Transcript Multimedia Attachment to the Book “Manufacturing Technologies for Machines of the Future” EXIT Editorial Board of the Book Prof.

Multimedia Attachment to the
Book
“Manufacturing
Technologies for
Machines of the Future”
EXIT
Editorial Board of the Book
Prof. Pollmann W., Head of Editorial Board, Vice President Research, Materials and
Production DaimlerChrysler AG, Germany
Academician, Prof. Frolow K. V., Director of the Mechanical Engineering
Research Institute, Russian Academy of Sciences, Russia
Prof. Dr. Sc. Dashchenko A. I., Head of Dept., Moscow State Technical
University ”MAMI”, Russia
Mr. Inaba H., Senior Vice-President of ”Fanuc” Ltd, Japan
Prof. Dr.-Eng. Santochi M., Head of Section, University of Pisa, Italy
Prof. Dr.-Eng. Rehsteiner F., Head of the Institute of Machine Tools and
Manufacturing, Zurich University, Switzerland
Prof. Dr-Eng. habil. Peklenik J., Head of Department, University of
Ljubljana, Slovenia
Manufacturing
Technologies
for Machines
of the Future
Prof. W. Pollmann
Workgroup
1. Prof. Dr. Sc. A.I. Dashchenko, Moscow State
Technical University <<MAMI>>, Russia
2. Mr. W. Samlowski, DaimlerChrysler AG,
Germany
3. Prof. Dr. Sc. L.I. Volchkevich, Bauman TU, Russia
4. Prof. Dr. Sc. E.G. Nachapetjan, Mechanical
Engineering Research Institute, Russian
Academy
of Sciences, Russia
5. Dr. O.A. Dashchenko, DaimlerChrysler AG,
Russia
6. Mr. H. Grosser, Fraunhofer Gesellschaft,
We thank the following companies for the permission
to use their multimedia materials:
-
3D Systems, USA
-
Kuka Roboter GmbH, Germany
-
APS engineering, Germany
-
Hüller Hille, Germany
Cross Hüller
-
Heinz-Nixdorf Institute, Germany
-
University of Pisa, Italy
-
DaimlerChrysler AG, Germany
-
Heidelberger Druckmaschinen, Germany
-
Fanuc Ltd, Japan
-
Autoplant ZIL, Russia
-
MSTU <<MAMI>>, Russia
-
IFW University of Hannover, Germany
Multimedia Designers:
Dr. Dudin E., NIITAvtoprom, Russia
Dr. Dashchenko O., DaimlerChrysler AG,
Russia
Contents
Part 1. Global Aspects of Manufacturing
Part 2. Trends and Developments of Advanced
Manufacturing: Scientific Basis
Part 3. Trends and Developments of Advanced
Manufacturing: Examples of Real Implementation
Part 4. Advanced Manufacturing Equipment
Part 5. Future Trends
Part 1
Chapter 1. The Role of Mechanical Engineering in the 21st Century
K.V. Frolov
Chapter 2. Globalisation of production:Consequences of Product Design and
Technology
F. H. Rehsteiner
Chapter 3. Fractal Company – a Revolution in Corporate Culture
H. J. Warnecke
Chapter 4. Adaptable Production Structures
E. Westkaemper
Chapter 5. Life Cycle Engineering
S. K. Ong, A. Y. C. Nee
Part 2
Chapter 6. Fundamental Points of Mechanical Engineering
A. M. Dalsci, A. S. Vasiliev
Chapter 7. High-speed Machining
H. Schulz
Chapter 8. Aspects of Manufacturing Systems’ Integration
A. I. Dashchenko, W. Pollmann, O. A. Dashchenko
Chapter 9. CAPP systems for Machining, Assembly and Disassembly Operations
M. Santochi
Chapter 10. Modeling of Machine Tools and Assembly Systems
A. I. Dashchenko, W. Pollmann, O. A. Dashchenko
Chapter 11. Cybernethic Structures, Networks and Adaptive Control of Work
Systems in Manufacturing
J. Peklenik
Part 3
Chapter 12. Rapid Prototyping (RP) in Manufacturing
F. H. Rehsteiner
Chapter 13. Challenges in Electronic Production
K. Feldmann
Chapter 14. Electronic Vacuum Technologies
L. I. Volchkevich, Y. I. Panfilov
Chapter 15. New Solid-state Lasers and their Application Potentials
H. Hügel
Chapter 16. New Information Technologies in Industrial Activity of the
Enterprises (IAE)
R. Anderl
Chapter 17. Modeling of Manufacturing and Technological Processes in CIM
V. F. Gornev, V. V. Emelyanov, S. I. Iassinovski
Part 4
Chapter 18. New Machine Tools and Systems
M. Mandelli, T. Nagao, Y. Hatamura, M. Mitsuishi, M. Nakao,
F. Rehsteiner
Chapter 19. Reconfigurable Manufacturing Systems
Y. Koren, U. Heisel, F. Jovane, T. Moriwaki, G. Pritschow,
G. Ulsoy, H. Van Brussel
Chapter 20. Robot Technology
R. D. Schraft
Chapter 21. Methods for Nondestructive Testing and Diagnostics of Automatic
Equipment and Technological Systems of Machines
N. N. Kluev, E. G. Nachapetjan, V. V. Sherbakov
Part 5
Chapter 22. Prospects of Technologies Development
H. Inaba
Chapter 23. Perspectives of Innovative Technologies in Manufacturing
J. Gausemeier
Chapter 1
The role of mechanical engineering in the XXIst century
The present state of engineering technologies on a global
scale reflects primarily the progress made during the XXth
century. Astonishing results and successes have been
achieved in many respects, but there is also evidence of a
growing number of negative by-products.
K.V. Frolov
To see CV
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photo
Up to now progress in Mechanical Engineering has
concentrated mainly on developing and improving the scientific
basis and also on new design principles for yet more powerful
and capable machinery and machine systems. The technical
disciplines concerned most, are the structural, kinematic and
dynamic analysis and synthesis of machines and machine
systems for improved performance, safety aspects, tribology
with special emphasis on friction and wear and improving
machine resistance to the latter; understanding and avoiding
the effects of vibrations and noise on people and on machinery,
and, generally, improving the level of comfort and well being of
the operators.
Chapter 1
The role of mechanical engineering in the XXIst century
Konstantin FROLOV, Prof., Dr. Sc. (tech.), academician,
vice-president of the USSR Academy of Sciences (1985-1992)
and Russian Academy of Sciences (1992-1996) is an
outstanding Russian scientist in the field of mechanical
engineering, author of over 30 books and 800 papers, a
founder of new scientific branches in biomechanics, nonlinear
dynamics and safety of industrial objects. He achieved the
highest Russian honors: several State Prizes, Government
Awards (Gold Star of Labour Hero) and many orders and
medals of the Russian Federation.
K.V. Frolov
His work is well-known in America, Europe, Japan and other
countries. He is an honorable member of the American Society
of Mechanical Engineering (ASME), the Swedish Royal
Engineering Academy, the National Academy of Engineering
(USA), the Royal Academy of Engineering (Great Britain) and
of seven other National Academies, some of which have
awarded him with Golden Medals for significant contribution in
the Mechanical Engineering Sciences.
Chapter 2
Globalisation of production:
demands on products’ construction and technology
In this chapter mostly the position of the manufacturer
who is fully responsible for this product (the main
contractor) is presented. The viewpoint of those carrying
out the manufacturing, e.g., under subcontract, and of
others interested in globalized production such as
politicians and banks is not considered.
F. H. Rehsteiner
Fritz REHSTEINER, Prof., PhD., Dipl.-Eng., Act. Member of
CIRP, Ass. Fellow AIAA Studies was during 9 years the Head
of the Institute of Machine Tools and Manufacturing (IWF) at
the Swiss Federal Institute of Technology (ETH), Zurich.
His Research Interests are:
• Machine tools, primarily milling machines with special
attention to parallel kinematics machines (PKM)
• Cutting processes
• Aerodynamics
• Astronomy
F. H. Rehsteiner
Prof. Rehsteiner is the author of approximately
publications in these research fields.
20
Chapter 3
Fractal company – a revolution in corporate culture
H. J. Warnecke
To a large degree, it is possible to draw a parallel in the
field of flexible production. The vision of large, highly complex
and extremely flexible automatic production systems has not
yet become reality. On the other hand, it is now
commonplace within the metal processing industry for
processing centres to employ an automated, operator-free
exchange of tools and working materials during the third shift.
This trend is reflected, too, in a drastic reduction in demand
for consultancy services in recent years. The know-how
formerly sought from external sources during the introduction
of such systems, now constitutes part of standard expertise in
engineering technology, even within a large number of
medium-sized companies.
Hans-Juergen WARNECKE, Prof., Dr.-Eng., Dr. h. c. mult.,
President of the Fraunhofer Gesellschaft was born in 1934. He
studied mechanical engineering at the ”Technische Hochschule”
in Brunswick and was employed in engineering research. He
became a Doctor of Engineering in 1963.
Becoming a Professor in 197,1 he occupied the Chair of
Industrial Manufacturing and Factory Operation at the University
of Stuttgart, and also became head of the Fraunhofer Institute
for Manufacturing Engineering and Automation IPA.
H. J. Warnecke
Since 1993 Prof. Warnecke has been the President of the
Fraunhofer Gesellschaft (Association for the Promotion of
Applied Research) with its headquarters in Munich and from
January 1995 until January 1998 - the President of the
Association of German Engineers VDI. He has got numerous
honours, including honorary doctorates from the Universities of
Magdeburg, Ljubljana and Timisoara and the Distinguished
Service Cross, 1st class, of the Federal Republic of Germany.
Chapter 4
Adaptable production structures
Companies in processing industries operate today in a
turbulent environment. This is mainly caused by technology,
the globalization of markets and the permanent change in
supply and demand. Effective survival strategies can only be
developed if structures are adapted constantly.
E. Westkaemper
In this chapter strategies and methods contributing
towards new dynamics will be discussed. The starting point of
this article is the assessment of the adaptability of companies
in this turbulent environment. The theme “adaptable
production structures” is the subject of a long-term
interdisciplinary fundamental research project at the
University of Stuttgart in Germany, with the assistance of
economical, technical and biotechnological institutes.
Engelbert WESTKAEMPER, Univ.-Prof., Dr.-Eng., Prof.
E.h., Dr.-Eng., E.h. Dr. h.c., since 1995 Director of the Institut
für Industrielle Fertigung und Fabrikbetrieb (IFF) and Professor
at the University of Stuttgart and Managing Director of the
Fraunhofer Institut für Produktionstechnik und Automatisierung
(IPA) in Stuttgart, was born in 1946, graduated in 1977 from
the RWTH Aachen on the planning of flexible automated
manufacturing systems.
E. Westkaemper
Before rejoining the University in 1988 as the Director of the
Institut für Werkzeugmaschinen und Fertigungstechnik (IWF)
and Professor at the Technische Universität Braunschweig, he
worked for 12 years in the German aircraft (MBB) and
electronics industry where he was responsible for the
development, planning and introduction of new manufacturing
methods and technologies, finally as Director and Head of the
Central Department "Production Engineering" of AEG AG
Frankfurt.
Chapter 5
Life cycle engineering
A. Y. C. Nee
S. K. Ong
Life Cycle Engineering (LCE) refers to a relatively new
approach in designing products that incorporates
environmental issues and parameters across the entire
life cycle of a product. LCE, the discipline of handling the
new environmental parameters in product design, now
has a strong hold in the manufacturing industry. It is the
art of designing the product life cycle through choices
about product concept, structure, materials and
processes. The life cycle phases include pre-manufacture,
manufacture, transportation/distribution, use and disposal
of a product. In each phase, the choice of materials,
processes, energy consumption, recyclability, etc., are
carefully considered from the environmental viewpoint.
Andrew NEE Yeh Ching, Prof., received his PhD from the
Institute of Science and Technology, University of Manchester
(UMIST) in 1973. He then joined the University of Singapore in
1974. In 1986 he was appointed as the Director of
CAE/CAD/CAM Centre, when it was first established. In 1989 he
was promoted to the full professorship. In 1990 he was elected
as an Active Member of CIRP and a Fellow of the Society of
Manufacturing Engineers. He was the first person in the Asian
region to be elected in each case.
A. Y. C. Nee
From 1993 to 1996 worked as the Head of the Department of
Mechanical & Production Engineering and then as the Dean of
the Faculty of Engineering. Since 1998 he occupies two
directors‘ positions at the university level: Director (Special
Projects) of the Office of University Relations, and Director of the
Office of Quality Management. Since 1999 he is heading the
newly established Office of Admissions and since 2001 he is
working as a Deputy Executive Director in the Science and
Engineering Research Council (SERC) of the National Science
and Technology Board.
S. K. ONG received her B.Eng. (Honours in Mechanical
Engineering) from the National University of Singapore in 1992.
She obtained her PhD from the same University in 1996. Currently
she is lecturing in the Manufacturing Division in the Department of
Mechanical & Production Engineering. She is a member of the
Society of Manufacturing Engineers and the Engineering Alumni
Singapore.
S. K. Ong
Now she is the program manager for the Virtual Manufacturing
Program in the Laboratory for Concurrent Engineering and
Logistics (LCEL) in the Faculty of Engineering. She is also active
in the Academic Staff Social Committee, occupying the position of
a staff advisor to the Faculty's Students Engineering Club, as well
as the chairperson of the Student Self-Development Advisory
Committee.
Chapter 6
Fundamentals of parts’ manufacturing
The technology of machine-building manufacture represents
a set of various technological processes — casting, forging,
punching, heat treatment, painting etc. The technology of
machine-building covers the final stages of machine-building
manufacture — the work piece transformation into parts and
assembly, i.e. the machine manufacturing.
A. M. Dalsci
The practice of world engineering is characterized by the
requirements to increase the products quality. The speeds,
temperatures, accuracy and other parameters are augmented
sharply. Involuntarily there is a problem: to what values the
separate parameters can be increased, and others decreased. The answer to this problem is not simple enough.
A. S. Vasiliev
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Chapter 6
Fundamentals of parts’ manufacturing
Anton DALSCI, Prof., Dr .Sc. (eng.) graduated from the
Bauman Moscow Higher Technical School in 1949. For many
years he has been working in the Department for Technology of
Mechanical Engineering of the Bauman Moscow State
Technical University. He is a merited worker of Science and
Technology.
Prof. Dalsci is the author of over 120 publications in the field
of Technology of precise Mechanical Engineering.
A. M. Dalsci
Alexandr VASILIEV, Prof., Dr. Sc. graduated from the
Moscow Bauman Higher Technical School in 1972. He works in
the Department for Manufacturing Engineering of the same
Moscow State Technical University, which is now called Bauman.
Prof. Vasiliev is the author of more than 60 publications in the
field of precise Mechanical Engineering.
A. S. Vasiliev
Chapter 7
High Speed Machining
High speed machining is an advanced production
technology with great future potential. However, as it has been
in many other realisations of the technological progress, the
implementation of the fundamental knowledge into industrial
products, has taken a relatively long time. In this particular
case the period of approximately 60 years was not only due to
a cautious attitude of the industry, but also to the fact that the
existing production facilities corresponding to the state of the
art, at the time when the first findings became available from
research, did not meet the requirements of high-speed
machining.
H. Schulz
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High Speed Machining
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Herbert SCHULZ, Prof., Dr.-Eng. was born in 1936, studied
Mechanical Engineering at the Darmstadt University of
Technology and received the title of Dr.-Eng. in Mechanical
Engineering. Thereafter he worked as the Technical Sales
Manager at Olivetti NC-Machines in Frankfurt, as the Head of
Electro Heat Division at WC Heraeus in Hanau and then as the
Executive Vice President at Scharmann GmbH & Co. in
Mönchengladbach.
H. Schulz
In 1981 he became the Director of the Institute of Production
Engineering and Machine Tools (PTW) of the Darmstadt
University of Technology and in 1987 - the Dean of the Faculty of
Mechanical Engineering of the Darmstadt University of
Technology. He has a great amount of experience in high speed
cutting technology, design of hsc-machine tools and components,
development of special tools for high speed manufacturing and
also in specific CAD/CAM systems. The scientific output of this
research are 36 dissertations, 257 publications, appr. 260 papers
and 4 books.
Chapter 8
Aspects of manufacturing systems’ integration
A. I. Dashchenko
W. Pollmann
O. A. Dashchenko
This chapter presents research conducted within the field of modular manufacturing
machine synthesis. The focus within this field lays in optimising technological processes of
the initial stage. It is easier and less expensive to optimise a process in the initial stage
than to alter finished equipment. The concept employs computer-aided search in the initial
stages of process planning. This concept has already proved valid for mass and serial
manufacturing. Therefore, it is being further developed to suit flexible manufacturing
systems; the main goal thereby is to create cost-effective solutions for various types of
manufacturing.
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Chapter 8
Aspects of manufacturing systems’ integration
Anatoly I. DASHCHENKO, Scientific Editor of this book,
Merited Worker in Science and Engineering of Russia, Prof., Dr.Eng., Dr. Sc., Head of the Department "Complex Automation in
Machinebuilding” TU <<MAMI>>, Academician of International and
Russian Academies of Electrotechnical Sciences, Member of
Society of Automotive Engineers Inc. (N.Y.). was born in 1929.
The range of his scientific interests includes:
A. I. Dashchenko
• Theory and practice of complex automation of industry, based
on new technologies,
• Problems of analysis and optimal synthesis of technological
machines and machine systems (incl. reconfigurable) designed
on the module principle,
• New methods of calculation and experimental research of
productivity, accuracy of work of such systems, including
methods of statistical modelling.
He is the author of 19 books, more than 185 articles (60 of
which are published in different international editions) and has 7
patents and inventions.
Werner POLLMANN, Prof., Head of Editorial Board of this
project was born in 1941 in Paderborn. After studying
mechanical engineering at the University of Hannover he
worked as an assistant to the Chair of Design at the University
of Stuttgart. In 1969 he joined DaimlerChrysler.
After several years in the field of Manufacturing and
Engineering, Prof. Pollmann became Senior Vice President for
Production and Material Research and Chief Environmental
Officer in 1990. In 1995 he was appointed Professor of
Construction and Manufacturing at the University of Stuttgart.
W. Pollmann
Oleg A. DASHCHENKO, Manager of this book-project, Dr.Eng., researcher at the DaimlerChrysler AG, was born in 1962
and graduated from the Moscow State Technical University
<<MAMI>> in 1985. After several years of practical work as the
development engineer he finished his PhD in the field of
assembly automation. Since 1993 has been working as a
researcher at DaimlerChrysler.
The range of his scientific interests includes:
O. A. Dashchenko
• Theory and practice of assembly automation in automotive
industry;
• New assembly, machining and internal combustion engine
technologies.
He is the author of 6 patents (4 of them joint international
patents) and of about 12 articles in different European editions.
Chapter 9
CAPP systems for machining,
assembly and disassembly
This chapter discusses some issues regarding the
application of CAPP (Computer-aided Process Planing)
systems in the fields of machining, assembly and
disassembly. A few examples of successfully tested
CAPP systems, are presented and discussed. Some
conclusions on the future predictable developments of
CAPP systems are finally drawn.
M. Santochi
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Marco SANTOCHI, full Professor of manufacturing engineering
at the Faculty of Engineering of the University of Pisa since 1990.
He occupies the position of the Head of the Department of
Production Engineering at the University of Pisa and now he is the
Head of the Production section of the Department of Mechanical,
Nuclear and Production Engineering.
His research activity carried out in various areas like sensors for
cutting process monitoring, adaptive controls for machine tools,
CAPP, automated assembly, recycling of used consumer products.
M. Santochi
Prof. Santochi is an active member of CIRP with the role of the
Technical Secretary and Chairman of the STC Assembly, Member
of SME (Society of Manufacturing Engineers), responsible of a
national research project on CAPP, responsible of the monitoring
of the National Research Project on Industrial Design, Expert
Assessor at the EC for research projects.
Chapter 10
Results of machine-tool and assembly systems’ modelling
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Chapter 10
Results of machine-tool and assembly systems’ modelling
NEXT VIDEO
Chapter 10
Results of machine-tool and assembly systems’ modelling
Chapter 10
Results of machine-tool and assembly systems’ modelling
A. I. Dashchenko
W. Pollmann
O. A. Dashchenko
Statistical simulation is used to analyse complex manufacturing systems
(MS). The method is based on the statistical laws of technical systems.
Statistical simulation can be applied in varied situations. For example, one could
apply statistical simulation when analysing machine-tools or assembly lines.
The question is, should one analyse machine-tool/assembly lines using
statistical simulation? When working positions/machine tools in an area are
connected by rigid transports, the main parameters of such blocked-together
"simple" systems can be evaluated using elementary formulae. A model of a
blocked-together system is examined in this work at a later time.
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Chapter 10
Results of machine-tool and assembly systems’ modelling
Chapter 11
Cybernetic structures, operations
and control of work systems in manufacturing
J. Peklenik
This contribution presents some thoughts about the
importance of the Cybernetics, the new scientific discipline,
developed by N. Wiener, on the manufacturing science and
technology. The foundation of the approach is the Elementary
Work System (EWS). It is analysed from the cybernetic and
information viewpoint. The subject’s competence, as a decisive
factor for structuring, operating and controlling the EWS is
discussed in detail. The influence of the human factors on the
competence is explained. The control of EWS should consider
the information as well as the cybernetic laws. The conventional
factory system and an EWS adaptive network are briefly
discussed
Janez PEKLENIK, Prof., Dr.Eng., habil. was born in 1926
and is now working as the Head of Department of Control and
Manufacturing Systems at the University of Ljubljana. He is also
the President of the Engineering Academy of Slovenia and
Fellow of the International Institution for Production Engineering
Research (CIRP). In 1979/80 he was the President of CIRP.
His research interests are:
•
J. Peklenik
•
•
•
•
•
•
Online identification of manufacturing processes (cutting,
grinding),
Adaptive control,
Automation of manufacturing systems,
Surface charactirisation,
CA/group technology,
Generative CAPP,
Complex systems in manufacturing.
Prof. Peklenik is the author of more then 220 publications
and 11 patents.
Chapter 12
Rapid Prototyping (RP) in Manufacturing
Rapid Prototyping is the name for a group of novel part
manufacturing processes relying on the quick solidification of a
loose material. They are supposed to be faster and more
flexible than conventional techniques and therefore suited
particularly for producing prototypes in a very short time.
F. H. Rehsteiner
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Chapter 13
Challenges in electronic production
Increasing demands referring to the quality and the
functionality of electronic systems have contributed to a growing
diversity of component packages. Therefore the Surface Mount
Devices (SMD) have, except components for high power and
high mechanical strain (plugs, sockets, etc.), replaced devices
in Through Hole Technology (THT).
K. Feldmann
Klaus FELDMANN, Prof., Dr.-Eng. was born in 1943, studied
production engineering at the Technical University of Berlin. He
earned his doctorate at the Institute of Professor Spur on his
scientific research on design optimisation of automated lathes.
K. Feldmann
After some years of working as the R&D Manager in the fields
of automation and assembly technology in Erlangen and as the
production manager at the plant in Amberg he has become the
Head of the Institute for Manufacturing Automation and
Production Systems (FAPS) at the University of Erlangen in
1982. He is the Speaker of some collaborative research areas,
and the Chairman of the Research Association ”Molded
Interconnect Devices – 3D-MID”. More over he is an active
member of national and international science communities.
Chapter 14
Electronic-vacuum technologies
L. I. Volchkevich
Y. I. Panfilov
Electronic-vacuum Technologies (ET) are material’s
treatment process based on physical phenomenon of high
energy flow particles (electron, ion, atom and molecule beams
and optic, infrared and X-rays radiation as well) and can
operate on any material. There are other names of ET such as
“Electron-Ion-Plasma Technologies”, “Elion Technologies” as
well. A number of ET processes are untraditional for machine
building – vacuum technological fluid creation is the most
important of them.
Leonid I. VOLCHKEVICH, Prof., Dr. Sc. (techn.) was
born in 1930 and is now the Head of Department of
Electronic Technology in machinery at the Moscow Bauman
State Technical University.
His main scientific interests are:
L. I. Volchkevich
•
•
•
Productivity and reliability theory,
Design and Investigation of automated production lines,
Economy of manufacturing and technical politic.
Prof. Volchkevich is the author of more than 300 scientific
publications.
Yuriy V. PANFILOV, Prof., Dr. Sc. (techn.) was born in
1948 and is working in the Department of electronic
technology in machinery at the Moscow Bauman State
Technical University.
His main scientific interests are:
Y. I. Panfilov
• Thin film deposition in vacuum,
• Ultra pure technological environment,
• Electron-ion-plasma treatment methods in electronic
industry.
Prof. Panfilov is the author of more then 150 scientific
publications.
Chapter 15
New solid state lasers and their application potentials
In recent years, NdYAG-lasers have been found to show
increasing interest in many fields of high-power applications that
formerly had been the domain of CO2-lasers. This was mainly
due to several consequences of their wavelength, such as a
higher absorptivity, lower sensitivity against laser-induced
plasmas and, in particular, the use of flexible glass fibers for
beam handling.
H. Huegel
Helmut HUEGEL, Prof., Dr.-Eng. performed his research
work in the field of gas-dynamic lasers and electrically excited
gas flow lasers with emphasis on capacitive rf-excitation. In
1986 he was appointed as the full professor and Director of a
new institute to be built at the University of Stuttgart.
His main interests are:
• Development of lasers (high-power rf-excited CO2, diodepumped solid state; new concepts of high-power diode
lasers),
• Optical systems for beam guiding and shaping and laser
processing.
H. Huegel
From 1990 to 1992 he was the Dean of the Faculty of
Construction, Design and Production Engineering and from
1995 to 1996 the President of Scientific Society for Laser
Technology. Since 2000 he has become the Chair of the
Scientific Board of Max-Born-Institute in Berlin.
Prof. Huegel wrote numerous publications in the fields of
plasma-technology, gas lasers, material treatment processes
and is an author of "Strahlwerkzeug Laser" (Teubner 1992), the
first German textbook on laser technology for engineering
students.
Chapter 16
New information technologies
in industrial activity of the enterprises (IAE)
The rapid technological development of powerful
information and communication technologies (ICT) has a
major impact on enterprises and on their business
processes.
Along
with
globalisation
and
internationalisation, information and communication
technologies are changing the working culture, the
enterprise organisation and the workflow.
R. Anderl
R. Anderl
Reiner ANDERL, Prof., Dr.-Eng. was born in 1955 and
studied mechanical engineering at the University of Karlsruhe,
where he received his diploma in 1979 and then his doctorate
degree in 1984. From 1984 to 1985 he took the position as the
Technical Manager of a medium sized company. Since 1985 he
has been working as the Chief Engineer at the Institute for
Applied Computer Science in Mechanical Engineering (RPK) at
the University of Karlsruhe. In 1991 he habilitated and in 1992
has got the venia legendi, which includes the authorization to
teach CAD/CAM technology. In April 1993 he received the
professorship for computer integrated design in the Faculty
Mechanical Engineering at the Darmstadt Technical University.
Prof. Anderl´s main research activities are advanced CADtechnologies, CAX-integration, product data management
(PDM), product data technology and design methodologies.
Chapter 17
Modelling of technological and production processes
V. V. Gornev
V. F. Emelyanov
S. I. Iassinovski
Intellectual manufacturing is based on the organisation of work with knowledge and
therefore, the new structure of manufacturing organisation and new principles of
manufacturing management. Intellectual manufacturing (IM) and intellectual machine
building enterprises (IME) have just begun developing and while creating any complex
system it is necessary to develop the scientific basis of intellectual manufacturing, its
models and to study its behaviour.
Vadim F. GORNEV, Prof., Dr. Sc. (eng.), Academician of the
International Academies of Information and Sciences of higher
school was born in 1931. He has a rank of the European Teacher
of Engineering of HIGHER SCHOOL (under the register IGIP)
and is working now as the Head of the Department for Computer
Automated Systems and Computer Systems of Automated
Production.
His sphere of activity encompasses:
V. V. Gornev
• Complex automation of manufactures on the basis of new:
• Information technologies,
• Intellectual enterprises. New computer-oriented training
technologies.
Prof. Gornev is the author of more then 150 publications in the
field of automation in mechanical engineering.
Victor V. EMELYANOV, Prof., Dr. Sc., B. Sc., M. Sc. was born
in 1949 and is now working at the Moscow Bauman Higher
Technical School as the Head of the Department of ComputerAided Systems for Manufacturing Automation. He began his
research work in 1973.
V. F. Emelyanov
His main scientific activities were carried out in the fields of
research and development of the method for specifying optimal
strategy of on-line management in manufacturing and theoretic
basis, and method of building intelligence models for making
decision in CIM management and simulation. Hi is also involved
in research on artificial intelligence methods and systems, CIM,
complex discrete systems simulation, analysis and design,
production management, multi-agents systems.
Prof. Emelyanov is the author of the 5 books and more than
150 scientific papers in the field automation, production
management, simulation. He is a member of the Editorial Boards
of the journals ”Software&Systems” and ”AI News”.
C.V.
S. I. Iassinovski
Chapter 18
New machine tools and systems
18.1. New Machine Tools for New Manufacturing Processes.
M. Mandelli
18.2. Intelligent machine tools.
T. Nagao, Y. Hatamura, M. Mitsuishi, M. Nakao
18.3. Modern Concepts for Machine Tools.
F. Rehsteiner
Chapter 18
18.2 Intelligent machine tools
18.2.1. Necessity of Global Intelligent Manufacturing in Modern Societies
T. Nagao, Y. Hatamura, M. Mitsuishi, M. Nakao
18.2.2. Development of an Intelligent Machining Center
T. Nagao, Y. Hatamura, M. Mitsuishi
18.2.3. Development of an Intelligent Face Grinding Machine
Y. Hatamura, M. Nakao
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18.1 New machine tools for new manufacturing processes
The machine tool industry is enjoying a period of fast
innovation, driven by end-users that have re-discovered the
importance of production, after a long period, during which
finance and marketing seemed to be the sole instruments
to reach industrial success. Innovation is also pushed by
internal pressure: European manufacturers must keep
proposing new solutions to face the evolution of a market
that is more and more competitive.
M. Mandelli
In the case of machine tools, the market is particularly
pressing. Machine tools are used to produce other
machines, they are one basic factor of competitiveness for
mechanical firms.
Massimiliano MANDELLI, Dipl.-Eng., after his degree in
mechanical engineering from Politecnico of Milan, he began
his working experience at two of the main Italian machine tool
manufacturing companies. In 1989 he joined UCIMU, the
Italian Association of machine tool manufacturers, which today
covers the position of technical manager.
M. Mandelli
He is active in supporting member companies for
innovation and product development. He co-operates with
Politecnico of Milan and University of Brescia for lectures
related to machine tools and mechanical technology.
Associate member of CIRP, he is the author of more than 30
technical publications.
Mr. Mandelli is involved in many national and international
commissions dealing with technical developments in the
machine tool sector.
18.2.1. Necessity of global intelligent manufacturing in
modern societies
T. Nagao
Y. Hatamura
M. Mitsuishi
M. Nakao
Strong demands are in place on modern manufacturing systems, especially on
those machining systems for cutting and grinding. These demands include high
efficiency, high accuracy, conformance to information systems, and low impact on
the environment. The authors have introduced intelligence into manufacturing
systems to satisfy two of these needs, namely higher accuracy and support of
information systems.
Takaaki NAGAO, Prof., Bachelor, Master & Doctor of Eng. in
mechanical engineering at the University of Tokyo is now
working at the Kochi University of Technology in the Department
of Intelligent Mechanical Systems Engineering. He graduated
from the University of Tokyo in 1961.
Main fields of research are production engineering, materials
processing, mechanics of granular materials, production
economics.
T. Nagao
Yotaro HATAMURA, Prof., PhD studied mechanical
engineering at the University of Tokyo and later made his PhD
at the same University. During many years Prof. Hatamura
worked in the field of design theory and methodology, metal
casting and design, mechanics of powder, intelligent processes,
construction machinery, machine tolls, force sensors/actuators,
information processing machines, micro-machining, biomechanics, technology transfer and education.
His main scientific interests are:
Y. Hatamura
•
•
•
•
•
•
•
Fabrication of 3D micro structure,
Nano-manufacturing world,
Multi-axial force sensing,
Intelligent manufacturing,
Preventing crashes of magnetic disk heads,
Principles of creative design,
Metal forming with vibration.
Prof. Hatamura is a member of CIRP (International Institution
for Production Research), ASPE (American Society of Precision
Engineers), JSME (Japan Society of Mechanical Engineers),
JSPE (Japan Society of Precision), the Robotics Society of
Japan, Society of Powder Technology Japan, Japan Electronics
Society of Packaging, Japan Medical Society of Voice and
Speech, the horological Institute of Japan.
Mamoru MITSUISHI, Prof. is working at the Department of
Engineering Synthesis, Faculty of Engineering at the University
of Tokyo. In 1984 he got his Masters of Engineering in
mechanical engineering at the University of Tokyo. Two years
later he obtained a title of Doctor of Engineering in Mechanical
Engineering at the same University.
M. Mitsuishi
Prof. Mitsuishi worked as a lecturer at the University of Tokyo
as a visiting professor at the Fraunhofer Institute for Production
Technique and Automation (IPA) in Stuttgart and as the
Associate Professor at the University of Tokyo. Now he is
working as a professor at the University of Tokyo.
Masayuki NAKAO, Ass. Prof., Dr.-Eng. was born in Tokyo,
in 1958. He received the B.E., M.E. and Dr.-Eng. degrees from
the University of Tokyo in 1980, 1982 and 1991 respectively.
Since 1982 he had been engaged in the development of thin
film disk in Hitachi Metals, Ltd. and HMT Technology
Corporation.
Since 1992 he has been involved in the research of micro
manufacturing as an associate professor in the Department of
Engineering Synthesis at the University of Tokyo.
M. Nakao
18.2.2 Development of intelligent machining center
M. Mitsuishi
Y. Hatamura
T. Nagao
The authors have developed a high efficiency machining system which
maintains a stable cutting state using multi-axis force information from sensors
installed on the table of a machining center. The implemented system has the
capability for cutting state monitoring, adaptive control by modifying the spindle
speed and the feed speed in real-time, and learning through the storage of an
“experimentally determined stability lobe diagram'' which incorporates knowledge
representing the relation between machining conditions and the machining state.
18.2.3 Development of an intelligent face grinding machine
Information processing devices handle thin substrates,
such as silicon wafers, glass lithography masks, ceramic
circuit boards and glass display boards. These substrates
are 8-inch or larger in diameter with ultra-flatness of some
0.1 m per 200 x 200mm.
M. Nakao
Y. Hatamura
Current processes for finishing the substrates are lapping
and polishing. These processes suffer from low material
removal rate, and large machine footprints, e.g., a 5m
lapping plate used in a 2-hour batch processes to average
out variation in the removal with an alternative in individual
grinding. Various factors interfere with conventional grinding
of such substrates; the grinding force causes deformation at
the rotary bearing; irregular thermal expansion bends the
column; the table tilts along the linear guide etc.
Chapter 18
18.2.3 Modern concepts for machine tools
In this chapter an arbitrary selection of three novel
developments in the design of machine tools is presented. All
of them concern the machine tool properly speaking, i.e.,
neither software and communication aspects nor networked
systems like flexible manufacturing systems are addressed.
These latter fields, demanding as they may be, at least in their
function of presenting a ”background support” to the actual
production work have reached a high level of maturity and
therefore need not be discussed here.
F. H. Rehsteiner
All of the three selected topics: Non Cartesian machine tool
kinematics; doing away with idle time between different
processes, and improving the dynamics of large machine
tools, can not be considered as ”mature” by any means at the
time of this writing. This holds true for their technology as well
as their acceptance by the users. The intention here is to give
the reader an idea of ”where could the voyage go”, and to
show him that quantum leaps forward are still possible.
Chapter 19
Reconfigurable manufacturing systems
Y.Koren
U. Heisel
G. Pritschow
F. Jovane
G. Ulsoy
T. Moriwaki
H. Van Brussel
Strong demands are in place on modern manufacturing systems, especially on those
machining systems for cutting and grinding. These demands include high efficiency, high
accuracy, conformance to information systems, and low impact on the environment. In this
chapter an arbitrary selection of some novel developments in the design of machine tools is
presented. All of them concern the machine tool properly speaking, i.e., neither software and
communication aspects nor networked systems.
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Yoram KOREN, PhD., B.Sc., M.Sc is the Paul G. Goebel
Professor in the College of Engineering at the University of
Michigan. Since 1996 he is the founding Director of the National
Science Foundation (NSF) Engineering Research Center (ERC)
for Reconfigurable Machining Systems.
Prof. Koren is recognized as the founder and worldwide
intellectual leader of a new scientific discipline, reconfigurable
manufacturing systems (RMS) and has published 220 refereed
papers and 3 books in the automated manufacturing field. His
books have been translated into Japanese, French and Chinese,
have won two prestigious awards, and are used as textbooks at
universities around the world. He holds seven U.S. patents in
flexible automation and three additional are pending.
Y.Koren
Prof. Koren is a Fellow of both the Society of Manufacturing
Engineers – SME and .the American Society of Mechanical
Engineers – ASME. He received several awards including the
SME 1984 Textbook Award (given for Koren’s book Computer
Control of Manufacturing Systems; published by McGraw Hill),
and the 1999 William T. Ennor Manufacturing Technology
Award given by the Society of Mechanical Engineers – ASME
International.
Uwe HEISEL, Prof., Dr.-Eng., Dr. h. c. mult. was born in 1945.
He studied mechanical engineering in Berlin and received his
doctor's degree in 1979 with a thesis about "Possibilities to
Compensate Thermal Displacements".
U. Heisel
In 1980 he joined a machine tool company as a development
engineer and took over the management of the department for
design of manufacturing systems after a short time. In 1982 he
was appointed Head of the Mechanical Development and
Design. In 1988 Prof. Heisel was called to the Institute for
Machine Tools (IfW) at the University of Stuttgart as Professor
and Managing Director. Within his research work he is
concerned with machine tool design, machining processes,
automatisation and woodworking technologies.
Current research projects include the development of new
design for machine tools, especially with parallel kinematic
structures.
Francesco JOVANE, full professor of "Tecnologie
Meccaniche" (Manufacturing Technologies) at the University of
Bari and full Professor of "Sistemi Integrati di Produzione"
(Integrated Production Systems) at the Politecnico di Milano.
He carried out scientific activities at the Institute of
Technology, Naples University; National Engineering
Laboratory, East Kilbride (GB); Massachusetts Institute of
Technology, MIT, Boston (USA); University of California,
Berkeley (USA); Institute of Technology, Bari University;
Department of Mechanical Engineering, Politecnico di Milano.
F. Jovane
Prof. Jovane is the author of 140 papers in the field of
manufacturing and innovation. He is working as the Director of
ITIA - Institute of Industrial Technologies and Automation,
National Research Council of Italy (CNR) and is a member of
the Commettee for conceiving the National Research Program
on Innovating Production System, launched by the Ministry of
University and Scientific and Technological Research.
Toshimichi MORIWAKI, Prof. of mechanical engineering at the
Kobe University in Japan was born in 1944 and is working as a
Dean of the Engineering Department.
His Research Interests include:
•
•
•
•
T. Moriwaki
Intelligent manufacturing systems and machine tools,
Ultraprecision machining and machine tools,
Dynamics and thermal behavior of machine tools,
Sensor technology in manufacturing, ergonomics
in manufacturing.
He is a member of the Japan Society of Mechanical Engineers
(JSME), of the Japan Society of Precision Engineering (JSPE), of
the American Society of Mechanical Engineers (ASME),
International Institution for Production Engineering Research
(CIRP, Active Member), American Society for Precision
Engineering (ASPE), European Society for Precision Engineering
and Nanotechnology (EUSPEN) and was awarded with the F.W.
Taylor - Medaille in 1976.
Guenter PRITSCHOW, Prof., Dr.-Eng., Dr. h.c.mult. was born
in 1939. He studied telecommunication technology at the
Technical University of Berlin from 1959 to 1966. Afterwards he
worked for 12 years in research management positions in
industry. From 1976 to 1980 he taught automation technology for
quality assurance and manufacturing at the Technical University
of Berlin.
G. Pritschow
Since 1984 he is the Director of the Institute for Control
Engineering of Machine Tools and Manufacturing Units at the
University of Stuttgart. Important research work is done by the
Institute concerning direct drives, open controllers, parallel
kinematic machines and control algorithm for positioning
controllers.
Galip ULSOY born in 1950 is the William Clay Ford Professor
of Manufacturing and Chair of the Department of Mechanical
Engineering at the University of Michigan (UM). He has been at
the UM since 1980 and has served as the Director of the
Program in Manufacturing, Associate Chair of the Department of
Mechanical Engineering and Applied Mechanics as well as the
Chair of the Mechanical Engineering Graduate Program.
G. Ulsoy
Prof. Ulsoy is interested in dynamic modelling, analysis, and
control of mechanical systems; particularly manufacturing
systems. His research work utilises a combination of
experimental, analytical, and numerical methods. He has made
basic research contributions to the mechanics of axially moving
elastic systems (e.g., translating bands, rotating shafts), and to
control system design (e.g., state derivative feedback, coupling
between modelling and controller design).
C.V.
H. Van Brussel
Chapter 20
Robot technology
The demand for high-quality automation solutions remains
constant. Existing deficits and rapid advances in innovations,
especially in the fields of information and sensor technology,
aim to improve the abilities of robots with regard to their
ability to adapt to changing manufacturing conditions, their
ability to be quickly configured to carry out production tasks
and their intuitive operation in all operating modes from
installation and operating tasks right up to maintenance.
R. D. Schraft
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Rolf D. SCHRAFT, Prof., Dr.-Ing., Dr. h.c. mult. was born in 1942.
Presently he is the Director of the Fraunhofer Institute for
Manufacturing Engineering and Automation (IPA), Stuttgart. Prof.
Schraft studied Mechanical Engineering at the University of Stuttgart
and graduated in 1969. He got his Dr. degree in 1976.
He started the research group for Material Handling and Assembly
at the IPA, which did numerous projects and developments for
national and international research agencies and mainly for industry.
Currently he is very much involved in promoting and developing
service robots.
Since 1977 he has been a lecturer at the University of Stuttgart
and since 1981 also at the University of Dortmund. Since 1986 he is
honorary Professor at the University of Dortmund.
R. D. Schraft
Prof. Schraft received in 1986 the Golden Robot Award, in 1990
the JIRA Award (Japanese Industrial Robot Association), Japan and
in 1992 the Joseph Engelberger Award, from the Robotics Industries
Association, USA. In 1997 the University of Timisoara/Romania
conferred the ”Doctor honoris causa” to Prof. Schraft. In 1998 the
Georgian Technical University of Tiflis/Georgia conferred the ”Doctor
honoris causa” to Prof. Schraft. Since May 2000 he is speaker for the
head of the Fraunhofer IPA
He published more than 440 publications in national and
international journals and 40 books and contributions for books.
Chapter 21
Methods for control, testing, diagnostics and
reliability calculation of automatic equipment
and technological system of machines
N. N. Kluev
E. G. Nachapetjan
V. V. Sherbakov
Quality is important at all levels since it involves technological processes,
service and environment. Great efforts are being put into investigating the
relations between quality, innovation and research.
More than hundreds of physical methods and thousands of different types of
units are used today in non-destructive testing (NDT) and diagnostics for solving
the new approaches to technological problems of quality.
Vladimir KLUEV, Prof., Dr. Sc. (techn.), Corr.-member of the
Russian Academy of Science, Member of the European
Academy, the leading scientist in the field of electromagnetic,
radiographic and acoustic non-destructive methods for metals
and articles quality assurance. Since 1970 he works as the
Director General of the Research Institute of Introscopy of
Moscow-Scientific-Industrial Association "Spectrum", awarded by
several State Prizes.
V. N. Kluev
He is the author of approximately 100 patents, 268 research
papers including 18 monographs and made a big contribution to
the development of instruments for vibration measurements,
radiographic computerized tomography, the theory of
electromagnetic control of moving items and electromagnetic
modulating defectoscopy.
Evgeny NACHAPETJAN, Prof., Dr. Sc. (techn.) was born in
1922 and works now as an employee of the Mechanical
Engineering Research Institute of the Russian Academy of
Science (IMASH RAS) named after A. Blagonravov. He is a
leading specialist in the field of NDT and diagnostics of
mechanisms.
E. G. Nachapetjan
He is the author of 5 monographs and 120 research papers and
participated in the development of technological equipment
mechanisms diagnostics for evaluation of their technical level and
condition.
Victor SHERBAKOV, Dr. Sc., senior scientist, works as a leading
specialist at the Mechanical Engineering Research Institute of the
Russian Academy of Sciences. He is also a skilled specialist in the
area of experimental dynamics and diagnostics of automated
mechanisms.
V. V. Sherbakov
He has conducted a big volume of theoretical and experimental
research on the definition of quality criteria of the mechanisms of
automated equipment diagnostics and of mechanical processes at
different stages of machine life cycle. He has also conducted a
number of developments of the methods of qualimetric estimation of
quality and certification of the mechanisms of technological
equipment, industrial robots and automated methods and means of
control and diagnostics of automatic equipment.
A number of his developments have found practical realisation in
Industry. Dr. Sherbakov has published more than 50 scientific
articles.
Chapter 22
Prospects of the technologies development
Written by the
specialists
of FANUC Ltd
lead by Mr. Inaba
The 21st century has had a great impact on the information
revolution in changing our society towards the new creation of the
information society with much emphasis on individual pleasure
through convergence of time, distance and place. Its nature of
uncertainty due to the inexperienced new individual based
communication and network maybe received confusion and chaos
on the traditional mind, however, it will be transformed as an
excellent opportunity to the challenge and dynamism for new
upcoming generation. Factory automation and robots will perform to
converge our traditional industrial society with the new information
society and vice versa. In addition factory automation and robots with
networked intelligence will generate the great unlimited opportunity
as a bridge to bundle cultural behavior in manufacturing. A new
vision for the future will be provided with our insights on factory
automation with information technology.
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FANUC`s businesses were
founded in 1956 when it
started to develop numerical
control (NCs) and servo
systems. FANUC LTD was
established in July 1972 when
the
Computing
Control
Division became independent
from FUJITSU.
Since its founding, FANUC
has
always
emphasized
research and development in
its management.
”Technology has a history.
But engineers have no past.
They only need to create.”
These words of Dr. Inaba, the
founder of FANUC spell out
FANUC`s
stance
on
technological development.
Injection Molding Machine Factory
The factory has a capacity to produce 200 ROBOSHOTs a month. The machining area is
equipped with the latest "FANUC CELL 60" which enables un-manned operation even on
holidays. All production processes from machining to assembly are performed at FANUC
to deliver high quality products.
Tsukuba Factory
The factory at the foot of Mt. Tsukuba has a capacity to produce 400 ROBOCUTs and
ROBODRILLs a month. It is fully networked by the LAN system, which enables all relevant
information from design, sales to production to be comprehensively controlled - resulting in
a highly advanced CIM system.
Servo Motor Factory
The factory is equipped with the most advanced robotic automation system. All work
processes from receiving motor parts, assembling, testing, packing to shipping are
automated by using robots.
It has a capacity to produce 50,000 motors of approximately 2,000 different kinds a
month.
The motor parts are stored in the state-of-the-art automatic warehouse, which is linked to
distributed warehouses on the production floor, from which the robots take out the parts
and perform automatic assembly.
Hayato Factory
The factory in Kagoshima Prefecture is dedicated to the production of servo motor
sensors and has a capacity to produce 50.000 units a month. The machining and
assembly lines are fully robotized to perform highly efficient production from parts
machining, assembling to testing.
Sheet Metal Factory
The Sheet Metal Factory is manufacturing the cabinets for FANUC robot controllers. This is
the state-of-the-art factory, where every process from cutting to assembling is fully
robotized.
Chapter 23
Perspectives of innovative technologies in
manufacturing
The majority of mechanical engineering products today are
characterised by a close interaction between classical mechanics
with electronics, control engineering and software, expressed aptly
by the term mechatronics. However, further possibilities are
emerging that extend way beyond the scope of mechatronics systems with inherent intelligence. Future systems in the area of
mechanical engineering will comprise configurations of intelligent
system elements, which we also refer to as solution elements
since they enable the solution to a function. The performance of
the overall system is characterised by the communication and cooperation between intelligent system elements. In terms of
software, this involves distributed systems of interacting agents.
J. Gausemeier
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Perspectives of innovative technologies in manufacturing
Juergen GAUSEMEIER, Prof., Dr.-Eng., is professor of
computer integrated manufacturing at the Heinz Nixdorf Institute,
University of Paderborn since 1990. He graduated in 1977 from
the Institute for Machine Tools and Production Engineering at the
Technical University Berlin. His doctoral thesis supervisor was
Professor Spur. During his industrial career, Prof. Gausemeier
was Head of Engineering for CAD/CAM systems for ten years.
His last position was Division Manager for Process Control
System at a well-known Swiss company. Additional to his
professorship he is a Member of the Board and the Managing
Director of the scientific society ”Berliner Kreis –
Wissenschaftliches Forum fuer Produktentwicklung e.V.”.
J. Gausemeier
Prof. Gausemeier has written more than 180 publications for
scientific journals and also for national and international
conferences. There are three books to emphasise (published by
Carl Hanser Verlag).