Artificial Intelligence in Design

Artificial Intelligence in Industry Series

Series Editor: A. Kusiak

Titles in the series:

Artificial Intelligence: Implications for elM Expert Systems in Engineering Intelligent Diagnostic Systems

ARTIFICIAL INTELLIGENCE IN INDUSTRY

Artificial Intelligence in Design

Edited by D. T. Pham

With 229 Figures

Springer-Verlag London Berlin Heidelberg New York Paris Tokyo Hong Kong

DT Pham, PhD School of Electrical, Electronic and Systems Engineering University of Wales College of Cardiff PO Box 904, Cardiff CFl 3YH, UK

British Library Cataloguing in Publication Data Artificial intelligence in design. 1. Engineering. Applications of artificial intelligence I. Pham DT (Duc Truong) 1952- II. Series 620.0028563

Library of Congress Cataloging-in-Publication Data Artificial intelligence in designl edited by DT Pham. p. cm. - (Artificial intelligence in industry series) Includes index. ISBN-13: 978-3-642-74356-6 e-ISBN-13: 978-3-642-74354-2 001: 10.1007/978-3-642-74354-2

1. Engineering design. 2. Artificial intelligence. I. Pham, DT II. Series. TA174.A79 1991 620' .00425'02863--dc20 90-39029

CIP

Apart from any fair dealing for the purpose of research or private study, or criticism or review, as permitted under the Copyright, Designs and Patents Act 1988, this publication may only be reproduced, stored or transmitted, in any form or by any means, with the prior permission in writing of the publishers, or in the case of reprographic reproduction in accordance with the terms of licences issued by the Copyright Licensing Agency. Enquiries concerning reproduction outside those terms should be sent to the publishers.

© Springer-Verlag London Limited 1991 Softcover reprint of the hardcover 1 st edition 1991

The use of registered names, trademarks etc. in this publication does not imply, even in the absence of a specific statement, that such names are exempt from the relevant laws and regulations and therefore free for general use.

Typeset by Photo·graphics, Honiton, Devon Printed by Page Brothers, Norwich, Norfolk 69/3830-543210 Printed on acid-free paper

Series Editor's Foreword

The rapid development of manufacturing and computer techno­logies has generated new problems. To solve these problems modem tools and techniques are required. Artificial intelligence (AI) offers one of the most appropriate sets of tools for solving complex industrial problems.

This series represents an effort to disseminate valuable information on applications of AI in industry which have become well-utilized throughout the world.

AI has been recognized in many industrial countries as a means of solving complex problems arising in modem industry. All books in this series highlight issues that arise in the development and application of AI systems.

The series is intended for production and industrial engin­eers, managers, system designers, and programmers.

Andrew Kusiak The University of Iowa,

Iowa City, Iowa

Preface

Computers have been employed for some time in engineering design mainly as numerical or graphical tools to assist analysis and draughting. The advent of the technology of artificial intelligence (AI) and expert systems has enabled computers to be applied to less deterministic design tasks which require symbolic manipulation and reasoning, instead of only routine number processing. This book presents recent examples of such applications, focusing on mechanical and manufacturing design. The term "design" is interpreted here in its wider sense to include creative activities such as planning. The book covers a wide spectrum of design operations ranging from component and product design through to process, tooling and systems design. Its aim is to expose researchers, engineers and engineering designers to several developments in the emerging field of intelligent computer-aided design (CAD) and to alert them of the possibilities and opportunities in this exciting field.

The book comprises five sections. Section A deals with concepts and techniques of intelligent CAD. The first chapter, by Pham and Tacgin, provides an overview of techniques underlying the field of intelligent knowledge-based systems, particularly those which can be used to develop intelligent design programs. The chapter introduces and defines many of the terms encountered in the rest of the book. The second chapter, by Aldefeld et al., describes the concept of variational geometry in design and a method for implementing this concept based upon geometric reasoning. The latter technique is further examined in the third chapter, by Martin, which reviews its various aspects and relationships with topics such as computer algebra, automated theorem proving and expert systems. The final chapter in this section, by Akagi, discusses a powerful concept for representing design knowledge, the object-oriented concept, and presents an object-oriented expert system for engineering design.

viii Preface

Section B is concerned with the design of both individual components and complete products. The first chapter, by Dong and Soom, treats the problem of component dimensional tolerancing and suggests AI techniques for automating the tedious tasks of tolerance analysis and synthesis. The second chapter, by Kroll et al., is about product design for assembly and describes an intelligent knowledge-based system for this purpose. The third chapter, by ElMaraghy, also deals with intelligent product design. The emphasis of the chapter, however, is on integrating design and manufacture. The chapter presents a framework for supporting intelligent product design and manufacture. The framework comprises a feature-based modeller for design, high-level design languages and an assortment of expert process planning programs. Section B concludes with the chapter by Huang and Brandon which focuses on the knowledge-based design of machine tools after considering wider issues of managing knowledge bases for machine design.

Section C is devoted to process design. The first chapter, by Inui and Kimura, describes an intelligent system incorporating product modelling techniques for designing process plans for machining prismatic parts and bending sheet metal components. The second chapter, by Milacic, proposes the use of the theories of formal grammars and automata to acquire and represent knowledge for expert process design systems. The chapter also outlines two such systems, one for designing process plans for machining rotational parts and the other, for producing plans for prismatic components. The third chapter, by Ito and Shinno, discusses the philosophy to be adopted in the development of the next generation of AI-based systems for machining process design. The last chapter in this section, by Wright et al., reports on the progress achieved by the authors' team in building an AI system that integrates machining process design and workholding element configur­ation.

Section D covers tooling design. The first chapter, by Pillinger et al., describes an intelligent knowledge-based system for designing metal-forming dies. The system combines rule-based techniques with finite-element simulation and is able to improve its design rules automatically as it gains experience. The second chapter, by Nee and Poo, reviews the state of the art in expert CAD systems for jigs and fixtures. The third chapter, by Pham and de Sam Lazaro, presents two knowledge­based programs for jig and fixture design, one to provide design advice and the other to carry out design operations automatically.

Preface ix

Section E deals with systems design. The first chapter, by Li et aI., describes part of an intelligent software package for designing hydraulic systems. The second chapter, by McGuire and Wee, discusses the design of control systems and the use of knowledge-base technology in a tool for generating control programs for programmable logic controllers. The third chapter, by Kusiak and Heragu, presents a knowledge-based system for selecting equipment for a manufacturing plant. The system, which also performs optimization, is to be used in the design of the plant. The fourth and final chapter, by Parthasarathy and Kim, considers fundamental issues in designing intelligent manufacturing systems and discusses the representation and utilization of design knowledge by formal decision rules and performance measures.

Acknowledgements

My thanks are extended to the chapter authors for their contributions and to Dr Brian Rooks (IFS), Mr Nicholas Pinfield (Springer-Verlag) and Miss Linda Schofield (Springer-Verlag) for their expert help with the production of this book.

DT Ph am

Contents

List of Contributors .......................................................... xv

SECTION A. Concepts and Techniques

1. Techniques for Intelligent Computer-Aided Design D.T. Pham and E. Tacgin ................................................... 5

2. Rule-Based Variational Geometry in Computer­Aided Design B. Aldefeld, H. Malberg, H. Richter and K. Voss .............. 27

3. Geometric Reasoning for Computer-Aided Design R.R. Martin .... .... .................................. .............................. 47

4. Expert System for Engineering Design Based on Object-Oriented Knowledge Representation Concept S. Akagi .............................................................................. 61

SECTION B. Component and Product Design

5. Some Applications of Artificial Intelligence Techniques to Automatic Tolerance Analysis and Synthesis Z. Dong and A. Soom ........................................................ 101

6. Intelligent Analysis and Synthesis Tools for Assembly-Oriented Design E. Kroll, E. Lenz and J.R. Wolberg .................................... 125

7. Intelligent Product Design and Manufacture H.A. EIMaraghy ................................................................. 147

xii

8. Specification and Management of the Knowledge Base for Design of Machine Tools and their Integration into Manufacturing Facilities

Contents

G.Q. Huang and J.A. Brandon ........................................... 169

SECTION C. Process Design

9. Design of Machining Processes with Dynamic Manipulation of Product Models M. Inui and F. Kimura ....................................................... 195

10. Theoretical Approach to Knowledge Acquisition and Knowledge Representation in CAPP Expert Systems V.R. Milacic ................................. ......... .......... .......... .......... 229

11. Knowledge-Based Computer-Aided Process Planning Y. Ito and H. Shinno .... .......................... .......... .......... ........ 273

12. Applications of Artificial Intelligence to Part Setup and Workholding in Automated Manufacturing P.K. Wright, PI Englert and c.c. Hayes ......................... 295

SECTION D. Tooling Design

13. An Intelligent Knowledge-Based System for the Design of Forging Dies I. Pillinger, P. Hartley, C. E. N. Sturgess and T. A. Dean 319

14. Expert CAD Systems for Jigs and Fixtures A. Y. C. Nee and A. N. Poo .................. ............ ................ 343

15. Knowledge-Based Design of Jigs and Fixtures D. T. Ph am and A. de Sam Lazaro ...................................... 371

Contents xiii

SECTION E. Systems Design

16. An Expert System for Designing Hydraulic Schemes ex. Li, S.H. Huang and Y.G. Wang ................................ 391

17. Rule-Based Programming for Industrial Automation B.R. McGuire and W.G. Wee ............................................. 415

18. Knowledge-Based Programs for Manufacturing System Design A. Kusiak and 5.5. Heragu ................................................. 437

19. Design of Intelligent Manufacturing Systems: Critical Decision Structures and Performance Metrics S. Parthasarathy and S. H. Kim ......................................... 465

Subject Index ............................................................. ........ 493

Contributors

s. Akagi Department of Mechanical Engineering, Osaka University, 2-1 Yamadaoka, Suita, Osaka 565, Japan

B. Aldefeld Philips GmbH, Forschungslaboratorium Hamburg, Vogt­Kolln-Str. 30, Postfach 540840, 2000 Hamburg 54, Federal Republic of Germany

J.A. Brandon School of Engineering, University of Wales College of Cardiff, PO Box 917, Cardiff CF2 lXH, UK

T.A. Dean School of Manufacturing and Mechanical Engineering, University of Birmingham, Edgbaston, Birmingham B15 2TI, UK

Z. Dong Department of Mechanical Engineering, University of Victoria, PO Box 1700, Victoria, British Columbia VBW 2Y2, Canada

H.A. EIMaraghy Centre for Flexible Manufacturing Research and Development, McMaster University, 1280 Main Street West, Hamilton, Ontario L8S 4L7, Canada

P.J. Englert AT&T Bell Laboratories, Systems Packaging Development Department, Rm 4C-251 244A, 1 Whippany Road, Whippany, NJ 07981-0913, USA

P. Hartley School of Manufacturing and Mechanical Engineering, University of Birmingham, Edgbaston, Birmingham B15 2TI, UK

xvi Contributors

ee Hayes Robotics Institute, Carnegie Mellon University, Pittsburgh, PA 15213, USA

5.5. Heragu Department of Management and Marketing, School of Business and Economics, The State University of New York, Plattsburgh, NY 12901, USA

G.Q. Huang School of Engineering, University of Wales College of Cardiff, PO Box 917, Cardiff CF2 lXH, UK

S.H. Huang Department of Mechanical Engineering 2, Huazhong University of Science and Technology, Wuhan, Hubei, China

M. Inui Factory Automation Laboratory, RCAST: Research Center for Advanced Science and Technology, The University of Tokyo, Komaba 4-6-1, Meguro-ku, Tokyo 153, Japan

Y. Ito Department of Mechanical Engineering for Production, Tokyo Institute of Technology, 2-12-1 Ookayama, Meguro-ku, Tokyo, Japan

S.H. Kim Laboratory for Manufacturing and Productivity, Massachusetts Institute of Technology, 77 Massachusetts Avenue, Cambridge, MA 02139, USA

F. Kimura Factory Automation Laboratory, RCAST: Research Center for Advanced Science and Technology, The University of Tokyo, Komaba 4-6-1, Meguro-ku, Tokyo 153, Japan

E. Kroll Department of Mechanical Engineering, Texas A&M University, College Station, TX 77843, USA

A. Kusiak Department of Industrial and Management Engineering, The University of Iowa, Iowa City, Iowa 52242, USA

E. Lenz Faculty of Mechanical Engineering Technion, Israel Institute of Technology, Haifa 32000, Israel

ex. Li Department of Mechanical Engineering 2, Huazhong University of Science and Technology, Wuhan, Hubei, China

Contributors xvii

B.R. McGuire Cincinnati Milacron, 4701 Marburg Avenue, Cincinnati, Ohio 45209, USA

H. Malberg Philips GmbH, Forschungslaboratorium Hamburg, Vogt­K6lln-Str. 30, Postfach 540840, 2000 Hamburg 54, Federal Republic of Germany

R.R. Martin Department of Computing Mathematics, University of Wales College of Cardiff, PO Box 916, Cardiff, CF2 4YN, UK

V.R. Milacic Faculty of Mechanical Engineering, University of Beograd, 27 Marta 80, 11000 Beograd, Yugoslavia

A.Y.c. Nee Department of Mechanical and Production Engineering, National University of Singapore, 10 Kent Ridge Crescent, Singapore 0511, Republic of Singapore

S. Parthasarathy Laboratory for Manufacturing and Productivity, Massachusetts Institute of Technology, 77 Massachusetts Avenue, Cambridge, MA 02139, USA

D.T. Pham School of Electrical, Electronic and Systems Engineering, University of Wales College of Cardiff, PO Box 904, Cardiff CFl 3YH, UK

I. Pillinger School of Manufacturing and Mechanical Engineering, University of Birmingham, Edgbaston, Birmingham B15 2TT, UK

A.N. Poo Department of Mechanical and Production Engineering, National University of Singapore, 10 Kent Ridge Crescent, Singapore 0511, Republic of Singapore

H. Richter Philips Medical Systems, Roentgenstr. 24, Postfach 630560, D 2000 Hamburg 63, Federal Republic of Germany

A. de Sam Lazaro Department of Mechanical and Materials Engineering, Washington State University, Pullman, Washington 99164, USA

xviii Contributors

H. Shinno Department of Mechanical Engineering for Production, Tokyo Institute of Technology, 2-12-1 Ookayama, Meguro-ku, Tokyo, Japan

A. Soom Department of Mechanical and Aerospace Engineering, State University of New York at Buffalo, Amherst, NY 14260, USA

C.E.N. Sturgess School of Manufacturing and Mechanical Engineering, University of Birmingham, Edgbaston, Birmingham B15 2TT, UK

E. Tacgin School of Electrical, Electronic and Systems Engineering, University of Wales College of Cardiff, PO Box 904, Cardiff CFl 3YH, UK

K. Voss Philips GmbH, Forschungslaboratorium Hamburg, Vogt­K6lln-Str. 30, Postfach 54 08 40, 2000 Hamburg 54, Federal Republic of Germany

Y.G. Wang Department of Mechanical Engineering 2, Huazhong University of Science and Technology, Wuhan, Hubei, China

W.G. Wee Department of Electrical and Computer Engineering, University of Cincinnati, Cincinnati, Ohio 45221, USA

1.R. Walberg Faculty of Mechanical Engineering Technion, Israel Institute of Technology, Haifa 32000, Israel

P.K. Wright Robotics and Manufacturing Research Laboratory, Department of Computer Science, Courant Institute of Mathematical Sciences, New York University, 719 Broadway, NY 10003, New York, USA