Beruflich Dokumente
Kultur Dokumente
Data Analysis and Causal Identification for Gear Noise Reduction in Transmission Systems Cyclic Waveform Signal Analysis for Monitoring and Control of Powertrain Manufacturing Systems Throughput Analysis of Mfg Systems with Closed Loop MHS Computer Aided Simulation Model Verification, Testing and Optimization Hardware-in-the-Loop Simulation for Verification and Validation of Logic Control Manufacturing Network Time Synchronization Best Practices (NIST Funded) Reducing Unscheduled Downtime Through Automated Event-Based Control
Development, Application and Transfer of a Network ROI Cost Calculator (on hold after 12/07)
2 I 3
II
4 5 6 1 2 III 3 4 5
Wireless Network Analysis and Testing The Reconfigurable Factory Testbed (RFT) Cylinder Bore Inspection Pore Detection in Small Diameter Bores In line In-line Vale Seat Inspection Thread Measurement Camshaft / Crankshaft Polishing Testing Y. Koren Overview #2
Meeting Agenda
2:00 2:05 2:40 2:40 3:10 3:10 3:30 3:30 3:40 3:40 4:05 4:05 4:25 4:25 4:35 Introduction Reducing unscheduled downtime through automated event-based control Cyclic C li waveform signal analysis f monitoring and control f i l l i for it i d t l of powertrain manufacturing systems Computer aided simulation model verification, testing and optimization p Break In-line valve seat inspection / PKM introduction Thread Measurement New proposal: run-out measurement of crankshaft sprocket Discussions: Acceleration of tech implementation and transfer Third-party vendors involvement format Wrap-up and next steps Adjourn Adj Reuven Katz/Hagay B. Reuven Katz/Hongwei Z Reuven Katz James Moyne Judy Jin Sam Yang
4:35 5:00
All
5:00 5 00
NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan College of Engineering
Y. Koren Overview #3
NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan College of Engineering
TA2-2, Slide 1
Outline
Introduction
The idea, objectives and approach
Next Steps
Short term Longer term project planning Summary and discussion
NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan College of Engineering
TA2-2, Slide 2
The benefit of lower scheduled downtime is Idealized Cap. Cap UnScheduled nearly wiped out by the UnScheduled UnSched led Downtime UnScheduled (nounscheduled downtime (due downtime) Downtime Scheduled Downtime to longer times for Downtime Scheduled Scheduled diagnosis), and diagnosis) and Downtimefault prediction in place D With f ti Downtime unscheduled Low due to conservative downs are Productivity approach Production reduced (turned intoto maintenance caused by high cost of y g Production Production scheduled) unscheduled downs More aggressive approach to maintenance improves Current Aggressive Optimized productivity slightly, Maintenance Strategy Practice Practice however
NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan College of Engineering TA2-2, Slide 3
NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan College of Engineering
TA2-2, Slide 4
Long-Term: Schedule preventive maintenance through ECA rule based control Continuous: Provide and help implement best practices in data management for improvement in maintenance management and downtime prediction
Improving maintenance data quality Maintenance pooling Matching practice to specification Adjust project focus as necessary to adopt to the impact of changing economic conditions
NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan College of Engineering
TA2-2, Slide 5
D e v ia tio n fro m A v e ra g e F a u lt C o u n t
50 40 30 20 10
Data Stores
Excel
C u m u la tiv e P e rc e n ta g e
Operations p
TODAY
OPC
PLCs CNCs Production Machines PLCs
Reduced MTTR
Improved Productivity
Production Machines
Production Machines
NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan College of Engineering
TA2-2, Slide 6
Outline
Introduction
The idea, objectives and approach
Next Steps
Short term Longer term project planning Summary and discussion
NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan College of Engineering
TA2-2, Slide 7
Previous Deliverables
Look at main cost drivers of scrap, unscheduled tool changes and unscheduled maintenance Top Ten anomalies software installed at Global Engine and evaluated
Recognizing interesting events in process data Generate Excel report including Paretos
Lack of good data quality hurt effectiveness User interface design per Global Engine specifications somewhat
Matlab analysis module for maintenance event correlation installed at Global Engine and evaluated
Automated drill-down tool for maintenance investigation g C++ code auto-generated from MATLAB source no MATLAB license required
P2 50 _1
Operations
Excel output
Fast learning rampup Ease of drill-down
60 50 40 30 20 10 0
P3 00 _1
P1 90 _2
P1 80 _4
P1 80 _8
Operation
120 100 80 60 40 20 0
Operations
NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan College of Engineering TA2-2, Slide 9
Previous Result:
Strengthening Correlations with Normalized Overlay
A number of weaker Correlations can be grouped with overlays
After an overlay this operation demonstrates a gradual increase overlay, in faults over the week leading up to the unscheduled Maintenance. This can be used as a basis for predicting and rescheduling downtime downtime.
NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan College of Engineering TA2-2, Slide 10
Outline
Introduction
The idea, objectives and approach
Next Steps
Short term Longer term project planning Summary and discussion
NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan College of Engineering
TA2-2, Slide 11
Current Focus
Failure Prediction
Single fault type to maintenance g yp All fault types to maintenance
Leveraging improvements in data quality due to ongoing implementation of best practice improvements
Leveraging improved maintenance data quality through implementation of best practices Leveraging improved UMERC capabilities for analyzing per specific fault type, and for more automated analysis
NOSE PIECE WONT CLAMP TOGETHER @ 12:23
BOLTFEEDER NOT FEEDING BOLTS @ 18:21 BOLTFEEDER NOT FEEDING BOLTS @23:48 NOT FEEDING BOLTS @ 21:01 NOT FEEDING BOLTS ( y) @ 0:49 (Next Day)
It is not clear that these correlations will hold in the long term. However, if a relationship is confirmed, maintenance practices can be updated to reflect this knowledge The dataNSF Engineeringsufficient quality to where theseSystems is now of Research Center for Reconfigurable Manufacturing University of Michigan College of Engineering relationships can be confirmed our next step
TA2-2, Slide 13
BENEFITS Reduces the probability of unscheduled downtime occurrences Lower maintenance costs, higher MTBF, lower MTTR, more predictable machine operation
Reduces the number of faults on the system, increasing system performance Allows maintenance scheduling to become adaptive
25 30 35 40
10
15
20
Schd. Monthly S Downtime NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan College of Engineering
Unscheduled Downtime
TA2-2, Slide 14
Issues
Part tracking insufficient to support reliable count-based triggering Maintenance prediction needs to be verified with new data
NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan College of Engineering TA2-2, Slide 15
BENEFITS This alternative leverages existing information on the system It doesnt require an update to the part tracking system d t i d t t th t t ki t The maintenance system can support event-based triggering
ISSUES
Need to verify causal relationships with newer higher quality data y p g q y
NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan College of Engineering TA2-2, Slide 16
Schd. PM
Failure!
time
NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan College of Engineering
TA2-2, Slide 17
Schd. PM
Redundant; mis-timed
time
NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan College of Engineering
TA2-2, Slide 18
Schd. PM
KEYS TO MAKING THIS WORK Linkage between unscheduled maintenance events and triggers in DataStream Matching Unscheduled to Scheduled Maintenance work orders p best practices
time
Datastream Counter Reset
NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan College of Engineering
TA2-2, Slide 19
BENEFITS M E T A D A T A L A Y E R Allows for a more comprehensive visualisation and understanding of d t di f factory data.
ActivPlant
DataStream ataSt ea
MPTS
Allows islands of automation to be focused on the same factory objectives ISSUES * Poor data quality prevents unification of data.
TA2-2, Slide 20
Scrap Data
NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan College of Engineering
Test Stand
1.) No Problems in the Engine (Engine Passed) (90%) of time 2.) Minor Problems that can be fixed at cold stand (very rare) 3.) Major Problems, Engine needs to be Torn Down a.) O ti ) Option 1: problem exists i th B k of k 1 bl i t in the Book f knowledge, and l d d root cause can be identified. Result: Fix Operation Identified. b.) Option 2: problem's root cause cannot be identified. Engine is not immediately torn down due to lack of time and resources. resources c.) Option 3: Engine is immediately torn down and operation may halt in order to determine root cause.
Operation Operation Operation Operation Two One Four Three KEYS TO IMPROVING BEST PRACTICES The main decision that needs to be made is whether a reject that has not been observed is worth examining the root Reconfigurablethe problem causes of Manufacturing Systems NSF Engineering Research Center for TA2-2, Slide 21 University of Michigan College of Engineering The Largest Area of improvement is to determine a way for modeling the Likelihood of a reject seen occurring again
Outline
Introduction
The idea, objectives and approach
Next Steps
Short term Longer term project planning Summary and discussion
NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan College of Engineering
TA2-2, Slide 22
Next Steps:
Failure Prediction
Project has shifted focus somewhat in light of the current economic conditions
Focus on reducing cost NOW Ideas for reducing cost in light of operation under capacity
TA2-2, Slide 23
Next Steps:
Low Production Load Maintenance
Correlation, if verified will allow for implementation of event-based maintenance
Newer data (reflecting newer best practices) should be of sufficient quality to (1) verify correlations, and (2) determine if maintenance is a function of part count as opposed to (or in addition to) time
Implementation of improved part tracking and linking to p p p g g maintenance for part-count based maintenance scheduling is a longer term issue Longer term, all three types of maintenance scheduling term should be in place, based on prediction information (or lack thereof)
Time-based maintenance Part-count based maintenance Event-based maintenance Combinations
NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan College of Engineering TA2-2, Slide 24
Next Steps:
Reducing Redundant Maintenance
Global Engine is aware of what needs to be done Fix is largely a combination of engineering and best practices improvement at this point
Linking of unscheduled corrective maintenance events into the preventative maintenance system Aligning the work order descriptions of unscheduled maintenance operations with scheduled maintenance operations
NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan College of Engineering
TA2-2, Slide 25
Next Steps:
ROI Calculations
Impact of current efforts should be easy to convert into ROI numbers
E E.g., reduced number of maintenances per unit time X cost of d d b f i t it ti t f maintenance event in terms of man hours and consumables We hope to use ROI data to drive additional improvements in integration and best practices i t ti db t ti Improved part tracking / counting Aligning of unscheduled and scheduled downtime work order descriptions Resetting capability for maintenance schedules
NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan College of Engineering
TA2-2, Slide 26
Next Steps:
Other Efforts
Data consolidation / meta layer Improve best practices on test stands; decision process with rejects; analysis of continuous data E l Explore i incorporating MPTS d t i t model f ti data into d l for Unscheduled Downtime Prediction C ti Continue t impact implementation and refinement of to i ti l t ti d fi t f best practice improvements
Data quality improvements to support prediction, consolidation and ROI goals
NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan College of Engineering
TA2-2, Slide 27
Summary
Implementation of best practices for improved data quality are starting to pay off
We are seeing potential correlations between faults and maintenance events Signal could be strong enough for prediction
Next steps focus on verifying analysis with new data and providing justification for best practice improvement investment through ROI analysis
NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan College of Engineering TA2-2, Slide 28
Discussion
Need to determine the type and level of longer term support for the project
No Summer internship in 2009 Will likely have close interaction with Global Engine via regular visits
If there is a desire to close the project, 4 6 project months additional to tidy up deliverables would be ideal
There is still research to be done Prioritization with other projects
Questions?
NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan College of Engineering TA2-2, Slide 29
Backup Slides
NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan College of Engineering
TA2-2, Slide 30
Time
NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan College of Engineering TA2-2, Slide 31
BENEFITS INVESTMENTS A system by which to track parts. --OR OR A mechanism for scheduling downtimes w.r.t fault data. R d Reduced costs due to d t d t un-necessary maintenances on the system. Increased Production time. The ability to cope p variable production situations.
NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan College of Engineering
TA2-2, Slide 33
Excel
D e v ia tio n fro m A v e ra g e F a u lt C o u n t
40 30 20 10
MATLAB (C++)
Graphs, Correlations
0
C u m u la tiv e P e rc e n ta g e
50
30 O P 0_1 11 0 OP _2 6 O P 0 _3 16 O P 0_3 28 0_ 3
Machine Faults
OP
Operations
C u m u la tiv e P e r c e n ta g e
Operations
Analysis
Excel (Manual)
Excel (Manual)
NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan College of Engineering
NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan College of Engineering
TA2-2, Slide 35
Cyclic W C li Waveform Signal Analysis for Monitoring f Si l A l i f M it i & Diagnosis of Powertrain Manufacturing Systems
Research Team: R hT
ERC/UM: Judy Jin, Kamran Paynabar, Yong Lei, Qiang Li, GM: John Agapiou (R&D); Ed S Sponseller & St ll Steven N Norman (GMPT Li (GMPT- Livonia); i ) Thomas Gustafson & Phillip Steinacker (GMPT-Pontiac) Chrysler: James Wang, Eugene Kuo, Mark Skelly, John Gartner
NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan College of Engineering
#1
Outline
ProjectOverview&ProcessBackground Accomplishments & Tech Transfer Plan at GM Accomplishments&TechTransferPlanatGM NewinvestigationsatChrysler
Comparison of data collection between Chrysler and GM ComparisonofdatacollectionbetweenChryslerandGM AnalysisofavailableoriginalwaveformsignalsatChrysler
NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan College of Engineering
#2
Project Overview
Problem
Cyclic waveform signals are widely used for online monitoring of powertrain manufacturing process. The trial and errors approach for features extraction & monitoring limits may not always be effective.
Goal
To develop systematic waveform signal analysis methods to improve online monitoring systems for powertrain manufacturing processes.
Main tasks
W k with engineers at GM (&Ch l i this quarter) t collect production/DOE data from the Work ith i t (&Chrysler in thi t ) to ll t d ti /DOE d t f th selected process; Develop data analysis algorithms for data preprocessing/signal alignment/signal segmentation /online monitoring charts to characterize/monitor process operation states; Characterize process fault patterns to enhance diagnostic capability; p p g p y; Software development, plant testing, and validation.
NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan College of Engineering #3
ProcessBackground
Valve Seat Pressing Machine
Sensor data Sciemetric System Problem: A high false reject rate is a top concern. Goal: Improve production throughput by effectively using online sensor monitoring systems. i i Recorded manual inspection 28%
4000 Peak Force
3000 Loa ad
True Detection65%
2000
Gap
1000 Force Work 0 -0.25 -0.2 -0.15 -0.1 Distance Depth p -0.05 0
Unrecorded inspection72%
Reduced to 5% by ERC
NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan College of Engineering
#4
Alignment algorithms Segmentation algorithms Feature extraction algorithms Online monitoring limits Fault classification
5000
false reject
4000
3000
2000
1000
LVDT
-1000 -0.3 -0.25 -0.35 -0.2 -0.15 -0.1 -0.05 0 0.05
Sciemetric depth
l1
c1y,k
...
ci1,k
h i ciy,k
djy0,k
li
...
cy01,k j
hj0 cy0,k j
lj0
NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan College of Engineering
#5
NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan College of Engineering
#6
Newinvestigationsat g Chryslerinthisquarter
NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan College of Engineering
#7
Rejected parts
Allparts Allparts All parts
Two analyses have been done based on available original waveform signals: y g g For the rejected samples having regular signal profiles (8 samples), are they false rejects? For the rejected samples having irregular signal profiles (17samples), what are the root causes?
NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan College of Engineering
#8
Analysis1:
InvestigatewhetherSciemetricrejectedsampleswith regularsignalprofilesarefalserejectsornot(8samples).
NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan College of Engineering
#9
RejectionsBasedonOldSciemetricDepth
UL=0.5
(in)
Parts are rejected by the Sciemetric depth feature. (suspect of false reject)
LL=-0.5
NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan College of Engineering
#10 10
SignalComparisonbetweenRejectedandNonrejectedParts
10000
8000
6000
4000
Comment: Misaligned signals may cause false rejects g g y j based on Sciemetric depth feature.
2000
-2000 -35
-30
-25
-20
-15
-10
-5
LVDT (in)
NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan College of Engineering # 11
NewFeatureAlignedDepthafterSignalAlignment
Algorithm of calculating aligned depth: 1. Use wavelet analysis (Harr transformation) to find contact point. Contact point: The point where the press tool actually contacts the part leading to the change point of force signals. g g p g 2. Calculate new feature aligned depth. The difference between the contact point and the maximum LVDT value, which reflects the actual moving range.
4500 4000
-------
Out-of-control In-control
4500
4000
3500
3500
3000
3000
2500
2500
2000
2000
1500
1500
1000
1000
Contact point
500
500
-500 -0.25
-0.2
-0.15
-0.1
-0.05
0.05
0.1
-500 -0.1 01
-0.05 0 05
0.05 0 05
0.1 01
0.15 0 15
0.2 02
Misaligned Signals
NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan College of Engineering
Aligned Depth
# 12
SignalsAfterAlignment
10000
8000
Force (lbs)
6000
4000
2000
-2000 -25
-20
-15
-10
-5
10
LVDT (in)
NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan College of Engineering # 13
MonitoringBasedonNewAlignedDepth
UL=6.93
(in)
LL=5.93
NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan College of Engineering
#14 14
NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan College of Engineering
#15 15
Analysis2:
ClassifyIrregularSignalProfilesofRejectedParts Cl if I l Si l P fil fR j dP (17samples)
NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan College of Engineering
# 16
1000
1500
-2000 0
200
400
1000
1200
1400
-5
# 17
LVDT (in)
120 100
-28 28
80
LVD (in) DT
Force (lbs) e
200 400 600 800 Time (ms) 120 1000 1200
-28.5
60 40 20 0 -20
-29
-29.5
-30 0
-40 0
200
400
1000
1200
-27.5
# 18
LVDT (in)
Mapping Table Developed based on GM Data ___ Example of classified irregular profiles at GM
Faulttype LVDT (springproblem) LVDT
Highly oscillated LVDT HighLVDT Normal N l
Force
Force Highly oscillated (cableproblem) OscillatedLVDT LVDT &LVDT & LVDT (highvariance) (hi h i ) (springproblem)
Normalshape p
No correct reading
MissingPart
Normal Normal
NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan College of Engineering
# 19
Improvement by UM To Add a detection& classification module. Developed better monitoring features (e.g. aligned depth)
No
Providefaultreport& correctionaction
Yes No
Calculatemonitoring features
Outof specification limits(SL)?
Yes
Confirmfaultdetection
NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan College of Engineering
# 20
NewProjectProposedbyGM __ImproveLeakingTest
NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan College of Engineering
# 21
NewprojectatGM:ImproveATCLeakingTest
The Whole Leak Testing System
NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan College of Engineering
# 22
NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan College of Engineering
# 23
Defined project scope and candidate manufacturing processes. p j p gp Collected production data at GMPT plants at Pontiac and Livonia. Understand current practice and the GM need. Conducted experimental tests and analyzed DOE data. Developed signal alignment algorithms using Wavelets. p g g g g Found the root cause of high false rejects of Sciemtetric system. Developed new algorithms for reducing false rejects. Prove the concept of profile feature extraction for gap detection. Collect more data for further validation of new features and signal alignment algorithms. Integrating our proposed alignment algorithm with Scimetric software. Propose an algorithm for determining specification limits. Analyze irregular fault patterns to enhance diagnostic capability for detecting and classifying sensor problems and missing part. W k with Sciemetric company for software implementation. Work ith S i ti f ft i l t ti Work with Chrysler for algorithms validation and implementation Identify the new projects for improving leaking test at GM Continue validation analysis at Chrysler. Work with GM for the new projects of improving leaking tests.
NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan College of Engineering # 24
June 2008
Dec 2008
Next Quarter
Next year
NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan College of Engineering
# 25
NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan College of Engineering
# 26
Depth
0.4 0.2 Dept th 0 -0.2 -0.4
Featuresboxplotovertime
Work
12000 10000 8000 6000 4000
1 2 3 4 5 6 8 9 10 11 12 15 16 17 18 19 29 30 36 37 38 39 40 43 44 45 46 47 49 51 52 53 56 57 58 59 63 64 65 66 67 70 71 72 77 78 79 80 81 84 85 86 87 88 Date index
Peak
10000 9000 8000 7000
1 2 3 4 5 6 8 9 10 11 12 1 16 1 18 19 29 30 36 3 38 39 40 43 44 4 46 4 49 51 52 53 56 57 58 59 63 64 6 66 6 70 71 72 77 78 79 80 81 84 8 86 8 88 15 17 37 45 47 1 2 3 6 8 9 65 67 0 1 2 8 9 85 87 Date index
Force
3000 2000 1000
1 2 3 4 5 6 8 9 10 11 12 15 16 17 18 19 29 30 36 37 38 39 40 43 44 45 46 47 49 51 52 53 56 57 58 59 63 64 65 66 67 70 71 72 77 78 79 80 81 84 85 86 87 88 Date index
1 2 3 4 5 6 8 9 10 11 12 15 16 17 18 19 29 30 36 37 38 39 40 43 44 45 46 47 49 51 52 53 56 57 58 59 63 64 65 66 67 70 71 72 77 78 79 80 81 84 85 86 87 88 Date i d D t index
Sep 08
Oct 08
Date index
Nov 08
Dec 08
# 27
NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan College of Engineering
Depthboxplotovertime(goodparts)
0.4 0.3 0.2 0.1
Sep 08
Depth h Depth
Oct 08
Nov 08
Dec 08
Date index
NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan College of Engineering # 28
Date index
FeaturesScatterMatrix(goodparts)
NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan College of Engineering
# 29
FeaturesScatterMatrix(OcttoDec)
Low Peak and Center for Reconfigurable Manufacturing Systems NSF Engineering Research University of Michigan high force College of Engineering
# 30
Projectedfeatures (OcttoDec08)
All data correspond to good parts (based on Sciemetric report)
Although all parts are good, they can be g p g y clustered in two classes by using features. To understand the reasons further study is needed.
NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan College of Engineering # 31
10000
8000
Force(lb bs)
4000
2000
1800
1600 1400
-2000 -7
1200
-6
-5
-4
-3
-2
1000 800 600 400 200 0
-1
LVDT(in)
NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan College of Engineering
-200 -7 -6.8 -6.6 -6.4 -6.2 -6 -5.8 -5.6 -5.4 -5.2
# 32
-5
Black: rejected parts close to the lower limit Red: other rejected parts
-6 6
-5 5
-4 4 -3 3 LVDT(in)
-2 2
-1 1
NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan College of Engineering
# 33
AlignedSignals
10000 8000
Black: rejected parts close to the lower limit Red: other rejected parts
4000
2000
-2000 -1 1
3 4 LVDT (in)
NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan College of Engineering
# 34
Detecting and Classifying Sensor Failures ---- Proposed Mapping Algorithm by ERC/UM
Faulttype
TypeILVDT (springproblem) (spring problem) TypeIILVDT
LVDT
OscillatedLVDT (highvariance) (high variance) Stepshape (highlypositiveslope) Spikeshape (highlypositive& negativeslope) Normal Nocorrectreading/No slope HighLVDTreading
Force
Normal Normal
Normal eitherverylowforceor ith l f overpeakforce Nocorrect No correct reading/Oscillatedforce (highvariance) Nocorrect reading/Oscillatedforce (highvariance)
# 35
TypeVImissingSeat
NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan College of Engineering
SignatureOutputs
Quick Fill+Fill
Stability St bilit
Test T t
Master Part + EC
NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan College of Engineering
# 36
IdentifyRootCauseofHighFalseRejectRate
6000
Force
5000
Blue: classified as a good part by Sciemetric Red: false rejected as a bad part by Sciemetric
SL
4000
3000
2000
Rootcause:misalignmentonsignals.
1000
-1000 -0.35
-0.3
-0.25
-0.2
-0.15
-0.1
-0.05
0.05
Sciemetric depth is based on LVDT absolute value, which is not a true tr e reflection of the act al mo ing range actual moving
NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan College of Engineering
Depth p
Depth p
# 37
Outline Project Overview j SimuVeri System Architecture Introduction to Statistical Output Analysis Application Case Whats Next
NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan College of Engineering
#2
Project Overview
Background: The project arises from an earlier Ford-ERC project at CEP
The manufacturing processes and models are very complex; Model verification and experimenting are time consuming; Models are not completely tested on system level before experimenting; Resulting in exaggerated throughput and poor model applicability.
Goals:
To develop Computer Aided Testing (CAT) tools for automatic error checks; To provide user friendly software platform supporting various validation, experimentation and optimization tec ques techniques.
NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan College of Engineering #3
NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan College of Engineering
#5
NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan College of Engineering
#6
NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan College of Engineering
#7
Correlation Analysis
NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan College of Engineering
#8
NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan College of Engineering
#9
NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan College of Engineering
# 10
s x z1 / 2 * n
Central limit Theorem: regardless of the distribution of (n each Xi ,X ( ) will b approximately di t ib t d as a h ill be i t l distributed normal random variable when n
NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan College of Engineering
# 11
s x t n 1,1 / 2 * n
Assumes the sample average is from a normal distribution. di t ib ti
NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan College of Engineering
# 12
h = t n 1,1 / 2 * n=t
2 n 1,1 / 2
NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan College of Engineering
# 13
NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan College of Engineering
# 14
An Application Case
NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan College of Engineering
# 15
An Application Case
Time 1.484055403 1.931330511 3.498247812 6.424550926 24.20430586 33.38210516 33.78572903 46.44300943 47.72927941 47 72927941 60.97070454 80.76142078 Observation 1.484055403 0.200569173 0.416304048 2.639221143 6.142266534 5.722407758 5.420538552 2.564226808 0.695810334 0 695810334 12.17619063 30.96875537
Avg Stddev
8.187022 5.428285
NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan College of Engineering
# 16
An Application Case
z1 / 2 for t n 1,1 / 2 nz
2 1 / 2
s 2 (AvgTIS ) * h2
8.187022 5.428285
Avg. Stdev
NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan College of Engineering
# 17
Whats Next
LITERATURE REVIEW AND PROJECT DEFINITION
Project needs and direction Verification and validation approaches
VERIFICATIONMODULE
Code the module
Specific errors to be detected
Verificationstrategies Codethetestingstrategies
VALIDATIONMODULE
Validation needs Validation strategies Code strategies
OPTIMIZATIONMODULE
Code and test optimization Optimizationneeds methods Exploreoptimizationmethods Completed InProgress FutureWork
# 18
NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan College of Engineering
March,13th, 2009
Seat length
Valve guide
Deck seat (0 1o) throat angles Deck, (0.1 ), Seat length Seat roundness at gage Seat runout at gage wrt valve guide
NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan College of Engineering
Project Goal
In-line measurement of valve seat geometry (cycle time ~ 45 seconds) Rapid and accurate non-contact measurement Measurement of seat angles and seat length Preliminary repeatability test Evaluate in-line application feasibility Comment: All the study was done without having a defined specification of the problem
NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan College of Engineering
NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan College of Engineering
Seat angle
ERCResults CMMResults Run1 Run2 Run3 Run1 Run2 Run3 60segment angle SeatAngle Seat Angle 30segment angle SeatLength 60.53 59.39 59.99 45.18 45.18 44.98 45 18 45 18 44 98 30.28 30.33 30.27
1.7137 1.6979 1.6991 1.729 1.772 1.738
NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan College of Engineering
SeatAngle (degree)
DeckAngle (degree)
ThroatAngle (degree)
Roundness (mm)
SeatLength (mm)
GageDepth (mm)
Average
45.07468
60.40652
30.34172
0.02988506
1.747624
12.62412
Standard Deviation
0.017752769
0.043423985
0.017123847
0.002473562
0.012789657
0.002429748
NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan College of Engineering
Next Steps:
Evaluate the implementation feasibility i e increase measurement i.e. speed, optimize data collecting path Test serial robot and a evaluate the use of a PKM
NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan College of Engineering
Optimet Conoprobe Laser Scan Frequency : The Motion Stage Forward Motion Maximum Speed Possible : y (p y p ) Current System (presently not optimized for time) Forward Speed used : Backward Speed used : Stop time between scans : p
3000 KHz
NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan College of Engineering
NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan College of Engineering
Challenges
To find the minimum time : we need to increase the speed of th scan. d f the Increasing speed reduces the number of data points captured. captured The Speed Vs Data Capture is an OPEN ISSUE. Need to decide which parameter to compromise on for on, the best time optimized performance.
NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan College of Engineering
11
NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan College of Engineering
Laser Motionstage
SightPipe
NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan College of Engineering
Project Layout
Analysis & Synthesis: Ki Kinematics, D ti Dynamics, W k i Workspace, Si Singularities, l iti Structure, Joints Detailed mechanical design Detailed control design Building and calibrating Tests: Accuracy, Repeatability, Required resources: CAD designer Control expert Budget of ~$30K for hardware
NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan College of Engineering
Project Overview
Goals:
Develop methodologies for the inspection of geometrical features of internal threads in machined automotive parts.
Main tasks
Laser scan measurement using Optimet sensor Optical inspection using a CCD camera with sightpipe R&R test to be done partially
NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan College of Engineering
Probe
Mirror
Zaxis
Rotary Motion
Method:
Periscope
Measuring internal threads using a Laser Range Finder (Optimet Sensor) integrated with a motorized periscope designed at ERC.
45Mirrorinside StepperMotor Sensor
NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan College of Engineering
Measured Parameters 0 1.248 0.639 180 1.251 0.696 12.014 10.667 10 667 90 1.252 0.539 12.127 10.871 10 871 270 1.246 0.615 Average 1.249 0.622 12.071 10.769 10 769 Minor Dia. Major Dia.
Pitch (mm) Height (mm) Major Dia. (mm) Minor Dia (mm) Dia.
Pitch
Conclusion 1:
Compared to the standard data, all the parameters we get are within acceptable limits for the designated thread type.
axial cross section
NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan College of Engineering
Conclusion 2:
* The starting point of the thread is located in quadrant IV. * The helix is clockwise.
180 =1.942
III IV
0 =2.531
NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan College of Engineering
Lens& Illumination
CCD
Sight Pipe
Conical Lens
NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan College of Engineering
Measurements results
2. LabVIEW Shape detection is used to extract average angle of threads. 3. A series of line profiles are generated perpendicular to the thread lines and peaks are detected.
NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan College of Engineering
NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan College of Engineering
Challenges on 3D Digitalization
Phase shifting could be achieved by using Light Modulation Technique. With digital light source we can fulfill the phase shift. How to find the Sensitivity factor by changing the cylinder diameter as the reference plane moves. The angle of the illumination and optical axis is either very small or immeasurable which could cause K unsolvable ( we may start with flat surface calibration. ) The misalignment of the sight pipe system and surface quality variation may lead to errors in phase shifting measurement.
NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan College of Engineering
The End
NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan College of Engineering
10
NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan College of Engineering
11
Challenges on 3D Digitalization
Phase shifting could be achieved by using Light Modulation Technique. With digital light source we can fulfill the phase shift. How to find the Sensitivity factor by changing the cylinder diameter as the reference plane moves. The angle of the illumination and optical axis is either very small or immeasurable which could cause K unsolvable ( we may start with flat surface calibration. ) The misalignment of the sight pipe system and surface quality variation may lead to errors in phase shifting measurement.
NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan College of Engineering
12
Goals
The Objective
To decide if there is an agreement to initiate a project
Project Goals
Detect the presence of misaligned teeth i.e. outliers in sprockets Measure in line the location and the extent of deformation for each outlier relative to its neighbors while the sprocket rotates
NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan College of Engineering
Experimental setup
Optimet laser sensor
Sprocket
NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan College of Engineering
Suggested Method
Measure the distance to tip of the teeth of a rotating sprocket using a non-contact single-point laser range finder Each tooth is clearly observed as a bar (several points) Outliers are observed as peaks
NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan College of Engineering
Stationary Experiment
Measurement of the profile of two sets of teeth for a stationary sprocket and linearly moving Optimet sensor: one containing all normal teeth (blue) and the second containing outliers (red)
Observation : 3 outliers detected whose deformations are ~0.35 mm ~0 35 mm, 1mm and -0.21mm respectively 0 21mm
NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan College of Engineering
NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan College of Engineering
NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan College of Engineering
Conclusion
1. The proposed method is an accurate way for the detection of outliers in sprockets 2. It is also accurate in estimating the deformation/displacement of outliers 3. Can be applied in an industrial application with a rotating sprocket
NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan College of Engineering
Project Goal
Goals:
To develop a methodology to measure the small gap between valve seat and cylinder head y
Expected Deliverables:
I li measurement technique that can enable high speed automatic In-line tt h i th t bl hi h d t ti inspection
Work done: Proof on concept using a laser probe with a motorized periscope
NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan College of Engineering
Seat gaps set @ .001, .003, g p , , 006 & .010 inches in L-6 aluminum head.
47
46.0C
L6 Engine Head w/ .006 in gap in exhaust insert seat @ 118F Head Temperature
48.0C 48
47
46.0C
49.9C
49
48
47
46.0C
47.0C 47
46
45 45.0C
46
45 45.0C