EAGER: Cybermanufacturing: Design and analysis of a cyberphysical systems approach for custom manufacturing kiosks

EAGER：网络制造：定制制造信息亭的网络物理系统方法的设计和分析

基本信息

批准号：
1547075
负责人：
Panganamala Kumar
金额：
$ 30万
依托单位：
Texas A&M Engineering Experiment Station
依托单位国家：
美国
项目类别：
Standard Grant
财政年份：
2015
资助国家：
美国
起止时间：
2015-09-01 至 2018-08-31
项目状态：
已结题

来源：
https://www.nsf.gov/awardsearch/showAward?AWD_ID=1547075&HistoricalAwards=false
关键词：
EAGER Cybermanufacturing Design analysis cyberphysical

项目摘要

Recent advances in computing, communication and manufacturing technologies promise the possibility of cost-effective production of custom, high quality components especially in medical, energy, aerospace and consumer appliance industry. Custom manufacturing machines operating standalone in kiosks, possibly within home supply stores, operated by a non-technical workforce may enable broad retail customer use. A major challenge to this vision is the high cost of quality loss in the current 3-D printing processes. Breakthrough approaches for quality assurance, similar to what the photocopying sector has achieved, are necessary to deploy custom manufacturing technologies as service kiosks. Unlike in high volume manufacturing, real-time control is essential for deploying custom manufacturing systems as a service. It is unrealistic to design and plan a production process to realize arbitrary geometric features from a wide variety of materials. This EArly-concept Grant for Exploratory Research (EAGER) project explores real-time control issues at the core of a novel machine tool system for creating custom components from sheet precursors using a sequence of cut-bend-fold (kirigami) operations. A kirigami machine consists of a laser cutter, a robotic arm with a forming tool, and an indexer. It offers significant advantages over the current 3-D printing paradigms for custom manufacturing, as sheet precursors are cheaper and easier to handle, and it takes just minutes versus hours to create complex parts including large lightweight functional components.The project's approach combines recent advances in CPS, passive wireless sensing, low latency communications and digital image correlation for real-time quality assurance. The sheet precursors will be embedded with thermochromics particles so that as the sheet is being shaped, the particles serve as a swarm of mobile passive sensors whose instantaneous location and distortion are discerned using cameras to estimate the process state (mainly temperature and deformation fields) at unprecedented granularity, and control laws synthesized to tune process parameters and actuator motion to mitigate quality issues. This is a departure from the currently held thoughts on Cybermanufacturing using powder rather than sheet based process, and leverages dynamic CPS based coordination employing novel swarm based sensors instead of static open-loop planning. The novel passive swarm sensing is potentially a huge advancement in disaggregating process variables. The principal investigators will address the challenges associated with placement of cameras to capture information from dynamic sensors, addressing issues such as occlusions, fast prognostication of impending faults, and optimization of control actions using uncertain image data. They are working with a local sheet forming firm to develop a proof of concept machine. Their experiences in Morse theoretic exact kirigami construction of complex geometries, and sheet folding mechanics will be employed to plan kirigami operations and delineate attainable geometries.

计算，通信和制造技术的最新进展有望产生具有成本效益的定制，高质量组件的可能性，尤其是在医疗，能源，航空航天和消费电器行业中。由非技术人员运营的售货亭的定制制造机（可能是在房屋供应商店内）的独立运营机器可能会促进广泛的零售客户使用。这一愿景的主要挑战是当前3-D打印过程中质量损失的高成本。质量保证的突破性方法，类似于影印部门所取得的成就，对于将定制的制造技术部署为服务售货亭是必要的。与大型制造业不同，实时控制对于部署自定义制造系统作为服务至关重要。设计和计划生产过程以实现各种材料的任意几何特征是不现实的。这项探索性研究（急切）项目的早期概念赠款探索了新型机床系统核心的实时控制问题，该问题旨在使用一系列切割折叠（Kirigami）操作从工作表前体创建自定义组件。 Kirigami机器由一个激光切割器，带有成型工具的机器人手臂和索引器组成。它比当前的3D打印范例具有定制制造的显着优势，因为工作表前体更便宜且易于处理，并且仅需几分钟与数小时相比，创建复杂的零件，包括大型轻质功能组件。该项目的方法结合了CPS的最新进展，CPS的最新进展，无线无线传感，低延迟通信，低延迟通信和数字图像Correlation for实时质量。 The sheet precursors will be embedded with thermochromics particles so that as the sheet is being shaped, the particles serve as a swarm of mobile passive sensors whose instantaneous location and distortion are discerned using cameras to estimate the process state (mainly temperature and deformation fields) at unprecedented granularity, and control laws synthesized to tune process parameters and actuator motion to mitigate quality issues.这与目前对使用粉末而不是基于纸张的过程的网络制造的想法背道而驰，并利用采用新型基于群体的传感器而不是静态开环规划的基于CPS的动态协调。新颖的被动群传感可能是分解过程变量的巨大进步。主要研究人员将解决与放置相机相关的挑战，以捕获动态传感器的信息，解决诸如遮挡，快速预测即将发生故障的问题以及使用不确定图像数据对控制动作进行优化。他们正在与当地的成立公司合作，以开发概念验证机。他们在复杂几何形状的Morse理论精确基里加米（Kirigami）构建方面的经验将采用纸折折计划，以计划基里加米（Kirigami）操作并描述可达到的几何形状。