A new reconfigurable machine tool architecture for

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


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



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



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



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



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



Lego-like Reconfigurable Machine Tools(PCT/IB2017/050737)

)+= ( ;

Bed modulewith integral

racks

Movable table(s)with screws coupled to

the racks













Upper movable cross-table(processing device)

Bottom movable cross-table(workpiece holder)

Bed module(integral leadscrew racks)



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



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.



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



Complexity Control

How to control the Lego-like Reconfigurable Machine Tool



Lego-like RMT: Complex System & Emergent Synthesis

Problem of synthesis

Concept of emergence

Source: K. Ueda, Emergent synthesis approaches to biological manufacturing systems



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



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



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.



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)



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



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



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


Technologies Integration

Technologies classification & functions



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



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



Cross-tables, Bed units

Manufacturing capacity

sharing service

Industrial districtNew perspectives

Industrial Districts & Lego-like RMTs



Open issues for Lego-like RMT

• Industry 4.0 KETs implementation (e.g. Industrial Internet)• Capital Asset through 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



…. 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



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

CIRP foundation “…..in view of the importance and scale of the problems to be tackled, only international cooperative

action would be effective” https://www.cirp.net/about-cirp/history-col-250/cirp-history.html

For further information, please contact [email protected]

mailto:[email protected]



Lego-like RMT for….cooperative capacity sharing!

Thanks for your attention

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A new reconfigurable machine tool architecture for