the headlights and radiator grille. Furthermore, a design modification method is proposed. Because design differences between European and Japanese cars are quantitatively evaluated, identifying necessary modifications should be easy. As a trial, one Toyota car design is modified by changing the features of the radiator grille and headlights to more closely resemble the characteristic shape of European cars. Then to validate the design modification, a design image investigation is conducted with the cooperation of 39 German citizens. This investigation demonstrates the design evaluation is effectively improved by altering the design of the headlights and radiator grille.

Author Keywords :

culture of manufacturing,passenger car design evaluation,quantitative representation

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2012, Poland

SURVEY OF MACHINE TOOL ERROR MEASURING METHODS

Wojciech KWASNY¹,Pawel TUREK¹, Jerzy JEDRZEJEWSKI^1
1Institute of Production Engineering and Automation, Wroclaw University of Technology, Poland

Abstract

This paper presents the factors and needs which make it necessary to increase the accuracy of machine tools. Types of machine tool errors, their causes and ways of identifying, measuring, reducing and compensating them are described. The most effective methods of identifying machine tool errors are discussed and classified. The measuring methods and tools are compared with regard to their range of application, time consumption, cost, market availability and main limitations.

Author Keywords :

machine tool, volumetric error,identification, method

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2012, Poland

ACTIVE ALIGNMENT CHUCK FOR ULTRA-PRECISION MACHINING

Lorenzo DAGHINI¹, Andreas ARCHENTI¹,Amir RASHID¹,Cornel Mihai NICOLESCU^1
1Royal Institute of Technology, KTH Production Engineering, Stockholm, Sweden

Abstract

Ultraprecision (UP) components have become common in everyday life products such as mobile phones or compact high resolution digital cameras. Thus the need of producing such components with high accuracy and low production cost. UP machine tools are capable of extremely high accuracy in tool positioning but still today the workpiece is positioned by hand, hence the high production cost of UP components. A fully automated chain of production has been developed within the EU-IP project "Production 4 micro". This paper describes the active alignment chuck for workholding in UP machining. The chuck has been provided with a high damping interface (HDI) and to evaluate its efficiency the chuck has undergone an experimenta modal analysis (EMA) as well as machining tests. The chosen operation was grooving by fly cutting using a diamond tool. The EMA showed that the HDI was effective for those modes where there was relative displacement between one side and the other of the HDI. This result was confirmed by the machining tests as well. The HDI resulted being effective in damping high frequency modes (around 4 - 5 kHz), hence one expected benefit would be a longer tool life.

Author Keywords :

ultraprecision machining, high damping interface, active alignment

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2012, Poland

LIFE CYCLE COSTING USED FOR JUSTIFYING TRANSITION TO PREDICTIVE MAINTENANCE STRATEGIES

Jerzy MIKLER^1
1KTH Royal Institute of Technology, School of Industrial engineering and Management, Sweden

Abstract

the focus of maintenance toward predictive strategies. However, as any other investment, implementation of the required condition monitoring systems has to be cost justified. This paper presents a case study showing use of LCC calculations to assess changes of maintenance strategy for a CNC machining centre. It was proven that replacing reactive maintenance tasks with simple condition monitoring and preventive activities results in lower whole life cycle cost of the analysed machining centre.

Author Keywords :

reliability, life cycle costing, predictive maintenance

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2012, Poland

THE EFFECTS OF PROCESS PARAMETERS ON SPINDLE POWER CONSUMPTION IN ABRASIVE MACHINING OF CoCr ALLOY

Emma BRAZEL¹, Raymond HANLEY², Garret E. O'DONNELL^1
1Department of Mechanical and Manufacturing Engineering, Trinity College Dublin, Ireland ²DePuy Ireland, Johnson & Johson, Loughberg, Ringaskiddy, Co Cork, Ireland br>

Abstract

The production environment requires seamless integration, efficiency and robustness of process monitoring solutions. This research investigates data acquisition on the machine tool through the monitoring of NC kernel data. This approach provides many advantages, particularly in an industrial setting where it may be impractical to install additional sensors for process monitoring. The process investigated is abrasive machining of Cobalt Chrome alloy. Cobalt Chrome alloys are extensively used in the biomedical industry as both femoral and tibial components of prosthetic joints. Abrasive machining or grinding is widely employed as the main method for material removal for these components. Understanding the influence of key variables in such a process is necessary before optimization can be achieved. Significant information can be obtained by utilizing power consumption during machining as a process metric. Power consumption of a spindle during an abrasive machining process of Cobalt Chrome alloy is monitored under various conditions through a machine-NC-based application. The effects of changes in feed rate, wheel speed, depth of cut and tool condition are investigated here through Taguchi experimental design. Experimental results are presented with significant machining variables identified.

Author Keywords :

power monitoring, abrasive machining, grinding, taguchi, wheel wear, CBN

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2012, Poland

STABILITY ANALYSIS IN MILLING BASED ON OPERATIONAL MODAL DATA

Bartosz POWALKA¹, Marcin CHODZKO¹, Krzysztof JEMIELNIAK^1
1West Pomerania University of Technology, Szczecin, Poland

Abstract

Prediction of process stability in milling is usually based on experimental frequency response functions of machine tool and cutting force model. Alternatively, operational modal analysis may be applied for the prediction of a stability diagram. It does not require modal impact test but uses vibration signal acquired during actual cutting to identify modal parameters. Such an approach considers boundary conditions that may be different during cutting. On the other hand synthesis of frequency response function is not feasible due to the lack of scaled modal residues. Thus, in this paper modal mass obtained by means of impact test is used to calculate frequency response functions. Estimation of modal damping and natural frequency is carried out using only acceleration signals measured during flexible workpiece machining.

Author Keywords :

milling, chatter, operational modal analysis

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2012, Poland

COMPENSATION OF MACHINE TOOL ANGULAR THERMAL ERRORS USING CONTROLLED INTERNAL HEAT SOURCES

Martin MARES¹, Otakar HOREJS¹,Jan HORNYCH¹,Peter KOHUT^1
1Research Center of Manufacturing Technology of the Czech Technical University in Prague, Horská 3, 12800, Prague Czech Republic

Abstract

Thermal errors caused by the influence of internal and external heat sources in machine tool structure can cause up to 70% of total machine tool inaccuracy. Therefore, research on thermal behavior of machine tool structures is crucial for successful manufacturing. This paper provides an insight into the modeling of highly nonlinear (increasing with the complexity of the structure) machine tool thermal behavior using thermal transfer functions This approach to modeling is dynamic (uses thermal history) and, due to its relative simplicity, it enables real-time calculations. The method uses very few additional gauges and solves separately each influence participating in the thermal error. The main objective of the article is to describe the estimation of angular deformations occurring at the tool center point due to thermal influences. Transfer functions are used for the identification and control of additional internal heat sources. The second aim is to compare modeling effort with approximation quality. A partial objective is to cover other nonlinearities occurring generally in machine tool thermal behavior. The approach has been verified on a closed quill (a simple and symmetrical machine tool part) and applied on a model of a machine tool structure which has been chosen as the least favorable from the thermal point of view.

Author Keywords :

control, machine tool,angular thermal error,transfer function

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2012, Poland

A MECHATRONIC STUDY ON A MODEL-BASED COMPENSATION OF INERTIAL VIBRATION IN A HIGH-SPEED MACHINE TOOL

Paolo PARENTI¹,Giacomo BIANCHI¹,Nicola CAU²,Paolo ALBERTELLI¹,Michele MONNO¹,
¹MUSP - Machine Tool and Production Systems Laboratory , Via Tirotti 9 - Localita Le Mose - 29122 Piacenza, Italy
²ITIA - Institute for Industrial Technologies and Automation CNR, Via Bassini 15 - 20133 Milano, Italy

Abstract

A significant limitation to machine tool productivity in high-speed operations is due to inertial vibrations. During strong accelerations, inertial forces generate oscillations that are translated into surface geometrical errors on the machined parts. Machine tools users minimize these problems by reducing machine axes quickness, thus affecting productivity. In this paper the effects of inertial deformations on machine tool accuracy have been studied to evaluate the possibility of adopting a software compensation strategy. The proposed model-based solution, based on a reduced model of the machine tool dynamics, has been tested in a mechatronic simulation environment. In order to meet industrial needs, the compensation scheme has been designed to allow its implementation on standard numerical controllers. A detailed feasibility analysis has been carried out studying all aspects that can potentially impede the application of such approach. Simulations and some preliminary experiment tests prove the effectiveness of the developed technique on a five-axis machining center.

Author Keywords :

machine tools, mechatronic simulation, vibration control, inertial deformation

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2012, Poland

EVALUATION AND REPRESENTATION OF MACHINE TOOL DEFORMATIONS

Andreas ARCHENTI¹, Tomas OSTERLIND¹, Cornel Mihai NICOLESCU^1
1KTH Royal Institute of Technology, Production Engineering, Stockholm, Sweden

Abstract

This paper presents a novel test concept for the evaluation of the accuracy of NC machine tools. The evaluation of machine tools deformations is performed by help of a device similar to the double ball bar (DBB) with the difference that an adjustable load generated by the devic can be applied between spindle nose and machine tool table. This load eliminates the play existing in machine tool joints, thus reproducing the testing conditions that exist during machining. Collected data are used to plot diagrams displaying characteristic aspects of machine tool performance and a number of key figures such as static stiffness may be determined. The data can also be used for trend analysis; to predict any accuracy deviations, and further to conduct preventive maintenance instead of emergency calls. The determined static behaviour could also be used to improve digital models for process simulations and compensation of errors that are caused by deflection.

Author Keywords :

machine tool, testing, deformation, static stiffness, circular test, loaded double ball bar

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2012, Poland

FAILURE MODE ANALYSIS TO DEFINE PROCESS MONITORING SYSTEMS

Tom McLEAY¹, M. S. TURNER^1
1Advanced Manufacturing Research Centre with Boeing, University of Sheffield, UK

Abstract

The high costs of using skilled operators in production processes has built a demand for reduced manning, 'lights out machining' manufacture. Process monitoring systems have become a widely researched area in recent years since there is a need for intelligent systems to replace the manual intervention in existing processes. Furthermore, using modern sensors and signal processing techniques, monitoring systems can obtain more informatio about a process and therefore reduce costs further though maximised life of cutting tools, optimised cutting parameters and reduced scrap or re-work. With many application areas available, such as tool condition monitoring, chatter avoidance or feedback control of cutting parameters, it is not always apparent what the key aspects required by an intelligent monitoring system are. In addition, different machining processes have different demands and limitations for monitoring. This paper considers an analytical approach to define the requirements of a monitoring system. A process failure mode effect analysis (FMEA) is carried out to determine the weaknesses of current production processes. From this analysis, the relationships between failures, causes and effects can be used to populate conditional relationships between process faults and sensor signal features in a monitoring system.

Author Keywords :

fmea, process monitoring, bayesian networks, PCA, sensor fusion, acoustic emission

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2012, Poland

IMPROVING THE CONTOURING ACCURACY OF A HSC LINEAR MOTOR MILLING MACHINE

Zoran PANDILOV¹, Numan DURAKBASA², Vladimir DUKOWSKI^1
1University "Sv. Kiril i Metodij"-Skopje, Faculty of Mechanical Engineering, Karpos II b.b., P.O.Box 464, MK-1000, Skopje, Republic of Macedonia, Tel.: 389 2 3099 259 Fax: 389 2 3099 298 E-mail: panzo@mf.edu.mk
²Vienna University of Technology, Faculty of Mechanical and Industrial Engoineering ,Institute for Production Engineering and Laser Technology Karlsplatz 13/3113, A-1040, Vienna, Austria

Abstract

In recent years, instrumentation circular profile tests have been specified to assess the contouring accuracy of CNC machine tools. Such an instrumentation type test is the HEIDENHAIN grid encoder system, which is particularly appropriate for dynamic measurements, especially at high feed rates. In this paper influence of the position loop gain and sampling period on the contouring accuracy are effectively studied.

Author Keywords :

contouring accuracy, linear motor machine, position loop gain, sampling period

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2012, Poland

A COMPARISION OF MODEL AND SIGNAL BASED CONDITION MONITORING AND MODE SEPARATION FOR PREDICTIVE MAINTENANCE OF FEED DRIVES

Detlef MAIER¹, Uwe HEISEL^1
1Institut fuer Werkzeugmaschinen, Universitaet Stuttgart. Stuttgart, Germany

Abstract

Modern production strategies increase the demand for closer monitoring of the machine's condition. Especially wear affects its condition. This paper deals with the methodology of condition monitoring that can be based on different sources of data such as controller NC CNC and additional sensors. Two main methods for assessment are signal analysis based exclusively on measurement data and a model based method The latter is based on comparing the simulation of the objects behaviour with the acquired data. Ball screw drives are key elements of machine tools. They considerably contribute to the machine's performance. The paper compares two signal-based wear inducing characteristics and discusses the results. Afterwards a model-based approach is discussed.

Author Keywords :

mode separation, condition monitoring ball screw drive, predictive maintenance