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INTJADVMANUFTECHNOL200734430439DOI101007/S0017000606152ORIGINALARTICLEREUVENKATZDESIGNPRINCIPLESOFRECONFIGURABLEMACHINESRECEIVED6OCTOBER2005/ACCEPTED10APRIL2006/PUBLISHEDONLINE8JUNE2006SPRINGERVERLAG2006ABSTRACTRECONFIGURABLEMACHINESFORMANEWCLASSOFMACHINESTHATAREDESIGNEDAROUNDASPECIFICPARTFAMILYOFPRODUCTSANDALLOWRAPIDCHANGEINTHEIRSTRUCTURETHEYAREDESIGNEDTOALLOWCHANGESINMACHINECONFIGURATIONACCORDINGTOCHANGESINPRODUCTIONREQUIREMENTSTHERECONFIGURATIONMAYBERELATEDTOCHANGESINMACHINEFUNCTIONALITYORITSSCALABILITY,IE,THECHANGEINPRODUCTIONVOLUMESORSPEEDOFOPERATIONRECONFIGURABLEMACHINESREPRESENTANEWCLASSOFMACHINESTHATBRIDGESTHEGAPBETWEENTHEHIGHFLEXIBILITYANDHIGHCOSTOFTOTALLYFLEXIBLEMACHINESANDTHELOWFLEXIBILITYANDLOWCOSTOFFULLYDEDICATEDMACHINESTHEDESIGNPRINCIPLESOFRECONFIGURABLEMACHINESFOLLOWASIMILARPHILOSOPHY,WHICHWASDERIVEDFORRECONFIGURABLEMANUFACTURINGSYSTEMS,ANDPRESENTANAPPROACHFORTHEDESIGNOFMACHINESTOBEUSEDMAINLYINHIGHVOLUMEPRODUCTIONLINESTHISPAPERINTRODUCESDESIGNPRINCIPLESFORRECONFIGURABLEMACHINES,WHICHMAYBEAPPLIEDINDIFFERENTFIELDSOFMANUFACTURINGBASEDONTHESEDESIGNPRINCIPLES,THREETYPESOFRECONFIGURABLEMACHINESWEREDESIGNEDFORVARIOUSTYPESOFPRODUCTIONOPERATIONSSUCHASMACHINING,INSPECTIONANDASSEMBLYTHISPAPERSHOWSHOWTHESUGGESTEDDESIGNPRINCIPLESWEREUTILIZEDINTHEDESIGNOFSEVERALFULLSCALEMACHINEPROTOTYPESANDTESTEDEXPERIMENTALLYKEYWORDSMACHINEDESIGNRECONFIGURABLEMACHINESRMRECONFIGURABLEMANUFACTURINGSYSTEMSRMSRECONFIGURABLEMACHINETOOLRMTRECONFIGURABLEINSPECTIONMACHINERIMRECONFIGURABLEASSEMBLYMACHINERAMABBREVIATIONSRMRECONFIGURABLEMACHINERMSRECONFIGURABLEMANUFACTURINGSYSTEMSRMTRECONFIGURABLEMACHINETOOLRIMRECONFIGURABLEINSPECTIONMACHINERAMRECONFIGURABLEASSEMBLYMACHINEDMSDEDICATEDMANUFACTURINGSYSTEMSFMSFLEXIBLEMANUFACTURINGSYSTEMSERC/RMSENGINEERINGRESEARCHCENTERFORRECONFIGURABLEMANUFACTURINGSYSTEMSCNCCOMPUTERNUMERICCONTROLCMMCOORDINATEMEASUREMENTMACHINEFRFFREQUENCYRESPONSEFUNCTIONFFTFASTFOURIERTRANSFORM1INTRODUCTIONTHETWOMAINTRADITIONALMETHODSUTILIZEDBYMANUFACTURINGINDUSTRIESINTHEPRODUCTIONOFMEDIUMANDHIGHVOLUMEPARTSAREDEDICATEDMANUFACTURINGSYSTEMSDMS1,2ANDFLEXIBLEMANUFACTURINGSYSTEMSFMS35DMSISUSEDWHENPARTPRODUCTIONVOLUMESAREHIGHANDCONSTANT,ANDTHEPARTDOESNOTCHANGEFMSISUSEDWHENTHEREQUIREDQUANTITIESARERELATIVELYLOWERANDMANYMODIFICATIONSINTHEPARTDESIGNAREFORESEEN,ORMORETHANONETYPEOFPRODUCTISPRODUCEDONTHESAMELINESIMULTANEOUSLYANINNOVATIVEAPPROACHOFCUSTOMIZEDMANUFACTURING,TERMEDRECONFIGURABLEMANUFACTURINGSYSTEMSRMSISDESCRIBEDIN6THEMAINADVANTAGEOFTHISNEWAPPROACHISTHECUSTOMIZEDFLEXIBILITYOFTHESYSTEMTOPRODUCEA“PARTFAMILY”OFPRODUCTSWITHLOWERINVESTMENTCOSTTHANANFMSASETOFCORECHARACTERISTICSMODULARITY,SCALABILITY,INTEGRABILITY,CONVERTIBILITY,CUSTOMIZATIONANDDIAGNOSIBILITYCOMPRISESTHEHEARTOFANRMS7ATYPICALRMSINCLUDESBOTHCONVENTIONALFLEXIBLEMACHINESANDANEWTYPEOFMACHINECALLEDTHERECONFIGURABLEMACHINERMONITSPRODUCTIONLINETYPICALLY,ADEDICATEDMACHINEUSEDINADMSISDESIGNEDAROUNDASPECIFICPARTTHATISMASSPRODUCEDITISDESIGNEDTOPERFORMASINGLEOPERATIONWITHHIGHRELIABILITYANDREPEATABILITY,ANDHIGHPRODUCTIVITYANDTHEREFOREISRELATIVELYSIMPLEANDLESSEXPENSIVEMACHINESTHATAREUSEDINANFMSAREDESIGNEDTOPERFORMMOSTOPERATIONSINAFLEXIBLEMANNERTHESEFLEXIBLEMACHINESARECOMPUTERNUMERICALCONTROLLEDCNCANDCANPRODUCEMANYDIFFERENTPARTSBYCHANGINGTHEIRCOMPUTERPROGRAMSSINCERELIABILITY,REPEATABILITYANDHIGHPRODUCTIVITYARERKATZNSFENGINEERINGRESEARCHCENTERFORRECONFIGURABLEMANUFACTURINGSYSTEMS,UNIVERSITYOFMICHIGAN,ANNARBOR,MI,USAEMAILREUVENUMICHEDUTEAEQUIREDFORMASSPRODUCTIONLINES,FLEXIBLEMACHINESDESIGNEDFORHIGHVOLUMEPRODUCTIONARERELATIVELYEXPENSIVEINCONTRAST,THERMISDESIGNEDFORCUSTOMIZEDFLEXIBILITY,IE,THEFLEXIBILITYNEEDEDTOPRODUCEAPARTICULARPARTFAMILY7THERMCANPERFORMAPREDESIGNEDSETOFREQUIREDOPERATIONSASSPECIFIEDFORTHESPECIFICPARTFAMILYWITHHIGHRELIABILITY,REPEATABILITYANDHIGHPRODUCTIVITYTHELIMITED,CUSTOMIZEDFLEXIBILITYALLOWSREDUCTIONOFINVESTMENTCOSTSONTHEONEHANDANDFASTRESPONSEWHENAPRODUCTCHANGESONTHEOTHER,BOTHREPRESENTINGECONOMICALBENEFITSTHEINNOVATIVEIDEAOFRMSANDITSSIXCORECHARACTERISTICSWASORIGINALLYDEVELOPEDFOR“SYSTEMS”,NAMELY,MASSPRODUCTIONLINESDEVELOPMENTOFNEWDESIGNPRINCIPLESBASEDONRMSPHILOSOPHYWASREQUIREDINORDERTODESIGNRMSTHESEMACHINESARETOBEUSEDONRMSLINES,THEREBYEXTENDINGTHERMSCONCEPTFROMASYSTEMLEVELTOTHEMACHINELEVELINTHELITERATURE,SEVERALGENERALPRINCIPLESOFMACHINEDESIGNHAVEBEENPROPOSEDANDDISCUSSEDFOREXAMPLE,DOUBBELDESCRIBESPRINCIPLESOFEMBODIMENTDESIGNSUCHASPRINCIPLEOFDIVISIONOFTASKS,FORCEANDENERGYTRANSMISSION,ASWELLASSAFETYANDRELIABILITYPRINCIPLES8NORTONDEFINESENGINEERINGDESIGNAS“THEPROCESSOFAPPLYINGTHEVARIOUSTECHNIQUESANDSCIENTIFICPRINCIPLESFORTHEPURPOSEOFDEFININGADEVICE,APROCESSORASYSTEMINSUFFICIENTDETAILTOPERMITITSREALIZATION”ANDALSODESCRIBESTHEPHASESOFTHEDESIGNPROCESS9SUHPRESENTSATHOROUGHDISCUSSIONOFTHEDESIGNPROCESSINENGINEERINGUSINGMATHEMATICALTOOLSANDSHOWSEXAMPLESOFMACHINEDESIGN10HEPRESENTSTHEDESIGNEQUATIONTHATRELATESTHEFUNCTIONALREQUIREMENTSVECTORFRTOTHEDESIGNPARAMETERSDPVECTORUSINGTHEDESIGNMATRIXAUSINGTHISAPPROACH,HESTUDIESDIFFERENTCASESOFCOUPLEDDESIGN,REDUNDANTDESIGNANDIDEALDESI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UTTINGEXPERIMENTSWEREREPEATEDAT45DEGREESINCLINATIONANDTHERESULTSSHOWEDSIMILARCHARACTERISTICSTHERESULTSINTERESTINGLYSHOWEDTHATTHERECONFIGURATIONOFMACHINESTRUCTUREDOESNOTAFFECTARCHTYPERMTSTABILITYTHEARCHTYPERMTWASDESIGNEDASANONORTHOGONALMACHINETOOL,EXCEPTWHENINHORIZONTALPOSITIONATTHEDESIGNPHASE,ATHOROUGHSTUDYOFTHECONTROLPROBLEMASSOCIATEDWITHTHISDESIGNCONCEPTWASPERFORMED28ANEWTYPEOFCROSSCOUPLINGCONTROLLERWASSUGGESTEDTHESTABILITYOFTHECONTROLSYSTEMWASINVESTIGATED,ANDFIG1ARCHTYPERMTFIG2RMTPARTFAMILYTWOAUTOMOTIVECYLINDERHEADSV8LEFTANDV6RIGHT26433SIMULATIONWASUSEDTOCOMPAREDIFFERENTTYPESOFCONTROLLERSTHEARCHTYPERMTWASDESIGNEDFORRAPIDANDEASYCONVERTIBILITYTHEPROCESSOFMOVINGTHESPINDLEFROM15DEGREESANGLETO45DEGREESBYMEANSOFAMOTORIZEDLINEARSTAGEANDFIXINGITATAPRECISELOCATIONWASTESTEDITTAKESLESSTHAN5MINTOCOMPLETETHERECONFIGURATIONPROCESSINTHELABORATORYTHEARCHTYPERMTISCAPABLEOFDRILLINGONASURFACEWITH45DEGREESINCLINATIONATONELOCATIONALONGTHEPRODUCTIONLINEANDANOTHERSIMILARARCHTYPERMTJUSTDIFFERENTLYCONFIGUREDISCAPABLEOFMILLINGONASURFACEWITH15DEGREESINCLINATIONINADIFFERENTLOCATIONINTHEDESIGNPHASETHEREWASAPLANTOINTRODUCEMODULARITYFEATURESTOTHEARCHTYPERMTBYUSINGSTANDARDINTERFACESINORDERTOENABLEEASYSPINDLESEXCHANGEABILITYWEHAVENOTSUCCEEDEDINTHISEFFORTSINCEITREQUIREDCLOSECOOPERATIONWITHSPINDLESSUPPLIERANOUTSTANDINGEXAMPLEOFMODULARDESIGNOFSPINDLEINTERFACESFORMACHINETOOLSISPRESENTEDIN15,WHERETHESPINDLEHASSTANDARDINTERFACESFORPOWER,MEDIA,DATA,ALIGNMENTANDTOOLCHANGETHATALLOWEDTHEDEVELOPMENTOFTHE“MULTICOUPLING”CONCEPTTHATUTILIZESMODULARITYPRINCIPLES4RECONFIGURABLEINSPECTIONMACHINERIM41BRIEFDESCRIPTIONTHERECONFIGURABLEINSPECTIONMACHINERIMWASDESIGNEDFORRAPID,INPROCESS,INSPECTIONOFTHEMACHINEDFEATURESOFAPARTFAMILYOFCYLINDERHEADSTHERIMHASBEENORIGINALLYDEVELOPEDFORMEASURINGGEOMETRICFEATURESSUCHASFLATNESS,PARALLELISMANDPROFILEASSOCIATEDWITHTHECOVERANDJOINTFACESOFANENGINECYLINDERHEAD2931UNDERADIFFERENTCONFIGURATION,BYADDINGAMACHINEVISIONSYSTEMTOTHESTRUCTURE,THERIMALSOALLOWSINSPECTIONOFCYLINDERHEADSURFACESFORPORESANDOTHERSURFACETEXTUREIMPERFECTIONSTHERIMUSESNONCONTACTMEASUREMENTMETHODSBASEDONCOMMERCIALLASERSENSORSANDHIGHDEFINITIONLINESCANCAMERASINCONJUNCTIONWITHCOMPUTERVISIONTECHNOLOGYANDOTHERCOMMERCIALLYAVAILABLENONCONTACTSENSORSAPROTOTYPEOFTHERIMISSHOWNINFIG4ATHEINSPECTEDPARTMOVESALONGALINEARAXISANDPASSESTHESENSORSONASERVODRIVENSINGLEAXISMOTIONSTAGETHATISEQUIPPEDWITHAHIGHPRECISIONLINEARSCALEOF1MACCURACYTHEVELOCITYOFTHEMOTIONSTAGE,ASWELLASTHEPROBESAMPLINGFREQUENCY,CANBEVARIEDINACCORDANCETOFIG3RMTDYNAMICCHARACTERISTICSFIG4RECONFIGURABLEINSPECTIONMACHINE434THEREQUIREDSAMPLINGDENSITYANDINSPECTIONCYCLETIMETHELINEARPOSITIONALONGTHEAXISOFTRAVELISRECORDEDFOREACHMEASUREMENTPOINT,WHICHENABLESAPRECISEMAPPINGOFTHEPARTSURFACEWITHOUTBEINGAFFECTEDBYVARIATIONSINTHEMOTIONSTAGEVELOCITYTHERIMISINTENDEDFORUSEINANINDUSTRIALENVIRONMENTITISLOCATEDADJACENTTOTHEMACHININGLINEWITHATOTALCYCLETIMEINCLUDINGPARTTRANSFEREQUALTOTHATOFTHEMACHININGLINE,WHICHISASSUMEDTOBEAROUND40SECO