CIRP STC-OGA part II Technical TalksLugano, 25th August, 2017
A new reconfigurable machine tool architecture for technologies integration and cooperative capacity sharing
Alessandro A.G. Bruzzonea, Doriana M. D'Addonab
aDIME, University of Genova, Genova, ItalybDICMaPI, University of Naples Federico II, Naples, Italy
CIRP STC-OGA part II Technical TalksLugano, 25th August, 2017
A.A.G. Bruzzone, D.M. D’Addona A new reconfigurable machine tool architecture for technologies integration and cooperative capacity sharing
Preamble
The Lego-like Reconfigurable Machine Tool Architecture
CIRP STC-OGA part II Technical TalksLugano, 25th August, 2017
A.A.G. Bruzzone, D.M. D’Addona A new reconfigurable machine tool architecture for technologies integration and cooperative capacity sharing
Towards a shift in manufacturing paradigm(through the core elements)
Analysis of the essential elements present in every machine tool
ELEMENTS PRESENT IN EVERY MACHINE TOOL•a device that supplies energy, by virtue of which a relative coupled motion is obtained between the tool used to provide the process and the workpiece•a device for fixing and orientating the workpiece•a device for conveniently fixing and orientating a tool•a device for controlling the three above mentioned elements•a device for operating the tool according to the used transformation process
CIRP STC-OGA part II Technical TalksLugano, 25th August, 2017
A.A.G. Bruzzone, D.M. D’Addona A new reconfigurable machine tool architecture for technologies integration and cooperative capacity sharing
A new kinematics for linear axisFrom the ball screw (leadscrew sleeve) linear axis
Source: https://www.youtube.com/watch?v=wCD9eSIZ8ug
to …… the leadscrew rack - screw new concept
Topological exchange =>
Functions exchange between screws & sleeve
Holding structures to support the screw not required
CIRP STC-OGA part II Technical TalksLugano, 25th August, 2017
A.A.G. Bruzzone, D.M. D’Addona A new reconfigurable machine tool architecture for technologies integration and cooperative capacity sharing
A new kinematics for linear axis
The leadscrew rack - screw new concept (topological exchange)
Modular extendibility
WIP very preliminary kinematics demonstration test with3D printed PLA leadscrew rack & screw
CIRP STC-OGA part II Technical TalksLugano, 25th August, 2017
A.A.G. Bruzzone, D.M. D’Addona A new reconfigurable machine tool architecture for technologies integration and cooperative capacity sharing
Machine Tools Evolution & Industry 4.0 KETs
Industrial internetCloud manufacturingAdditive manufacturingCyber securityBig data & analyticsAugmented realityAdvanced manufacturing solutions
• Universal machine tools• Dedicated Manufacturing Line (DML)• Flexible Manufacturing Systems (FMS)
• Reconfigurable Machine Tools (RMT)•Modular machine tools RMT•Multi-tool RMT•Arch-type RMT
CIRP STC-OGA part II Technical TalksLugano, 25th August, 2017
A.A.G. Bruzzone, D.M. D’Addona A new reconfigurable machine tool architecture for technologies integration and cooperative capacity sharing
Lego-like Reconfigurable Machine Tools(PCT/IB2017/050737)
)+= ( ;
Bed modulewith integral
racks
Movable table(s)with screws coupled to
the racks
CIRP STC-OGA part II Technical TalksLugano, 25th August, 2017
A.A.G. Bruzzone, D.M. D’Addona A new reconfigurable machine tool architecture for technologies integration and cooperative capacity sharing
Lego-like Reconfigurable Machine Tools(PCT/IB2017/050737)
CIRP STC-OGA part II Technical TalksLugano, 25th August, 2017
A.A.G. Bruzzone, D.M. D’Addona A new reconfigurable machine tool architecture for technologies integration and cooperative capacity sharing
Lego-like Reconfigurable Machine Tools(PCT/IB2017/050737)
CIRP STC-OGA part II Technical TalksLugano, 25th August, 2017
A.A.G. Bruzzone, D.M. D’Addona A new reconfigurable machine tool architecture for technologies integration and cooperative capacity sharing
Lego-like Reconfigurable Machine Tools(PCT/IB2017/050737)
CIRP STC-OGA part II Technical TalksLugano, 25th August, 2017
A.A.G. Bruzzone, D.M. D’Addona A new reconfigurable machine tool architecture for technologies integration and cooperative capacity sharing
Lego-like Reconfigurable Machine Tools(PCT/IB2017/050737)
Upper movable cross-table(processing device)
Bottom movable cross-table(workpiece holder)
Bed module(integral leadscrew racks)
CIRP STC-OGA part II Technical TalksLugano, 25th August, 2017
A.A.G. Bruzzone, D.M. D’Addona A new reconfigurable machine tool architecture for technologies integration and cooperative capacity sharing
Flexibility & scalability enabled by Lego-like RMTBASIC FUNCTIONALITY 1 bed module + 1 upper cross-table +bottom cross-table
conventional Machining Tool
NETWORK OF MACHINING CENTERS2 or more bed module + 2 or more upper cross-table +2 or more bottom cross-table
• parallel processing• interconnected MT• processing/measuring technologies integration• concurrent and/or sequential operations
NB•Time & cost to add/remove upper/bottom table ≌ 0•Time to add/remove bed modules very short, i.e. reconfiguration cost negligible
CIRP STC-OGA part II Technical TalksLugano, 25th August, 2017
A.A.G. Bruzzone, D.M. D’Addona A new reconfigurable machine tool architecture for technologies integration and cooperative capacity sharing
A new machine tool proposal within Industry 4.0Industry 4.0 KETs Possible implementation
Industrial internet Provide a physical network and other items embedded with electronics, software, sensors, actuators, andnetwork connectivity which enable these objects to collect and exchange data.
Cloud manufacturing A framework structure to transform manufacturing resources and manufacturing capabilities intomanufacturing services to enable the full sharing and circulating of manufacturing resources andmanufacturing capabilities.
Additive manufacturing An open architecture to host AM technologies and other technologies that will be developed by externalproviders.
Cyber security A control of the physical access to the hardware, as well as the protection against harm that may come vianetwork access, data.
Big Data & Analytics A capacity to handle high volume, high variety, and high throughput data velocity storage required bynew technologies of processing to enable better decision making, knowledge discovery and processoptimization.
Augmented reality Permit the complete exploitation of the Reconfigurable Manufacturing System throughout its life cycle.Through the Digital Twins it is possible to integrate artificial intelligence, machine learning and softwareanalytics with data to create living digital Simulation models that update and change as their physicalcounterparts’ change.
Advanced ManufacturingSolutions
Novel instrument to implement the Industry 4.0 Advanced Manufacturing Solutions KET thanks to itsmodularity and open structure.
CIRP STC-OGA part II Technical TalksLugano, 25th August, 2017
A.A.G. Bruzzone, D.M. D’Addona A new reconfigurable machine tool architecture for technologies integration and cooperative capacity sharing
Lego-like RMT potential & problemsPOTENTIAL
•Possibility of immediate reconfiguration through the addition or removal of processing components•Co-existence of different technologies•From fixed a capacity manufacturing system to a variable capacity system
PROBLEMS• System complexity
CIRP STC-OGA part II Technical TalksLugano, 25th August, 2017
A.A.G. Bruzzone, D.M. D’Addona A new reconfigurable machine tool architecture for technologies integration and cooperative capacity sharing
Complexity Control
How to control the Lego-like Reconfigurable Machine Tool
CIRP STC-OGA part II Technical TalksLugano, 25th August, 2017
A.A.G. Bruzzone, D.M. D’Addona A new reconfigurable machine tool architecture for technologies integration and cooperative capacity sharing
Lego-like RMT: Complex System & Emergent Synthesis
Problem of synthesis
Concept of emergence
Source: K. Ueda, Emergent synthesis approaches to biological manufacturing systems
CIRP STC-OGA part II Technical TalksLugano, 25th August, 2017
A.A.G. Bruzzone, D.M. D’Addona A new reconfigurable machine tool architecture for technologies integration and cooperative capacity sharing
Lego-like RMT: Complex System & Emergent Synthesis
•Class l: Problem with complete description:If the information concerning the environment and specification are wholly given, then the problem is completely described. However, it is often difficult to find an optimal solution. Optimization Strategy•Class II: Problem with incomplete environment description:The specification is complete, but the information on the environment is incomplete. Since the problem is not wholly described now, it is difficult to cope with the dynamic properties of the unknown environment. Adaptation Strategy•Class III: Problem with incomplete specification:Not only the environment description but also the specification are incomplete. The problem solving, therefore, has to start with an ambiguous purpose, and the human interaction becomes significant. Co-creation Strategy
By Kanji Ueda Presentation , “Forward-looking View of Emerging Fields of Importance within or Closely Related to STC O”, August 27, 2010, Pisa, CIRP STC O Meeting
CIRP STC-OGA part II Technical TalksLugano, 25th August, 2017
A.A.G. Bruzzone, D.M. D’Addona A new reconfigurable machine tool architecture for technologies integration and cooperative capacity sharing
Lego-like RMTs: Emergent Synthesis Approach
CLASS II & III PROBLEMS
CLASS II – purpose defined, environment unknown:• Resources (beds modules, processing cross-tables and configuration layout) + manufacturing goal are fixed• Market demand unknown
CLASS III – purpose undefined, environment unknown:• Resources (beds modules, processing cross-tables and configuration layout) + manufacturing goal are undefined• Market demand unknown
CIRP STC-OGA part II Technical TalksLugano, 25th August, 2017
A.A.G. Bruzzone, D.M. D’Addona A new reconfigurable machine tool architecture for technologies integration and cooperative capacity sharing
Lego-like RMT: Complex System & Emergent SynthesisEmergence based approaches
Instead of traditional approaches (analytic and deterministic) the difficulties in synthesis problem-solving related to the three classes (I, II, III) of problems can be faced by using emergence based approaches, developed with both bottom-up and top-down features.They include:
• evolutionary computation,• self-organization,• behavior-based methods,• reinforcement learning,• multi-agent systems,• game theory, etc.
CIRP STC-OGA part II Technical TalksLugano, 25th August, 2017
A.A.G. Bruzzone, D.M. D’Addona A new reconfigurable machine tool architecture for technologies integration and cooperative capacity sharing
Lego-like RMT controlMAS approach
Upper movable cross-table(processing device)
Bottom movable cross-table(workpiece holder)
Bed module(integral leadscrew racks)
Agents associated to physical RMT components(embedded physical agents)
CIRP STC-OGA part II Technical TalksLugano, 25th August, 2017
A.A.G. Bruzzone, D.M. D’Addona A new reconfigurable machine tool architecture for technologies integration and cooperative capacity sharing
Lego-like Reconfigurable Machine ToolsMAS Control Architecture
EnterpriseLevel
Bed Unit Level
Machine LevelBottom movable
cross-tablesAgent (BA)
Upper movablecross-tables
Agent (UPA)
Screw Agent
Coordination Agent (CA)
K&DB Agent (KA)
Bed Unit Agent (BUA)
SW
SW + HW
SW + HW
CIRP STC-OGA part II Technical TalksLugano, 25th August, 2017
A.A.G. Bruzzone, D.M. D’Addona A new reconfigurable machine tool architecture for technologies integration and cooperative capacity sharing
Lego-like RMT: MAS Communication Acts
Bottom movablecross-tablesAgent (BA)
Screw Agent
Coordination Agent (CA)
K&DB Agent (KA)
Bed Unit Agent (BUA)
C-B proposeB-C agree (refuse)
BU-B
B-BU
B-K
info
rm
Upper movablecross-tables
Agent (UPAi)
Ui-C
refu
se
C-U
i req
uest
Ui-C
agr
ee
C-U
i req
uest
Enterprise Level
Bed Unit Level
Machine Level
CIRP STC-OGA part II Technical TalksLugano, 25th August, 2017
A.A.G. Bruzzone, D.M. D’Addona A new reconfigurable machine tool architecture for technologies integration and cooperative capacity sharing
Technologies Integration and Cooperative Sharing
Possibilities enabled by the Lego-like Reconfigurable Machine Tool
CIRP STC-O
GA part II Technical Talks
Lugano, 25th August, 2017
A.A.G. Bruzzone, D.M. D’Addona A new reconfigurable machine tool architecture for technologies integration and cooperative capacity sharing
Technologies Integration
Technologies classification & functions
CIRP STC-OGA part II Technical TalksLugano, 25th August, 2017
A.A.G. Bruzzone, D.M. D’Addona A new reconfigurable machine tool architecture for technologies integration and cooperative capacity sharing
Cooperative SharingEnabled models: 1 Manufacturing Company
Lego-like RMT 1
Lego-like RMT n
Shop floor A
Intra sharing
Lego-like RMT 1
Lego-like RMT m
Shop floor B
Intra sharing
Shop floors inter-sharing, Company intra-sharing)Shared items:- Beds- Processing cross-tables- Workpiece cross-tables
CIRP STC-OGA part II Technical TalksLugano, 25th August, 2017
A.A.G. Bruzzone, D.M. D’Addona A new reconfigurable machine tool architecture for technologies integration and cooperative capacity sharing
Cooperative SharingEnabled models: >1 Manufacturing Companies
RMT Shop floor Aα
RMT Shop floor Kα
Company α
Company intra-sharing
RMT Shop floor Aβ
RMT Shop floor Hβ
Company β
Company intra-sharing
Companies inter-sharingShared items:- Beds- Processing cross-tables- Workpiece cross-tables
CIRP STC-OGA part II Technical TalksLugano, 25th August, 2017
A.A.G. Bruzzone, D.M. D’Addona A new reconfigurable machine tool architecture for technologies integration and cooperative capacity sharing
Cross-tables, Bed units
Manufacturing capacity
sharing service
Industrial districtNew perspectives
Industrial Districts & Lego-like RMTs
CIRP STC-OGA part II Technical TalksLugano, 25th August, 2017
A.A.G. Bruzzone, D.M. D’Addona A new reconfigurable machine tool architecture for technologies integration and cooperative capacity sharing
Open issues for Lego-like RMT
• Industry 4.0 KETs implementation (e.g. Industrial Internet)• Capital Asset through Capacity Sharing • ……….
CIRP STC-OGA part II Technical TalksLugano, 25th August, 2017
A.A.G. Bruzzone, D.M. D’Addona A new reconfigurable machine tool architecture for technologies integration and cooperative capacity sharing
From a static manufacturing structure ….
Lego-like RMT with
Fixed Resources:Bed modules
Processing cross-tables
Static layout
Workpiecesby cross-tables
Productsby cross-tables
CIRP STC-OGA part II Technical TalksLugano, 25th August, 2017
A.A.G. Bruzzone, D.M. D’Addona A new reconfigurable machine tool architecture for technologies integration and cooperative capacity sharing
…. to a morphing manufacturing structure
Lego-like RMT with
Variable Resources:Bed modules
Processing cross-tablesWorkpiece cross-tables
Dynamic layout
Bed modulesProcessing cross-tablesWorkpieces cross-tables
Bed modulesProcessing cross-tablesWorkpieces cross-tables
CIRP STC-OGA part II Technical TalksLugano, 25th August, 2017
A.A.G. Bruzzone, D.M. D’Addona A new reconfigurable machine tool architecture for technologies integration and cooperative capacity sharing
Conclusion
• New Lego-like Reconfigurable Machine Tool through a new linear axis kinematics
• Emergent Synthesis Approach
• MAS approach to control complexity of the Lego-like RMT systems
• New manufacturing paradigm by technologies integration & cooperative capacity sharing
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action would be effective” https://www.cirp.net/about-cirp/history-col-250/cirp-history.html
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