System Design and Control Integration for Advanced Manufacturing

Han-Xiong Li, XinJiang Lu

• Publisher: Wiley-IEEE Press
• Year: 2014
• Print ISBN: 9781118822265
• eBook ISBN: 9781118822333
• Edition: 1
• Topic: Tecnología e ingeniería
• Subtopic: Ingeniería industrial

Most existing robust design books address design for static systems, or achieve robust design from experimental data via the Taguchi method. Little work considers model information for robust design particularly for the dynamic system. This book covers robust design for both static and dynamic systems using the nominal model information or the hybrid model/data information, and also integrates design with control under a large operating region. This design can handle strong nonlinearity and more uncertainties from model and parameters.

Part I
Background and Fundamentals

CHAPTER 1
Introduction

This chapter is an introduction of the book. It briefly introduces background, motivation, and objectives of the research, followed by the contribution and organization of the book.

1.1 Background and Motivation

Since we moved into the Industrial Age, most of the products used have been manufactured by machines and production lines. The manufacturing industry has changed much from the traditional sector, like steel and auto factory, to the semiconductor or IC industry in 1980s, and to the internet-based global manufacturing nowadays. Advanced manufacturing uses the so-called “advanced,” “innovative,” or “cutting-edge” technology to improve products and/or processes. The distinctions between traditional sectors of manufacturing and advanced manufacturing are in terms of volume and scale economies, labor and skill content, and intelligence added in the system.

In modern IC industry, the higher speed, the higher precision, and the higher intelligence have become common requirements to many of the processes involved, for example, epoxy/silicone dispensing (Li et al., 2007), curing process (Li, Deng, and Zhong, 2004; Deng, Li, and Chen, 2005), bonding/wiring process (Li and Zuo, 1999), and so on. Even in a traditional industry, like the forging press machine (Lu, Li, and Chen, 2012), the machine will seek help from an intelligence unit for meeting quality and economic constraints. Modern information technology can make a traditional system more advanced.

No matter how complex or advanced the manufacturing operation is, it always consists of basic actions offered by basic systems. These basic systems could be classified into the following three different categories.

• The static system. The performance is invariant over time, so it is discrete.
• The dynamic system. The performance is varying over time, so it is continuous.
• The hybrid system. It is a combination of the above two, which forms a hybrid system with discrete/continuous parameters, or a hybrid discrete/continuous system.

Design for advanced manufacturing is actually centered on the design and control of these basic systems, as the performance of every basic system is crucial to the overall performance of the manufacturing.

Since advanced manufacturing usually involves more complex system configuration and more advanced technologies, it will require a higher quality design of each basic system involved in the operation. However, unavoidable external variations in manufacturing operations, material properties, and a complex operating environment will result in an inconsistent performance of the system, which will be a big challenge to design for manufacturing. If these variations are not properly considered in product design, the degraded performance may result in a failure in operation (Caro, Bennis, and Wenger, 2005). Thus, robust performance, insensitive to all possible changes in demand, model uncertainties, and external disturbance, is one of the most important concerns in the design of any system.

In system design, robust design is the most important method commonly used to achieve robust performance. Its fundamental principle is minimizing the sensitivity of the performance to uncontrollable variations. Most of these approaches are for static systems, a few for dynamic systems. Furthermore, design and control are always separated in both academic research and industrial applications, which leads to few effective methods for the hybrid system.

The principal goal in this book is to develop effective design methods for fundamental systems existing in advanced manufacturing, including

1. novel robust design methods for both static and dynamic systems; and
2. robust design and control integration methods for the hybrid discrete/continuous system.

Though these methods are studied for basic systems in this book, they should be easily applied to any advanced manufacturing or production.

There are three different sets of variables that will appear in robust design.

• Design variable (or control variable). This is the controllable variable with its nominal value to be designed ideally between the upper and lower bounds. The variations around its nominal value are usually caused by poor manufacturing.
• Uncertainty. This usually includes parameter variation, noise, and model uncertainty. It cannot be adjusted by the designer, and thus is uncontrollable.
• Performance. This is the objective of the design and depends on the system model, design v...

Table of contents

• Cover
• Chronology
• Title Page
• Copyright
• Preface
• Acknowledgments
• Part I: Background and Fundamentals
• Part II: Robust Design for Static Systems
• Part III: Robust Design for Dynamic Systems
• Part IV: Integration of Design and Control
• References
• Index
• IEEE Press Series on Systems Science and Engineering
• End User License Agreement