Data processing: generic control systems or specific application – Specific application – apparatus or process – Product assembly or manufacturing
Reexamination Certificate
1998-05-27
2002-02-19
Sheikh, Ayaz (Department: 2155)
Data processing: generic control systems or specific application
Specific application, apparatus or process
Product assembly or manufacturing
C700S094000, C700S039000, C705S007380, C714S712000
Reexamination Certificate
active
06349237
ABSTRACT:
TECHNICAL FIELD
This invention relates to reconfigurable manufacturing system (as illustrated in
FIG. 1
) and methods for designing and changing the production capacity of same.
BACKGROUND ART
Most medium and high-volume manufacturing industries currently use a portfolio of dedicated manufacturing lines (DML's) and flexible manufacturing systems (FMS's) to produce their products. DML's, or transfer lines, are based on fixed automation and produce the core products of the company at high-volume. These lines are customized hardware lines that can control cutting tools in fixed directions determined at the design stage. They are designed to produce a single product and cannot be changed. Each dedicated line typically produces a single part (e.g., a pump housing). The dedicated lines are economical when large numbers of the same part are to be produced for a period of several years or more.
FMS's produce a variety of products on the same system. They typically consist of computer numerically controlled (CNC) machines, and other programmable automation. CNC machines often use large tool magazines and several axes-of-motion to provide general flexibility which has the potential to produce a variety of parts of different types. But in many cases not all these axes-of-motion are utilized in the production of each part, which means that the machine is underutilized and its initial cost is partially wasted. Typically, the structure of each FMS and the structure of its CNC machines cannot be changed. The production capacity of FMS's is fixed and is usually lower than that of dedicated lines, because their initial cost is higher.
The common denominator for the current two types of manufacturing systems (i.e. dedicated and flexible) is that they use fixed structure and fixed hardware (as illustrated in FIG.
2
).
However, medium and high-volume manufacturers are now facing new market conditions characterized by: (i) pressure to quickly introduce new products at low cost, and (ii) large fluctuations in product demand. To cope with these needs and to stay competitive, manufacturing companies must possess a new type of manufacturing system that is very responsive to global markets; a system whose production capacity is adjustable to fluctuations in product demand, and which is designed to be upgradable with new functionality needed to produce new products with tighter product specifications. Current systems, even so-called flexible manufacturing systems, do not have these characteristics.
U.S. Pat. No. 5,691,945 discloses a technique for reconfiguring a high density memory.
U.S. Pat. No. 5,570,292 discloses an integrated method and apparatus for selecting, ordering, and manufacturing art glass panels.
U.S. Pat. No. 5,247,861 discloses a method of manufacturing laminated plastic tooling and tooling produced thereby.
U.S. Pat. No. 4,816,757 discloses a reconfigurable integrated circuit for enhanced testing in a manufacturing environment.
U.S. Pat. No. 4,807,108 discloses a product realization method.
U.S. Pat. No. 4,783,782 discloses a manufacturing test data storage apparatus for a dynamically reconfigurable cellular array processor chip.
U.S. Pat. No. 5,155,679 discloses a set-up optimization method of flexible manufacturing systems.
U.S. Pat. No. 5,456,332 discloses a multiple-degree of freedom vehicle which employs a compliant linkage.
U.S. Pat. No. 5,559,696 discloses a mobile robot internal position error correction system.
Other related publications include:
Goldman, S., Nagel, R. and K. Preiss, 1995, AGILE COMPETITORS AND VIRTUAL ORGANIZATIONS, 1995;
Hu, S. J., 1997, “Stream of Variation Theory and Its Application to Body Assembly”, CIRP ANNALS, 1997;
Koren, Y, Pasek, Z. J., Ulsoy, A. G. and U. Benchetrit, “Real-Time Open Control Architectures and System Performance”, ANNALS OF THE CIRP, Vol. 45, No. 1, 1996; and
Villasenor, J. and W. H. Mangione-Smith, 1997, “Configurable Computing”, SCIENTIFIC AMERICAN, June 1997.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a reconfigurable manufacturing system (RMS) including reconfigurable machines, reconfigurable controllers, and a reconfigurable material handling system, as well as methodologies for its systematic design and changing its production capacity including reconfiguration and ramp-up (see FIG.
3
).
In general, a reconfigurable manufacturing system (RMS) is one designed at the outset for rapid adjustment of production capacity and functionality, in response to new market circumstances, by basic change of its structure as well as its hardware and software components.
Another object of the present invention is to provide a reconfigurable manufacturing system (RMS) which allows rapid changes in the system structure simultaneously with changes in the structure of machines or apparatus that make up the system. The invention also enables the rapid conversion of the system and its machines from production of one product to another by relocating their basic building modules and having means for their quick and reliable integration. This can be done economically by designing a system to produce parts of the same part-family, or product-family (“product family” means, for example, several types of engine blocks or several types of microprocessors). This enables the quick and economic conversion of the reconfigurable manufacturing system from the production of one part or product to another, where both products are from the same product family.
In carrying out the above objects and other objects of the present invention, a reconfigurable manufacturing system (RMS) having an adjustable structure to quickly change from a first desired production capacity to a second desired production capacity to manufacture a desired mix of products from a family of products is provided. The system includes a plurality of work stations including reconfigurable machines, a control system including a plurality of reconfigurable controllers for controlling the reconfigurable machines, and a reconfigurable material handling system in communication with the control system for transporting material or parts between the work stations. The reconfigurable machines and controllers are modular to permit rapid and reliable integration of the machines and controllers during a change in the structure of the RMS so that the RMS will have the second desired production capacity.
Preferably, the adjustable structure of the RMS also allows the RMS to quickly change from a first functionality to a second functionality (which is typically achieved by adding new features to existing machines of the RMS).
The material handling system may include a plurality of conveyor modules for moving parts or materials between the work stations. Alternatively, the material handling system may include a plurality of wireless-controlled transport vehicles for moving parts or materials between the work stations.
The machines may include reconfigurable machines, CNC machines, modular machine tools, and other machines, at least one of which is capable of performing machining operations.
The controllers typically include modular, open-architecture controls. The machines, the controllers and the material transport system all obey an open standard so that the machines, the controllers and the material transport system can be improved and upgraded rather than replaced.
In one embodiment, at least one of the machines is a CNC machine and at least one of the machines is a machine having reconfigurable hardware components.
At least one of the controllers is a controller having reconfigurable software components or modules. Each of the controllers, the machines and the material transport system has an interface to permit rapid and reliable mechanical and electrical integration with the rest of the RMS.
The family of products has at least one dominant feature and wherein the controllers and the machines are customized to fit the at least one dominant feature. The machines are configured to fit the at least one dominant feature. Each of the controllers includ
Koren Yoram
Ulsoy A. Galip
Backer Firmin
Brooks & Kushman P.C.
Sheikh Ayaz
The Regents of the University of Michigan
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