Advances in Manufacturing

Interpretation and compensation of backlash error data in machine centers for intelligent predictive maintenance using ANNs

Ke-Sheng Wang, Zhe Li, Jørgen Braaten, Quan Yu

2015, 3(2): 97-104. doi:10.1007/s40436-015-0107-4

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It is especially significant for a manufacturing company to select a proper maintenance policy because maintenance impacts not only on economy, reliability and availability but also on personnel safety. This article reports on research in the backlash error data interpretation and compensation for intelligent predictive maintenance in machine centers based on artificial neural networks (ANNs). The backlash error, measurement system and prediction methods are analyzed in detail. The result indicates that it is possible to predict and compensate for the backlash error in both forward and backward directions in machine centers.

High-accuracy turning with slender boring bars

Knut Sørby, Einar Sundseth

2015, 3(2): 105-110. doi:10.1007/s40436-015-0112-7

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The paper presents the theoretical background for new approaches for achieving high accuracy in finish turning with slender tools. The approaches are developed especially for high-accuracy turning with vibrationsdamped boring bars with a length-to-diameter ratio up to 14. The approaches are based on established force models of turning operations and utilize a three-pass scheme where the deflection of the boring bar is calculated and compensated for in the final passes. Very good results are achieved in practical machining tests for a great variation of cutting conditions. Experiments show that the typical diameter error is 0.01 mm, even in situation where the tool deflection is 0.3 mm.

Designing a performance measurement system to support materials management in engineer-to-order: a case study

Børge Sjøbakk, Ottar Bakås, Oksana Bondarenko, Tara Kamran

2015, 3(2): 111-122. doi:10.1007/s40436-015-0109-2

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There are many different production situations that can be employed to meet demand. In the engineer-toorder (ETO) production situation, products are manufactured to meet specific customer needs by unique engineering or significant customization. In such an environment, failing to supply the required materials in the right quantities and at the right time increases the risk of breaching due date agreements and thereby losing customer satisfaction. As such, materials management is one of the most important and critical processes within production planning and control in ETO. To bring attention and improvement to this area, ETO companies may benefit from a performance measurement system (PMS) that systematically monitors how well materials management is carried out. The design of a company's PMS varies with its production situation. Within the large body of literature on performance management and measurement, limited literature specifically addressing performance measurement in ETO has been identified. After being approached by a Norwegian ETO company requesting a PMS for materials management, the authors therefore set out to design the PMS from scratch, using literature on ETO, materials management and performance management and measurement as a starting point. The paper presents the proposed PMS. It provides a basis for further studies on the topic, and could be used by managers in ETO companies to assess and improve their materials management practice.

Research on the influences of torsional deformation on contour precision of the crank pin

Jing Li, Hui Qian, Biao Li, Nan-Yan Shen

2015, 3(2): 123-129. doi:10.1007/s40436-015-0108-3

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The span and length to diameter ratio of the large-scale crankshaft are big, and the structure and the distribution of crank pins are complex. Thus it is easier for crankshaft to generate biggish torsional deflection which finally influences the contour precision of the crank pin in tangential point tracing grinding. Based on the analyses of force and torsional deformation of the crankshaft under different crankshaft driving modes of the headstock and the tailstock, the relationship between torsional deformation and rotation angle error of the crankshaft in tangential point tracing grinding is discussed in this paper. According to crankshaft rotational motion and wheel frame coordinated motion in tangential point tracing grinding, contour error of the crank pin caused by torsional deflection is established under different crankshaft driving modes. The simulation results show that minimum contour error of the crank pin can be obtained when crankshaft is synchronously driven by both the headstock and the tailstock, and speed error does not exist in tangential point tracing grinding.

Advances in numerical computation based mechanical system design and simulation

Hirpa G. Lemu

2015, 3(2): 130-138. doi:10.1007/s40436-015-0110-9

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This paper highlights the available numerical computation techniques in mechanical engineering field with focus on application of modeling and simulation within renewable energy conversion machines as a particular research case. The study makes special focus on simulation approaches based on finite elements and multibody dynamics that are currently focused within the research community. Developing the simulation model in a computer-aided design (CAD) tool is a precondition for a successful simulation-based mechanical system research. The article discusses and elaborates the methods implemented to integrate design data with other computer-aided engineering functions. The motivation is the fact that simulation-based research is useful for design optimization of mechanical systems that operate in harsh and unfriendly environment where conducting physical testing of prototypes is difficult. In addition, the manufacturing environment is benefiting from the developments in numerical computation techniques through machining simulation that significantly reduce the time-to-market and thus increase competitiveness. The study is also intended to explore the existing gaps of capabilities in current approaches in application of computational techniques in order to draw attention to future challenges and trends.

Profit loss indicator: a novel maintenance indicator applied for integrated planning

Harald Rødseth, Terje Skarlo, Per Schjølberg

2015, 3(2): 139-150. doi:10.1007/s40436-015-0113-6

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In production environment today, "silo thinking" is a challenge where controlling an asset associated with several disciplines and departments can lead to a suboptimal result. This requires a more integrated approach with an integrated planning (IPL) framework. In this framework novel maintenance key performance indicators (KPIs) are needed. The purpose of this article is to develop the novel maintenance KPI profit loss indicator (PLI). This indicator is based on measuring both on the "hidden factory" and waste in production, presenting it as a financial measure. The notion "hidden factory" is used as a metaphor for measuring the time losses in industry through the maintenance KPI overall equipment effectiveness (OEE). This indicator divides the time losses into availability losses, performance losses and quality losses. In addition, a financial measure for waste based on literature from Toyota production system (TPS) and waste treatment and disposal is also included in PLI. Through a case study in the saw mill industry PLI is demonstrated and evaluated. It is expected that this indicator will be demonstrated in several industry branches in the future.

Production network flexibility: case study of Norwegian diary production network

Taravatsadat Nehzati, Heidi C. Dreyer, Jan Ola Strandhagen

2015, 3(2): 151-165. doi:10.1007/s40436-015-0111-8

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By increasing advances in the production networks planning, understanding of relations and dynamics of production networks is gaining more attention in order to use all network capabilities. To achieve this understanding, it is not only important to have a good understanding of individual firm's manufacturing flexibility next to supply chain flexibility, but also to consider the internal (among production network's facilities) and external (other tiers of supply chain) relationships in a production network. Studying the production network's flexibility dimensions facilitates the effective use of the synergy of cooperation in the network. On other words, the potential in the network structure cannot be exploited unless the planning and control of network consider the available flexibility of network and operationalize the opportunities which arise. This paper identifies different dimensions of flexibility in a production network and describes how they can support firms in responding to customers' needs. This research employs exploratory and descriptive approaches and uses a single case study of Norwegian diary to capture the dynamics of production networks. Three product categories with different network characteristics are selected, and the identified network flexibility dimensions are investigated for these products. The status of case company under each flexibility dimension is presented and discussed.

Fast-growing forest pruning robot structure design and climbing control

Guang-Hua Fu, Xue-Mei Liu, Yan-Fu Chen, Jin Yuan

2015, 3(2): 166-172. doi:10.1007/s40436-015-0114-5

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According to the requirement of fast-growing forest pruning operation, the pruning robotwas developed.The structure and control system of pruning robot were described, the work flow of pruning robot was expounded. The type and structure of the drivingmotor and the compression springwere decided with force-balance analysis. The tilt problem of pruning robot was resolved by ADAMS and Matlab co-simulation, and the control scheme of climbing mechanism was determined. The experiment results of the prototype indicate that pruning robot can climb tree trunk smoothly at a speed of 20 mm/s and cross the raised trunk. The pruning saw which is driven by the adjustable speed motor can cut the branches of 30 mm. And the residual amount of branches is less than 5 mm. Pruning robot can meet the practical requirements of the fast-growing forest pruning work.

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