CAD/CAM Robotics and Factories of the Future '90

Suren N. Dwivedi Alak K. Verma J ahn E. Sneckenberger Editors

CADjCAM Robotics and Factories of the Future '90 Volume 2: Flexible Automation

5th International Conference on CAD/CAM, Robotics and Factories of the Future (CARS and FOF'90) Proceedings

International Society for Productivity Enhancement

With 245 Figures

Springer-Verlag Berlin Heidelberg GmbH

Suren N. Dwivedi Department of Mechanical and

Aerospace Engineering West Virginia University Morgantown, WV 26506-6101 USA

lohn E. Sneckenberger Concurrent Engineering Research Center West Virginia University Morgantown, WV 26506 USA

Alok K. Verma Chairman Department of Mechanical Engineering Technology Old Dominion University Norfolk, VA 23508 USA

Library of Congress Cataloging-in-Publication Data International Conference on CAD/CAM, Robotics, and Factories of the

Future (5th: 1990: Norfolk, VA.) CAD/CAM, robotics, and factories of the future: 5th International

Conference on CAD/CAM, Robotics, and Factories ofthe Future (CARS and FOF'90) proceedings /S.N. Dwivedi, Alok Verma, lohn Sneckenberger.

p. cm. "International Society for Productivity Enhancement." Includes bibliographical references. Contents: v. I. Concurrent engineering-v. 2. Flexible

automation. ISBN 978-3-642-63504-5 ISBN 978-3-642-58214-1 (eBook) DOI 10.1007/978-3-642-58214-1

l. CAD/CAM systems-Congresses. 2. Flexible manufacturing systems-Congresses. 3. Robotics-Congresses. 4. Manufacturing processes-Automation-Congresses. I. Dwivedi, Suren N. Ir. Verma, Alok. III. Sneckenberger, lohn. IV. International Society for Productivity Enhancement. V. Title. TSI55.6.I58181990 670.42'7-dc20 90-19478

Printed on acid-free paper.

© 1991 by Springer-Verlag Berlin Heidelberg Originally published by Springer-Verlag Berlin Heidelberg New Y ork in 1991 Softcover reprint of the hardcover 1 st edition 1991 This work is subject to copyright. All rights are reserved, whether the whole or part of the material is concerned, specifically the rights of translation, reprinting, reuse of illustrations, recitation, broadcast­ing, reproduction on microfilms or in other ways, and storage in data banks. Duplication of this publication or parts thereof is only permitted under the provisions of the German Copyright Law of September 9, 1965, in its version ofJune 24, 1985, and a copyright fee must always be paid. Violations fall under the prosecution act of the German Copyright Law. The use of general descriptive names, trade names, trademarks, etc., in this publication, even if the former are not especially identified, is not to be taken as a sign that such names, as understood by the Trade Marks and Merchandise Act, may accordingly be used freely by anyone.

Camera-ready prepared by the editors.

987654321

ISBN 978-3-642-63504-5

Conference Objective

The last decade has seen the emergence of a unified approach for product design which attempts to combine traditionally distinct tasks like design, management, marketing, analysis, manufacture and materials. Often called "Concurrent Engineering" or "Simultaneous Engineering", this new philosophy aims at improving cost competitiveness by reducing waste of time, money, and other resources inherent in the iterative traditional methods. In view of the importance of this new philosophy, Concurrent Engineering is selected as the theme for this conference.

The main objective of the conference is to bring together researchers and practitioners from government, industries and academia interested in the multi­disciplinary and inter-organizational productivity aspects of advanced manufacturing systems utilizing CAD/CAM, CAE, CIM, Parametric Technology, AI, Robotics, AGV Technology, etc.

Conference Organization

Sponsors

International Society for Productivity Enhancement (ISPE), USA

Center for Innovative Technology, Virginia, USA

Old Dominion University, Norfolk, Virginia, USA

Concurrent Engineering Research Center (CERC) West Virginia University, West Virginia, USA

Department of Mechanical and Aerospace Engineering, West Virginia University, West Virginia, USA

Committee Chairpersons

Conference General Chairperson: Alok K. Verma, Old Dominion University, USA.

Conference co-chairs: Suren N. Dwivedi, West Virginia University, USA. Gary Crossman, Old Dominion University, USA.

Program Chairpersons: John Sneckenberger, West Virginia University, USA.

Technical Chairperson: Virendra Kumar, General Electric, USA.

International Chairperson: Jean Marie Proth, INRIA, France.

Reception Chairperson: John. M. Jeffords, Old Dominion University, USA.

Workshop Chairpersons: Stewart Shen, Old Dominion University, USA. Bharat Thacker, Universal Computer Services, USA. Sumitra Reddy, CERC, West Virginia University, USA. Hal Schall, Ford Motor Co., Dearborn, USA.

Printing and Publication Chairperson: Sacha ria Albin, Old Dominion University, USA.

Abstract and Paper Review Chairperson: Jean Hou, Old Dominion University, USA. Resit Unal, Old Dominion University, USA.

University Chairperson: Robert Ash, Old Dominion University, USA.

Industrial Chairpersons: Gary Crossman, Old Dominion University, USA. Larry Richards, Old Dominion University, USA.

Plenary Chairperson: Suren N. Dwivedi, West Virginia University, USA.

Exhibit Chairperson: Thomas Houlihan, Jonathan Corporation, USA.

Student Chairpersons: Drew Landman, Old Dominion University, USA. Francis M. Williams, Old Dominion University, USA.

International Coordinators

H. Bera (U.K.) M. Dominguez (Spain) K. Ghosh (Canada) V.M. Ponomaryov (USSR) J.M. Proth (France) R. Sagar (India) T.-P. Wang (Taiwan) T. Yamashita (Japan)

vii

Committee Rosters

Abstract and Paper Review Committee

Dr. Ralph Wood Dr. John Spears Dr. Cheng Y. Lin Dr. Duc Nguyen Dr. Nageswara Rao

Program Committee

Donald W. Lyons John Sneckenberger Suren N. Dwivedi Sumitra Reddy Larry Banta John Hackworth Bob Creese B. Gopalkrishnan Waeik Iskander Bruce Kang Ken Means Jacky Prucz Nithi Sivaneri Emil Steinhardt

Editorial Board and Publication Committee

Donald W. Lyons Ralph Wood John Spears William Bentley Zenon Kulpa Michael Sobolewski Sati Maharaj Sisir Padhy BinDu Prashanth Murthy Deepak Kohli Dandamudi Venugopal Dhananjay Salunke

Industrial Committee

Thomas Houlihan Moustafa R. Moustafa Ed Wilson Jim Fox Larry Wilson

Reception Committee

Taj Mohieldin Linda Vahala Nancy Short

Professional Relations Committee

John Jurewicz Donald W. Lyons Ramana Reddy Ralph Wood Biren Prasad Kumar Singh John Spears

Conference Coordinators

William Bentley Nancy Short Georgette Ingram

Conference Staff

Sati Maharaj Robin Johnson Joette Claiborne Marylin Host Indira Dwivedi Iva Dwivedi Fern Wood Vicki Grim Pat Logar Jean Shellito

ix

Letter from the President, ISPE The International Society for Productivity Enhancement (ISPE) is

entering its seventh year. The Conference you are attending is our fifth of the international series on CAD/CAM, Robotics and Factories of the Future (CARS & FOF). The fourth conference was held at the Indian Institute of Technology, New Delhi, India in 1989. During the past seven years, we have expanded our activities significantly. The membership interest and international participation are also growing. During the past year alone, the Society has made tremendous progress in the following major frontiers:

J 0 URN A L: The Society now has its own journal entitled The International lournal of Systems automation Research and diJplications (SARA), an international, multidisciplinary research and applications-oriented journal to promote a better understanding of systems considerations in interdisciplinary automation using computers. The Journal contains important reading for design, engineering, and manufacturing persons as well as those with interest in research and development and applications of productivity tools, concepts and strategies to multidisciplinary systems environments. The Journal will only publish original, quality papers. To receive more information about this Journal, write to: Editor-in-Chief, ISPE, SARA Journal Department, P.O. Box 731, Bloomfield Hills, Michigan 48303-0731.

PROCEEDINGS: Starting this year (with the Fifth Conference), the Society is now making the Conference Proceedings available at the Conference. Selected papers from this Proceedings will also be considered for publication in SARA.

CONFERENCES: ISPE's annual conferences are now book until 1994. The Sixth International Conference will take place at South Bank Polytechnic, London from August 19-21, 1991. The Seventh and Eight International Conferences will be held in Leningrad, USSR and France, respectively.

COOPERATIVE PROGRAMS: In 1989, ISPE started a new cooperative program called the Indo-U.S. Forum for Cooperative Research and Technology Transfer (lFCRTT) in cooperation with West Virginia University and the National Science Foundation (NSF). The first joint meeting of the IFCRTT was held from December 17-18, 1989, in New Delhi, India. The meeting attracted a large body of scholars from industry, universities, and research institutions from both the United States and India. Similar cooperative programs are being arranged in the U.K., U.S.S.R. and France.

xii

As you can see, we have made great strides, but significant changes are taking place in the manufacturing sectors due to global competitiveness and economic factors. Productivity enhancement needs are even larger than before, and such needs require us to be more dynamic and resourceful. ISPE is looking for a few good people to take leadership positions in its organization and committees for sponsored events. If you would like to help us build our technical program or if you would like to work on ideas of your own, please write to us. There are openings in the following areas:

* SARA Journal - Readers' Committee * Productivity Directors * Workshop and Tutorial Organizers * CARS & FOF Conferences: University, Industry, International

Representatives, Session Organizers, and Technical and Program Chairpersons.

We are still a very young organization and your leadership can play a significant role. Please do not hesitate to write us with your ideas and opinions.

Biren Prasad, Ph.D. ISPE, P.O. Box 731, Bloomfield Hills, MI 48303-0731, USA.

Acknowledgments

The Fifth International Conference on CAD/CAM, Robotics, and Factories of the Future (Cars & FOF '90) was hosted by the College of Engineering and Technology at Old Dominion University and was endorsed by more than ten societies, associations, and international organizations. The conference was held in Norfolk, Virginia at the Omni International Hotel from December 2-5, 1990. Over 200 presentations organized into 40 specialty sessions, three plenary sessions, and eight workshops were conducted during the four days. Authors, plenary session speakers, and participants from 17 different countries around the world converged in Norfolk for this Conference. In view of the ever-increasing importance for integrating different facets of manufacturing with design process, the organizing committee selected "Concurrent Engineering" as the theme of the Conference.

I wish to acknowledge, with many thanks, the contributions of all the authors who presented their work at the Conference and submitted the manuscripts for publication. It is also my pleasure to acknowledge the role of banquet, luncheon, and plenary session speakers who shared their vision of the manufacturing industry and issues related to productivity. My sincere thanks to the session organizers, session chairs, and members of the Organizing Committee both at Old Dominion University and West Virginia University without whose cooperation this Conference would not be possible. Thanks are due to Ms. Georgette Ingram and other staff members in the MET Department for their patience and hard work. Financial support from the Center for Innovative Technology and industrial sponsors also made this Conference possible.

I acknowledge, with gratitude, the help and support received from Dr. James V. Kock, President, and Dr. Ernest J. Cross, Dean of the College of Engineering and Technology at Old Dominion University. From West Virginia University, I thank Dr. Donald W. Lyons, Chairman, MAE Department, for his support; Drs. Ralph Wood and John Spears for their help in reviewing conference papers and for allowing us to use the facilities of the Concurrent Engineering Research Center; and Ms. Sati Maharaj for her assistance in coordinating the conference. In addition, I extend my deepest gratitude to Dr. Suren N. Dwivedi for providing me with support and encouragement in organizing this conference. Furthermore, I express my sincere thanks to all my colleagues,friends, student volunteers, and family members who extended their help in organizing this conference.

I also acknowledge with great appreciation the excellent work done by Springer-Verlag in publishing both volumes of the proceedings.

Alok K. Verma Conference General Chairperson

Preface

Flexibility is as acceptable an objective for today's industrial community as is automation. Thus, the title of this conference proceedings volume -Flexible Automation - reflects an added emphasis to the usual industrial automation. As with general automation that has impacted every component of the manufacturing office and plant, the identity of flexible automation can possess various forms and functions.

The papers in this volume have been grouped into two main categories. One category deals with implementation of so-called "intelligent manufacturing". This means use of algorithmic methods and artificial intelligence approaches to various problems encountered in practical factory automation tasks. The placement of papers into five chapters of this part cannot be very precise, due to multidisciplinary nature and constant rapid change of the field. The categories are arranged starting from problems of enhancement of current factory settings, and followed by the papers addressing more specific issues of production planning, process technology and product engineering. The fifth chapter contains papers on the very important aspects of factory automation - problems of design, simulation, operation and monitoring of manufacturing cells.

In the second category, papers dealing with practical developments in applied automation, especially robotics, have been grouped. The section starts from a parade of industrial applications of robotics, proceeding then to task performance analysis. The specific problems of robotics, namely motion specification and manipulator mechanics are thoroughly covered by the papers in next two chapters. The final chapter groups four papers addressing the topic of engineering education and training in the field of automated manufacturing - a problem of considerable importance to preapare people so that the idea of "factories of the future" may become a reality.

Suren N. Dwivedi

Contents, Volume 2

Conference Objective ................................................................ v

Conference Organization.............................................. ............. VI

Committee Rosters........................................ ... ......................... VIll

Letter from the President, ISPE................................................. xi

Acknowledgments ..................................................................... xiii

Preface....................................................................................... xv

Section A: Implementation of Intelligent Manufacturing

Chapter I: Factory Enhancements ............................................. 1

Introduction............... .... ...... ............. ......... ......... ... ...... .... ..... ......... .... ....... 1

From the Existing Manufacturing System to CIM D.S. LVOV, E.I. ZAK, and YU.M. ZYBAREV............................................. 3

Flexible Manufacturing System in Manufacture of Precision Engineering Components - Key Issues in Implementation

V.K. GUPTA and R. SAGAR......................................................................... 9

A Survey of CIM Strategic Planning in U.S. Industry MARK D. PARDUE and FREDERICK 1. MICHEL..................................... 19

Modelling and Optimization of a Flexible Manufacturing System R.N. CHAVALI, S. KESWANI, and S.c. BOSE........................................... 25

Computer Based Safety System for the FMS - Management Logic C.F. MARCIOLLI........................................................................................... 31

CIM Repositories H. T. GORANSON.......................................................................................... 45

The Selection and Prospect of CAD/CAM System for Diesel Engine Design and Manufacturing

GU ZE-TONG and HU GANG....................................................................... 56

A Model for the Factory of the Future for Industrialized Housing AHMAD K. ELSHENNAWY, MICHAELA. MULLENS, WILLIAM W. SWART, and SUBRATO CHANDRA .................................. 62

Enabling Automation Technologies for an Automated Mail Facility of the Future

JAY LEE and GARY HERRING.................................................................... 71

Some Optimization Problems of Scheduling in a Flexible Manufacturing System

TOMASZ AMBROZIAK................................................................................ 77

Some Methods of Modeling for Computer Integrated Workshop V.N. KALACHEVand YE.N. KHOBOTOV................................................. 83

Combined Procedures for Simulation of Manufacturing Systems SUREN N. DWIVEDI and YE.N. KHOBOTOV ........................................... 88

Expert Systems in CIM V.M. PONOMARYOV, V.V. IVANISTCHEV, AA LESKIN, and N.N. LYASHENKO................................................................................. 94

:hapter II: Production Planning ........................................ 100

Introduction .............................................................................................. 100

A Taxonomy on Event-Driven Production Systems S.S. IYENGAR, NITIN S. NAIK, and RAJENDRA SHRIVASTAVA........ 105

An Improved Lot Sizing Policy for Variable Demand M.D. SREEKUMAR, e. ESWARA REDDY, and O.V. KRISHNAlAH CHETTY ................................................................ 120

Simulation for Real-Time Control: Advantages, Potential Pitfalls, Opportunities

C.M. HARMONOSKY ................................................................................... 126

Decomposition Approach for the Job-Shop Scheduling Problem H.D. LEMON lAS and Z. BINDER ................................................................ 132

Evaluation of the Impact of Plant and Production Management Automation on Job-Shop Manufacturing Performances

M. PESSINA, A POZZETTI, and A SIANESl............................................. 138

Role of Non-Productive Time in the Evaluation of Computer Generated Process Plans

N.K. MEHTA, P.e. PANDEY, and AV.S.R.K. PRASAD............................ 144

:hapter III: Process Technology........................................ 151

Introduction .............................................................................................. 151

Computer Managed Process Planning for Cylindrical Parts AMY J. KNUTILLA and BOBBY e. PARK................................................. 153

An Application of Non-Linear Goal Programming in Electrodischarge Machining of Composite Material

M. RAMULU, H.-W. SEE, and D.H. WANG ................................................ 166

xix

An Expert System for Metalforming K. HANS RAJ and V.M. KUMAR................................................................. 173

Optimal Process Planning for Robotic Assembly Operations SHY ANGLIN LEE and HSU-PIN WANG .................................................... 179

Effect of Angular Errors in Part Registration for PC Board Assembly T. RADHAKRISHNAN .................................................................................. 185

An Evaluation Framework for AGVS Within FMS P.F. RIEL and M.S. JONES ............................................................................ 191

Computer Aided Machine Loading Technique USHIR SHAH, SAUMIL TRIVEDI, KETAN SHAH, and P.B. POPAT ...... 197

An Optimal Parallel Algorithm for Channel-Assignment STEPHEN OLARIU, JAMES L. SCHWING, and JINGYUAN ZHANG..... 203

Chapter IV: Product Engineering ....................................... 217

Introduction .............................................................................................. 217

Design Using Case-Based Reasoning COSTAS TSATSOULIS................................................................................. 219

An Interactive Programming System for Design of Mechanical Clutches B. SATYANARAYANA, K.V. MOHAN, and M. MALLIKHARJUNARAO 225

An Expert System for the Design and Selection of Ball Bearing Parameters

M.A. PATHAK and R.S. AHLUW ALIA........................................................ 231

Computer-Aided Optimal Design of Gears HUNGLIN WANG and HSU-PIN WANG .................................................... 237

CAD for Underground Structure GU HANLIANG ............................................................................................. 243

A Microcomputer Aided Design of Technical Systems W. PRZYBYLO ............................................................................. _............... 249

Solid Modeling With Tension DA-PAN CHEN .............................................................................................. 259

Integration of Design Optimization in Finite Element Analysis FRED BA.~EZ................................................................................................. 265

Automatic Generation of Finite Element Modeling for Integrated CAD and CAE

TATSUHIKO AlZAWA................................................................................. 273

Three Dimensional Mesh Generation: A New Approach M.H. KADIVAR and H. SHARIFI................................................................. 279

xx

Effective Modeling of Elastic Mechanical System Through Objective-Aimed Finite Element Strategies

V.H. MUCINO, W.G. WANG, and J.E. SMITH............................................ 285

Design and Evaluation of Shock Isolation of Trailer Mounted Electronic Equipments

V. SUNDARARAMAN .................................................................................. 297

Chapter V: Workcell Operations ........................................ 303

Introduction ......... ....... ........... .......... ...... ... ...... ............... ........... .... ............ 303

Group Technology: Cell Formation Using Simulated Annealing J.M. PROTH .................................................................................................... 305

Cost Considerations for Cell Design in Group Technology KENNETH R. CURRIE.................................................................................. 311

Application of CAD/CAM in the Textile Industry P.B. JHALA .................................................................................................... 317

CAD/CAM of Cams for Use in Automatic Lathes P.c. PANDEY, N.K. MEHTA, and AATUL WADEGAONKAR................. 323

An Objective SIMTOOL in FMS C. ESWARA REDDY, O.V. KRISHNAIAH CHETTY, and D. CHAUDHURI ..................................................................................... 329

A Methodology for Automating the Redressing of the Grinding Wheel AC.S. KUMAR and U.R.K. RAO.................................................................. 336

Experimental Investigations on Tool Vibrations in Turning for On-Line Tool Wear Monitoring

D.N. RAO, P.N. RAO, and U.R.K. RAO........................................................ 342

!1p-Based Industrial Grade Multi-Channel Temperature Controller For Sugar and Allied Industries

H. SINGH, S.M. SHARMA, and C.R.K. PRASAD........................................ 348

Use of SenSors for Safety of Personnel in Robotic Installations K. GHOSH, J.-J. PAQUES, and Y. BEAUCHAMP ............................................ 355

Section B: Developments in Applied Robotics and Automation

xxi

Chapter VI: Industrial Applications .......................................... 361

Introduction .............................................................................................. 361

Determining the Workspace Design of Robotized Cells in Pre-Determined Environments

LOUISE CLEROUX....................................................................................... 363

Judicious Selection of a Robot for an Industrial Task - An Expert System Approach

SURENDER KUMAR and ALOK VARMA ................................................. 369

Fixtureless Robotic Assembly Workcell LARRY BANTA and THOMAS BUBNICK................................................. 374

Design of a Wall-Scaling Robot for Inspection and Maintenance BEHNAM BAHR and SAMI MAARI............................................................ 381

A Telemanipulator for Hazardous Mining Operations M.R. UDAYAGIRI, T.R. RANGNATH, K.C.S. MURTY, S. RAGHUNATH, and PRAVEEN DHYANI................................................ 388

Adoption of Robotic System for Inter-Station Handling Operations for Nagpur Milk Scheme, India

J.P. MODAK, R.D. ASKHEDKAR, and A.V. PESHWE............................... 394

Integration and Realtime Monitoring of Robotic Controllers SUDHAKAR R. PAIDY and MICHAEL SHEA............................................ 400

On the Applications of Part Image Reconstruction Systems in Automated Manufacturing

SAEID MOTAVALLI and BOPAYA BIDANDA......................................... 406

Kalman Filter Application to Tridimensional Rigid Body Motion Parameter Estimation from a Sequence of Images

R. VASQUEZ and J. MA YORA..................................................................... 412

Optimization Techniques for Mathematical Routines Available through High-Level Source Code

S. ROY and A. CHAUDHURI ........................................................................ 421

Chapter VII: Task Performance ................................................ 427

Introduction .... ....... .... ......... .......... ... ..... .... .... ..... ..... ..... .... ............. ... ... ... ... 427

Sensing and Analysis of End-Effector Forces for Precision Assembly ANTHONY DE SAM LAZARO, ECHEMPATI RAGHU, and BERAT GUROCAK ................................................................................ 429

xxii

Accuracy Test From Kinematic Parameter Errors in a Closed-Loop Robot

CHENG Y. LIN, ALOK K. VERMA, and LOUIS J. EVEREIT................... 435

The Effect of Robot Kinematic Parameter Errors on Joint Torques JING TIAN and JOHN E. SNECKENBERGER ............................................ 441

Kinematic Error Budgeting to Obtain the Best Feasible Task Performance for a Specified SCARA Manipulator

TONY M. LAMB and JOHN E. SNECKENBERGER .................................. 448

Demonstrating Robot Calibration in a Manufacturing Environment KEN PFEIFFER and LOUIS J. EVERETT .................................................... 454

On-Line Robot Calibration F. TUIJNMAN and G.R. MEIJER .................................................................. 460

Expert System for Robot Hand Design Using Graph Representation M. CHEW, G.F. ISSA, and S.N.T. SHEN ...................................................... 466

Pre Grasp Pose Estimation of Objects Using Local Sensors on Dexterous Hands

V.H. PINTO, L.1. EVERETT, and M. ORIELS ............................................. 472

Chapter VIII: Motion Specification .......................................... 479

Introduction .............................................................................................. 479

Approximate and Hierarchical Path Planning NAGESWARA S.V. RAO, WENCH ENG WU, and PAl-SHAN LEE.......... 481

Bandlimited Trajectory Planning for Continuous Path Industrial Robots J.T. HUANG .................................................................................................... 487

Trajectory Planning and Kinematic Control of a Stewart Platform-Based Manipulator

CHARLES C. NGUYEN, SAMI S. ANTRAZI, and ZHEN-LEI ZHOU....... 493

Planning and Execution of Polynomial Manipulator Trajectories FRED BAREZ................................................................................................. 500

Efficient Trajectory Planning Algorithm for Coordinately Operating Multiple Robots

YUNG-PING CHIEN and QING XUE........................................................... 509

Path Planning for Coordinated Planar Robot Arms Moving in Unknown Environment

YUNG-PING CHIEN and QING XUE........................................................... 515

A Theory of Collision Avoidance on Visual Guidance of Robot Motion in Dynamic Environment

Q. ZHU and J. LIU .......................................................................................... 521

xxiii

A Collision Prediction System for a Robotic Environment NANCY SLIWA, WILLIAM BYNUM, and CHARLES WATLAND ......... 527

Multivalue Coding: Application to the Autonomous Robots A. PRUSKI ...................................................................................................... 533

Information Management for Off-Line Robot Programming H. AFSARMANESH, G.R. MEIJER, and F. TUIJNMAN ............................ 539

Chapter IX: Manipulator Mechanics ......................................... 545

Introduction ......... ..................................... ......... ............................ ..... ...... 545

Computer Aided Analysis of a Planar Robot SHAILESH SHAH and YOGESHWAR HARI.............................................. 547

Computer Aided Analysis of the First Three Links in a Puma Robot DURAISWAMI PALANIVELU and YOGESHWAR HARI ........................ 553

Work-Space Calculation of a Robotic Arm Using the Articulated Total Body Model

XAVIER J.R. A VULA, INTS KALEPS, and LOUISE OBERGEFELL ....... 559

Effect on Flexibility on Manipulator Dynamics H. ASHRAFIUON and C. NATARAJ ............................................................ 565

Dynamics of Flexible Manipulators With Application to Robotic Assembly

E. WEHRLI and P. COIFFET......................................................................... 576

Kineto-Elastodynamic Effect on the Design of Elastic Mechanisms ECHEMPATI RAGHU and A. BALASUBRAMONIAN.............................. 585

Scheme for Active Positional Correction of Robot Arms SAEED B. NIKU ............................................................................................ 590

Feedback Control of Robot End-Effector Probable Position Error Y.c. PAO and L.c. CHANG........................................................................... 594

An Intelligent Signal Recognition System T. HOU and L. LIN ......................................................................................... 600

State Estimation Under Unknown Noises - A Least-Squares Approach CHUNG-WEN CHEN and JEN-KUANG HUANG....................................... 606

Chapter X: Educational Endeavors ........................................... 613

Introduction .............................................................................................. 613

Combined EE-ME Senior Capstone Projects In Robotics at West Virginia University

NIGEL T. MIDDLETON and LARRY BANTA............................................ 615

xxiv

Automated Manufacturing at Western Kentucky University R.I. EVERSOLL, H.T. LEEPER, and L.T. ROSS .......................................... 621

Manufacturing Systems Engineering Education at the University of Pittsburgh

JOHN H. MANLEY ........................................................................................ 626

Human Factors Considerations in the Design of a Teach Pendant ALOK K. VERMA and CHENG Y. LIN........................................................ 632

Contents, Volume 1

xxvi

Conference Objective ................................................................ v

Conference Organization. ... ......... ......... ......... ......... ...... ...... ....... vi

Committee Rosters .................................................................... viii

Letter from the President, ISPE................................................. xi

Acknowledgments ........ ............ ......... ............... ...... ... ... ............. xiii

Preface....................................................................................... xv

Chapter I: General Issues .......................................................... 1

Introduction ........... .................. ... ......................... ......... ........... .......... ......... ....... 1

Concurrent Engineering: An Introduction SUREN N. DWIVEDI and MICHAEL SOBOLEWSKI................................ 3

Quality Design Engineering: The Missing Link in U.S. Competitiveness

H. BARRY BEBB........................................................................................... 17

New Activities in the Manufacturing Domain to Support the Concurrent Engineering Process

KEITH WALL and S.N. DWIVEDI ............................................................... 31

Chapter II: Intelligent Information Networks ........................... 37

Introduction .............................................................................................. 37

Artificial Intelligence in Concurrent Engineering A. KUSIAK and E. SZCZERBICKI ............................................................... 39

An Open Ended Network Architecture for Integrated Control and Manufacturing

K.C.S. MURTY and RAMESH BABU .......................................................... 49

A Data Base Inconsistency Checker for EASIE K.H. JONES, S. OLARIU, L.F. ROWELL, J.L. SCHWING, and A. WILHITE............................................................................................. 55

xxvii

Database Exchange in the CAD/CAM/CIM Arena BRUCE A. HARDING.................................................................................... 61

Formation of Machine Cells: A Fuzzy Set Approach CHUN ZHANG and HSU-PIN WANG.......................................................... 67

Design Assessment Tool DANIEL M. NICHOLS and SUMITRA REDDy.......................................... 73

Support of PCs in Concurrent Engineering NARESH C. MAHESHWARI and BRADLEY S. BENNETT...................... 80

Chapter III: Neural Network ..................................................... 87

Introduction .............................................................................................. 87

Artificial Neural Networks In Manufacturing KENNETH R. CURRIE .................................................................................. 89

Using Artificial Neural Networks For Flexible Manufacturing System Scheduling

LUIS CARLOS RABELO and SEMA ALPTEKIN ....................................... 95

Machine-Part Family Formation Using Neural Networks RAM HUGGAHALLI and CIHAN DAGLI................................................... 102

Neural Networks in Process Diagnostics SOUNDAR R.T. KUMARA and NAJWA S. MERCHA WI.......................... 108

Chapter IV: Knowledge Based Engineering ............................. 115

Introduction .............................................................................................. 115

DICEtalk: An Object-Oriented Knowledge-Based Engineering Environment

M. SOBOLEWSKI .......................................................................................... 117

Data Models of Mechanical Systems for Concurrent Design KIRK J. WU, FOOK CHOONG, and S. TWU ............................................... 123

Manufacturing Knowledge Representation Using an Object Oriented Data Model

RASHPAL S. AHLUWALIA and PING 11 .................................................... 130

Knowledge-Based Evaluation of Manufacturability SIPING LlU, VASILE R. MONTAN, and RAVI S. RAMAN....................... 136

Knowledge-Based Graphic User Interface Management Methodology STEWART N.T. SHEN and 1IH-SHIH HSU ................................................. 142

xxviii

Knowledge Augmentation Via Interactive Learning in a Path Finder Q. ZHU, D. SHI, and S. TANG....................................................................... 148

Graphical User Interface with Object-Oriented Knowledge-Based Engineering Environment

Z. KULPA, M. SOBOLEWSKI, and S.N. DWIVEDI.................................... 154

Knowledge Automation: Unifying Learning Automation and Knowledge Base

A. CHANDRAMOULI and P.S. SATSANGI ................................................ 160

Developing a Knowledge Based System for Progressive Die Design PRATYUSH KUMAR, P.N. RAO, and N.K. TEWARI ................................ 166

An Expert System Model for the Use in Some Aspects of Manufacturing

R.B. MISHRA and SUREN N. DWIVEDI ..................................................... 172

Chapter V: Feature Based Design and Manufacturing.............. 179

Introduction .............................................................................................. 179

Using a Feature Algebra in Concurrent Engineering Design and Manufacturing

RAGHU KARINTHI and DANA NAU.......................................................... 181

Feature Recognition During Design Evolution HYOWON SUH and RASHPAL S. AHLUWALIA ...................................... 187

Extraction of Manufacturing Features from an I-DEAS Universal File JONG-YUN JUNG and RASHPAL S. AHLUWALIA.................................. 193

Feature Based Design Assembly SISIR K. PADHY and SUREN N. DWIVEDI................................................ 199

Feature Based Machining Analysis and Cost Estimation for the Manufacture of Complex Geometries in Concurrent Engineering

B. GOPALAKRISHNAN and V. PANDIARAJAN ....................................... 205

Use of Part Features for Process Planning S.K. GUPTA, P.N. RAO, and N.K. TEWARI ................................................ 211

Chapter VI: CAD and FEM ...................................................... 217

Introduction .............................................................................................. 217

Model Based 3-D Curved Object Recognition Using Quadrics M. HANMANDLU, C. RANGAIAH, and K.K. BISWAS............................. 219

Finite-Element Model for Modal Analysis of Pretwisted Un symmetric Blades

xxix

N.T. SIVANERI and Y.P. XIE....................................................................... 225

Computer Based Life Prediction Methodology for Structural Design T.L. NORMAN, T.S. CIVELEK, and J. PRUCZ............................................ 231

Chapter VII: Process Modeling and ControL........................... 237

Introduction .............................................................................................. 237

Processing of Superalloys in the 1990s F. ROBERT DAX............................................................................................ 239

Application of the Finite Element Method in Metal Forming Process Design

SHANKAR RACHAKONDA and SUREN N. DWIVEDI ............................ 253

Strategic Value of Concurrent Product and Process Engineering EDWIN R. BRAUN and JASON R. LEMON ................................................ 259

The Design Process for Concurrent Engineering NICHOLAS J. YANNOULAKIS, SANJA Y B. JOSHI, and RICHARD A. WYSK............................................................................... 265

Modeling Concurrent Manufacturing Systems Using Petri Nets KELWYN A. D'SOUZA................................................................................. 271

Production Planning and Control in the Factory of the Future W.H. ISKANDER and M. JARAIEDI ............................................................ 281

Expert Control of Turning Process P.S. SUBRAMANYA, V. LATINOVIC, and M.O.M. OSMAN.................... 287

Expert System for Milling Process Selection B. GOPALAKRISHNAN and M.A. PATHAK.............................................. 293

Forging Die Design with Artificial Intelligence S.K. PADHY, R. SHARAN, S.N. DWIVEDI, and D.W. LyONS................. 299

Chapter VIII: Process Simulation and Automation................... 307

Introduction. ...... .... ...................... .............. ......... ......... .... ......... ............. ... 307

Simulation Modeling in CIM Systems Design COLIN O. BENJAMIN, MELINDA L. SMITH, and DEBRA A. HUNKE 309

EXSEMA-An EXpert ~ystem for SElecting Simulation Software for Manufacturing Applications

COLIN O. BENJAMIN and OSSAMA A. HOSNY....................................... 315

xxx

Group Technology Analysis for Manufacturing Data ABDELLAH NADIF, RENE-PIERRE BALLOT, and BERNARD MUTEL 321

Dispatching Mobile Robots in Flexible Manufacturing Systems: The Issues and Problems

HIMANSHU BHATNAGAR and PATRICK D. KROLAK.......................... 327

Automation of Prototype General Aviation Aircraft Development GEORGE BENNETT...................................................................................... 334

Determining Organizational Readiness for Advanced Manufacturing Technology: Development of a Knowledge-Based System to Aid Implementation

DONALD D. DAVIS, ANN MAJCHRZAK, LES GASSER, MURRAY SINCLAIR, and CARYS SIEMIENIUCH ................................... 340

Planning and Realization of Skill Based Flexible Automation for Developing Countries

S. KUMAR and A.K. JHA............................................................................. 346

Chapter IX: PCB Manufacturability and Assembly .................. 353

Introduction .. ............. ....... ... ......... ............. .... ... ...... ......... .... ...... ... ...... ... ... 353

An Expert System Based Concurrent Engineering Approach to PCB Assembly

K. SRIHARI .................................................................................................... 355

Real Time Production Scheduling and Dynamic Parts Routing for Flexible Assembly Lines

J.P. BOURRIERES, O.K. SHIN, and F. LHOTE ........................................... 361

A Knowledge-Based proach for Manufacturability of Printed Wiring Boards

SISIR K. PADHY and S.N. DWIVEDI ......................................................... 369

Design of an IOES Post Processor and Integration with a Robotic Workcell

R.H. WILLISON and G.M. PALMER............................................................ 376

Discrete Optimum Assembly Methods for Automated Workcells KENNETH H. MEANS and JIE JIANG......................................................... 382

Trajectory Planning for Obstacle-Avoided Assembly of Planar Printed Circuit Boards

TAK-LAI LUK and JOHN E. SNECKENBERGER...................................... 388

Development of a Vision Assisted Optimal Part-To-Pad Placement Technique for Printed Circuit Board Assembly

S.H. CHERAGHI, E.A LEHTIHET, and PJ. EGBELU................................ 394

xxxi

Chapter X: Quality Control Techniques.................................... 401

Introduction ...... ...................... ..... .......... ...................... ......... ........... ......... 401

Quality Function Deployment, a Technique of Design for Quality CHIA-HAO CHANG ...................................................................................... 403

Quality Value Function and Consumer Quality Loss FU QIANG YANG, MAJID JARAIEDI, and WAFIK ISKANDER ............ 409

Implementation of a Computer Aided Quality System (CAQ) in CIM Environment: Advantages and Disadvantages

M. DOMINGUEZ, M.M. ESPINOSA, J.I. PEDRERO, and J.M. PEREZ..... 415

Computer Aided Quality Assurance Systems V.K. GUPTA and R. SAGAR......................................................................... 421

Quality Consideration During DFA Analysis SUDERSHAN L. CHHABRA and RASHPAL S. AHLUWALIA ................ 436

Selection of Acceptance Sampling Plans Through Knowledge Based Approach

S.S.N. MURTY and D. CHANDRA REDDy................................................ 443

Chapter XI: Cost Analysis Concept .......................................... 451

Introduction .............................................................................................. 451

Analysis of Quality Costs: A Critical Element in CIM RES IT UNAL and EDWIN B. DEAN ............................................................ 453

A Databased Time and Cost Estimation Algorithm for Piece Part Design and Manufacturing

K.W.-N. LAU and M. RAMULU.................................................................... 458

Improvement Curves in Manufacturing R.C. CREESE and MADHU SUD HAN ......................................................... 466

Chapter XII: Materials: Composite ........................................... 473

Introduction .............................................................................................. 473

The Payoffs of Concurrent Engineering in Advanced Materials Development

JACKY C. PRUCZ.......................................................................................... 475

xxxii

A Practical Engineering Approach for Predicting Interlaminar Stresses in Composites

JACKY PRUCZ and MARIOS LAMBI ......................................................... 487

Interactive Optimum Parametric Design of Laminated Composite Flange

B.S.-J. KANG, JACKY PRUCZ, and F.K. HSIEH ........................................ 506

Computer Aided Dynamic Analysis of Laminated Composite Plates ALEXANDER E. BOGDANOVICH, ENDEL V. IARVE, and SUREN N. DWIVEDI.............................................................................. 519

Integration of Rigid-Plastic Simulation Engines into Engineering Database System for Advanced Forging

T ATSUHIKO AIZA WA and JUNJI KIHARA............................................... 528

Chapter XIII: Implementation .................................................. 535

Introduction ............ ....... ...... ......... ........ ......... ... ...... .... ......... ... ........... .... ... 535

Transitioning CE Technology to Industry S.N. DWIVEDI, RAV! PRASAD, and D.W. LYONS ................................... 537

Integrated Models of FMS in Concurrent Engineering Environment A.A. LESKIN and S.N. DWIVEDI................................................................. 553

Implementing QFD at the Ford Motor Company HAROLD F. SCHAAL and WILLIAM R. SLABEY .................................... 563