Page 56 - ASME DSCC 2015 Program

Technical Program

Diesel Engine fuel Injection Control using a Model-Guided Extremum- A Model Predictive Repetitive Process Control formulation for Additive
Seeking Method Manufacturing Processes
Invited session paper. DSCC2015-9967 Contributed regular paper. DSCC2015-9780
prasad divekar, qingyuan Tan, xiang chen, Ming Zheng, University of Patrick Sammons, Doug Bristow, Robert landers, Missouri University of
Windsor, Windsor, ON, Canada, Ying Tan, University of Melbourne, Victoria, Science and Technology, Rolla, MO, United States
Australia
Additive Manufacturing (AM) processes are a class of manufacturing
Diesel engine fuel injection control is presented as a feedback based processes in which parts are fabricated in a layer-by-layer fashion. The
online optimization problem. Extremum seeking (ES) approach is used to layer-by-layer fabrication method creates layer-to-layer dynamics. Imple-
address the online optimization formulation. The cost function is synthesized menting process control that neglects the layer-to-layer dynamics can lead
from extensive experimental investigations such that the indicated thermal to process instability. While repetitive process controllers which utilize only
efficiency of the engine is maximized while minimizing the NOx emissions layer-to-layer feedback are a viable method, their usefulness is limited in
under external boundary conditions. Knowledge of the physical combustion that they are not well-suited for tracking non-periodic layer-domain referenc-
and emission formation process based on a pre-calibrated non-linear engine es. However, since the entire reference signal is typically known a priori in
model output is used to determine the ES initial control input to minimize the AM process fabrications, a predictive control methodology can be useful for
seeking time. The control is demonstrated on a hardware-in-the-loop engine controlling fabrications in which the reference signal is non-periodic. In this
simulator bench. paper a model predictive control formulation is extended to two-dimensions
and utilized for repetitive process control Simulation results comparing
1-16 MaNufacTurINg open-loop and controlled fabrications for a Laser Metal Deposition process
1-16-1 TM7 Manufacturing
Elijah Pierce A 1:30pm–3:30pm are given.
A novel Method to Reduce Inspection Process Cycle Time While using
Session Chair: Doug Bristow, Missouri University of Science and a Coordinate Measurement Machine
Technology, Rolla, MO, United States Contributed regular paper. DSCC2015-9911
Session Co-Chair: Prabhakar Pagilla, Oklahoma State University, nilanjan Choudhury, Oakland University, Auburn Hills, MI, United States,
Stillwater, OK, United States Sankar Sengupta, Robert Vantil, Oakland University, Rochester, MI, United
States
Robust nonlinear Model Predictive Control for Infrared Drying of
A touch-based probe of a coordinate measurement machine (CMM) is
Automotive Coatings
generally used to validate the dimensions of the artifacts and associated
Contributed regular paper. DSCC2015-9736
features which come out of the manufacturing line against its dimensions to
xiaoqing cao, Beshah ayalew, Clemson University, Greenville, SC, United ensure to be within prescribed GD&T [Wilson 14] limits. Although there could
States
be other applications using a CMM like reverse engineering, however the
In this paper, a scheme for estimation and control of moisture content in stated inspection process is quite crucial for maintaining quality factor and
infrared (IR) drying of paints/coatings is proposed. To deal with the in- to regulate merits of the manufacturing process especially with the
finite-dimensional nature of the process model associated with the moisture continuous wear-tear of the involved tooling. However this inspection
diffusion in the coating film, POD-Galerkin method is first applied for model process, which is considered as auxiliary process, needs to have minimum
reduction. Then, an unscented Kalman filter (UKF) is devised for distrib- cycle time in order to effectively have more quality units to be produced.
uted moisture content estimation and nonlinear model predictive control In this paper we describe Computer Aided Process Planning (CAPP) in order
(NMPC) system is designed for tracking a desired average moisture content to complete Computer Aided Inspection (CAI) process using CMM on the
profile with optimized energy needs. To enhance the control performance work-piece which is created through Computer Aided Design (CAD) and
in the presence of potential modeling uncertainties, a robust design is also Manufacturing (CAM). This leads to Computer Integrated Manufacturing
included in the proposed NMPC scheme. The effectiveness of this approach (CIM) process. As a result, the features, which need to be inspected, could
is demonstrated via simulated applications to IR drying of automotive water- be recognized from its corresponding CAD file and appropriate information
borne coatings. could be culled out by the Dassault Software System to calculate the
approach and retract points to inspect the features [Choudhury 03].
The main objective of this research paper is to determine the shortest
collision free trajectory from the retract point of one feature being inspected
to the approach point of another feature being inspected so that the
sequencing for the set of trajectories could be calculated through existing
Traveling Sales Person (TSP) algorithm in order to shorten the total distance
travelled by the CMM probe, which in turn would linearly reflect in reducing
the cycle inspection time. Further since different features in the work-piece
might need to be inspected by different probes, an overhead time and
displacement for probe change, needs to consider in order to shorten the
cycle time. These include clustering of similar type of features, which can be
56 inspected by the same probe. Also clustering of similar type of features
need to be assessed against spatial distance of separation between the