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以经济高效的方式生产定制的高质量组件，特别是在医疗、能源、航空航天和消费电器行业。定制制造机器在信息亭（可能在家居用品商店内）独立运行，由非技术人员操作，可以使广泛的零售客户使用。这一愿景面临的主要挑战是当前 3D 打印过程中质量损失的高昂成本。与复印行业所取得的成就类似，突破性的质量保证方法对于将定制制造技术部署为服务亭来说是必要的。与大批量制造不同，实时控制对于将定制制造系统部署为服务至关重要。设计和规划生产过程以利用多种材料实现任意几何特征是不现实的。这个早期概念探索性研究资助 (EAGER) 项目探索了新型机床系统核心的实时控制问题，该系统用于使用一系列切割-弯曲-折叠（剪纸）操作从板材前体创建定制组件。剪纸机由激光切割机、带有成型工具的机械臂和分度器组成。与当前用于定制制造的 3D 打印范例相比，它具有显着的优势，因为片材前体更便宜且更易于处理，并且只需几分钟而不是几小时即可创建包括大型轻质功能部件在内的复杂零件。该项目的方法结合了以下领域的最新进展： CPS、无源无线传感、低延迟通信和数字图像关联可实现实时质量保证。片材前体将嵌入热致变色颗粒，以便在片材成型时，这些颗粒充当一群移动无源传感器，使用相机识别其瞬时位置和变形，以估计工艺状态（主要是温度和变形场）。前所未有的粒度和控制法则综合调整过程参数和执行器运动，以减轻质量问题。这与目前使用粉末而不是基于片材的工艺进行网络制造的想法背道而驰，并利用基于动态 CPS 的协调，采用基于群体的新型传感器而不是静态开环规划。新颖的被动群体传感可能是分解过程变量方面的巨大进步。主要研究人员将解决与放置摄像机以从动态传感器捕获信息相关的挑战，解决遮挡、快速预测即将发生的故障以及使用不确定图像数据优化控制操作等问题。他们正在与当地一家板材成型公司合作开发概念验证机器。他们在复杂几何形状的莫尔斯理论精确剪纸构造和纸张折叠力学方面的经验将用于规划剪纸操作并描绘可实现的几何形状。