Multiobjective layout optimization of robotic cellular manufacturing systems

This paper proposes a multiobjective layout optimization method for the conceptual design of robot cellular manufacturing systems. Robot cellular manufacturing systems utilize one or more flexible robots which can carry out a large number of operations, and can conduct flexible assemble processes. The layout design stage of such manufacturing systems is especially important since fundamental performances of the manufacturing system under consideration are determined at this stage. In this paper, the design criteria for robot cellular manufacturing system layout designs are clarified, and objective functions are formulated. Next, layout design candidates are represented using a sequence-pair scheme to avoid interference between assembly system components, and the use of dummy components is proposed to represent layout areas where components are sparse. A multiobjective genetic algorithm is then used to obtain Pareto optimal solutions for the layout optimization problems. Finally, several numerical examples are provided to illustrate the effectiveness and usefulness of the proposed method.     

Loop layout design problem in flexible manufacturing systems using genetic algorithms

A common layout for flexible manufacturing systems is a loop network with machines arranged in a cycle and materials transported in only one direction around the cycle. Traffic congestion is usually used as the measure for evaluating a loop layout, which is defined as the number of times a part traverses the loop before its processing is completed. This paper investigates the problem of designing a loop layout system with genetic algorithms. The essence of the problem is how to determine the order of machines around the loop subject to a set of part-route constraints so as to optimize some measures. A hybrid approach of genetic algorithms and neighborhood search is developed for solving the problem. The proposed method is tested on hypothetical problems. Computational results demonstrate that genetic algorithms can be a promising approach for loop layout design in flexible manufacturing systems. Two typical measures, the minsum and minmax congestion measures, are examined and computational experiments show that the minsum approach outperforms the minmax approach.     

GENETIC ALGORITHMS: A TOOL FOR MODELLING,SIMULATION, AND OPTIMIZATION OF COMPLEX SYSTEMS

Until very recently genetic algorithms GAs were considered to be the proprietary field of general systems theoreticians and important for esoteric or extremely complex optimization studies. This paper endeavors to show that GA are of great utility in cases where complex systems have to be designed and, therefore, rational choices have to be made. The GA approach is based loosely on the theory of natural evolution, genetic diversity, and searching for beneficial adaptations to a complicated and changing environment. GAs can be viewed as a modelling tool and as a technique for simulation of complex systems represented by communities of interacting units. The representation of units can express characteristics, capabilities, or relatively simple strategies. These units compete and are modified by external operators, so that the overall system adapts to its environment. That environment defines the criterion by which the success in adapting can be measured. Genetic algorithms have been successfully applied to many optimization problems including mathematical function optimization, very large scale integration VLSI chip layout, molecular docking, parameter fitting, scheduling, manufacturing, clustering, machine learning, etc. and are still finding increasing acceptance. Modelling and optimization of a Kanban system from the field of flexible manufacturing systems is discussed in the last section.     

Computer-aided analysis of reconfigurable fixtures and sheet metal parts for robotic drilling

This paper presents an automated manufacturing system for drilling sheet metal parts. All stand-alone systems such as the robot, a set of reconfigurable fixtures and the CAD/CAM workstation have been integrated into a flexible manufacturing system. This system analyzes and evaluates a given fixturing layout and assembles the reconfigurable fixtures automatically using a robot manipulator. An optimum fixturing layout and assembly are achieved by examining the workpart from a stress-strain point of view. In addition, issues such as geometric constraints, yielding and buckling, database design, collision detection, fixturing sequential control and the automatic assembly of fixture elements are considered. The computational and analytical concepts for the reconfigurable fixturing and drilling system are also presented in this paper.     

PSO-ACSC: a large-scale evolutionary algorithm for image matting

Image matting is an essential image processing technology due to its wide range of applications. Samplingbased image matting is one of the main branches of image matting research that estimates alpha mattes by selecting the best pixel pairs. It is essentially a large-scale multi-peak optimization problem of pixel pairs. Previous study shows that particle swarm optimization (PSO) can effectively optimize the pixel pairs. However, it still suffers from premature convergence problem which often occurs in pixel pair optimization that involves a large number of local optima. To address this problem, this work presents a parameter-free strategy for PSO called adaptive convergence speed controller (ACSC). ACSC monitors and conditionally controls the particles by competitive pixel pair recombination operator (CPPRO) and pixel pair reset operator (PPRO) during the iteration. ACSC performs CPPRO to improve the competitiveness of a particle when the performance of most of the pixel pairs is worse than that of the best-so-far solution. PPRO is performed to avoid premature convergence when the alpha mattes regarding two selected particles are highly similar. Experimental results show that ACSC significantly enhances the performance of PSO for image matting and provides competitive alpha mattes comparing with state-of-the-art evolutionary algorithms.     

Operations management issues in design and control of hybrid human-robot collaborative manufacturing systems: a survey

A manufacturing system able to perform a high variety of tasks requires different types of resources. Fully automated systems using robots possess high speed, accuracy, tirelessness, and force, but they are expensive. On the other hand, human workers are intelligent, creative, flexible, and able to work with different tools in different situations. A combination of these resources forms a human-machine/robot (hybrid) system, where humans and robots perform a variety of tasks (manual, automated, and hybrid tasks) in a shared workspace. Contrarily to the existing surveys, this study is dedicated to operations management problems (focusing on the applications and features) for human and machine/robot collaborative systems in manufacturing. This research is divided into two types of interactions between human and automated components in manufacturing and assembly systems: dual resource constrained (DRC) and human-robot collaboration (HRC) optimization problems. Moreover, different characteristics of the workforce and machines/robots such as heterogeneity, homogeneity, ergonomics, and flexibility are introduced. Finally, this paper identifies the optimization challenges and problems for hybrid systems. The existing literature on HRC focuses mainly on the robotic point of view and not on the operations management and optimization aspects. Therefore, the future research directions include the design of models and methods to optimize HRC systems in terms of ergonomics, safety, and throughput. In addition, studying flexibility and reconfigurability in hybrid systems is one of the main research avenues for future research.     

An efficient chaotic based PSO for earliness/tardiness optimization in a batch processing flow shop scheduling problem

The flow shop is a well-known class of manufacturing system for production process planning. The need for scheduling approaches arises from the requirement of most systems to implement more than one process at a moment. Batch processing is usually carried out to load balance and share system resources effectively and gain a desired quality of service level. A flow shop manufacturing problem with batch processors (BP) is discussed in current paper so as to minimize total penalty of earliness and tardiness. To address the problem, two improved discrete particle swarm optimization (PSO) algorithms are designed where most important properties of basic PSO on velocity of particles are enhanced. We also employ the attractive properties of logistic chaotic map within PSO so as to investigate the influence of chaos on search performance of BP flow shop problem. In order to investigate the suggested algorithms, a comprehensive computational study is carried out and performance of algorithms is compared with (1) a commercial optimization solver, (2) a well-known algorithm from PSO’s literature and (3) three algorithms from BP’s literature. The experimental results demonstrate the superiority of our algorithm against others.     

Discussion on the optimization problem formulation of flexible components in multibody systems

This paper is dedicated to the structural optimization of flexible components in mechanical systems modeled as multibody systems. While most of the structural optimization developments have been conducted under (quasi-)static loadings or vibration design criteria, the proposed approach aims at considering as precisely as possible the effects of dynamic loading under service conditions. Solving this problem is quite challenging and naive implementations may lead to inaccurate and unstable results. To elaborate a robust and reliable approach, the optimization problem formulation is investigated because it turns out that it is a critical point. Different optimization algorithms are also tested. To explain the efficiency of the various solution approaches, the complex nature of the design space is analyzed. Numerical applications considering the optimization of a two-arm robot subject to a trajectory tracking constraint and the optimization of a slider-crank mechanism with a cyclic dynamic loading are presented to illustrate the different concepts.     

Comparison of four different heuristic optimization algorithms for the inverse kinematics solution of a real 4-DOF serial robot manipulator

In this study, a 4-degree-of-freedom (DOF) serial robot manipulator was designed and developed for the pick-and-place operation of a flexible manufacturing system. The solution of the inverse kinematics equation, one of the most important parts of the control process of the manipulator, was obtained by using four different optimization algorithms: the genetic algorithm (GA), the particle swarm optimization (PSO) algorithm, the quantum particle swarm optimization (QPSO) algorithm and the gravitational search algorithm (GSA). These algorithms were tested with two different scenarios for the motion of the manipulator’s end-effector. One hundred randomly selected workspace points were defined for the first scenario, while a spline trajectory, also composed of one hundred workspace points, was used for the second. The optimization algorithms were used for solving of the inverse kinematics of the manipulator in order to successfully move the end-effector to these workspace points. The four algorithms were compared according to the execution time, the end-effector position error and the required number of generations. The results showed that the QPSO could be effectively used for the inverse kinematics solution of the developed manipulator.     

Evolutionary techniques for optimization problems in integrated manufacturing system: State-of-the-art-survey

Integrated manufacturing system (IMS) is a novel manufacturing environment which has been developed for the next generation of manufacturing and processing technologies. It consists of engineering design, process planning, manufacturing, quality management, and storage and retrieval functions. Improving the decision quality in those fields give rise to complex combinatorial optimization problems, unfortunately, most of them fall into the class of NP-hard problems. Find a satisfactory solution in an acceptable time play important roles. Evolutionary techniques (ET) have turned out to be potent methods to solve such kind of optimization problems. How to adapt evolutionary technique to the IMS is very challenging but frustrating. Many efforts have been made in order to give an efficient implementation of ET to optimize the specific problems in IMS.In this paper, we address four crucial issues in IMS, including design, planning, manufacturing, and distribution. Furthermore, some hot topics in these issues are selected to demonstrate the efficiency of ET’s application, such as layout design (LD) problem, flexible job-shop scheduling problem (fJSP), multistage process planning (MPP) problem, and advanced planning and scheduling (APS) problem. First, we formulate a generalized mathematic models for all those problems; several evolutionary algorithms which adapt to the problems have been proposed; some test instances based on the practical problems demonstrate the effectiveness and efficiency of our proposed approach.     

机械臂最优运动规划问题的混合粒子群算法

多关节机械臂路径规划是一个高度受限的非线性优化问题,很难找到单一的优化解.提出一种基于单纯形算法和粒子群算法的混合算法,以解决机械臂的路径规划问题.仿真试验表明,相较于常规的A*算法,该混合算法具有更高的求解精度.     

Wind Farm Layout Design Using Cuckoo Search Algorithms

Wind energy has emerged as a strong alternative to fossil fuels for power generation. To generate this energy, wind turbines are placed in a wind farm. The extraction of maximum energy from these wind farms requires optimal placement of wind turbines. Due to complex nature of micrositing of wind turbines, the wind farm layout design problem is considered a complex optimization problem. In the recent past, various techniques and algorithms have been developed for optimization of energy output from wind farms. The present study proposes an optimization approach based on the cuckoo search (CS) algorithm, which is relatively a recent technique. A variant of CS is also proposed that incorporates a heuristic-based seed solution for a better performance. The proposed CS algorithms are compared with genetic and particle swarm optimization (PSO) algorithms, which have been extensively applied to wind farm layout design. Empirical results indicate that the proposed CS algorithms outperformed the genetic and PSO algorithms for the given test scenarios in terms of yearly power output and efficiency.     

Comparison of particle swarm optimization and genetic algorithm for FACTS-based controller design

Recently, genetic algorithms (GA) and particle swarm optimization (PSO) technique have attracted considerable attention among various modern heuristic optimization techniques. The GA has been popular in academia and the industry mainly because of its intuitiveness, ease of implementation, and the ability to effectively solve highly non-linear, mixed integer optimization problems that are typical of complex engineering systems. PSO technique is a relatively recent heuristic search method whose mechanics are inspired by the swarming or collaborative behavior of biological populations. Since the two approaches are supposed to find a solution to a given objective function but employ different strategies and computational effort, it is appropriate to compare their performance. This paper presents the application and performance comparison of PSO and GA optimization techniques, for flexible ac transmission system (FACTS)-based controller design. The design objective is to enhance the power system stability. The design problem of the FACTS-based controller is formulated as an optimization problem and both PSO and GA optimization techniques are employed to search for optimal controller parameters. The performance of both optimization techniques in terms of computational effort, computational time and convergence rate is compared. Further, the optimized controllers are tested on a weakly connected power system subjected to different disturbances over a wide range of loading conditions and parameter variations and their performance is compared with the conventional power system stabilizer (CPSS). The eigenvalue analysis and non-linear simulation results are presented and compared to show the effectiveness of both the techniques in designing a FACTS-based controller, to enhance power system stability.     

基于蒙特卡洛模拟的机器人工作站规划

机器人装配工作站是机器人柔性装配系统的主要组成部分。本文采用蒙特卡罗原理研究作业系统误差、机器人位姿误差补偿和机器人柔顺性对机器人装配过程的影响，从而确定上料装置和定位装置的最优位姿，本文所提出的工作站规划方法对设计机器人装配工作站具有实用价值。     

Study on Robot Sequencing Model in Flexible Manufacturing System Using Timed Petri Net

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Novel hybrid optimization algorithm using PSO and MADS for the trajectory estimation of a four track wheel skid-steered mobile robot

Several optimization algorithms, such as the particle swarm optimization (PSO), genetic algorithm (GA), and ant colony optimization, have previously been applied in order to reliably obtain more accurate trajectory estimation for mobile robot. However, these optimization algorithms can get easily trapped in local optima when solving a complex system, which has many local optima and many input variables. This paper proposes a novel hybrid optimization algorithm-based tuning of the extended Kalman filter, which involves the PSO and mesh adaptive direct search algorithms, prior to operation. As demonstrated by our experimental results, the advantages of the novel hybrid optimization algorithm resolve the limitations of other algorithms in the trajectory estimation of a four track wheel skid-steered mobile robot (4-TW SSMR).     

Facility layout problems: A survey

Layout problems are found in several types of manufacturing systems. Typically, layout problems are related to the location of facilities (e.g., machines, departments) in a plant. They are known to greatly impact the system performance. Most of these problems are NP hard. Numerous research works related to facility layout have been published. A few literature reviews exist, but they are not recent or are restricted to certain specific aspects of these problems. The literature analysis given here is recent and not restricted to specific considerations about layout design.

We suggest a general framework to analyze the literature and present existing works using such criteria as: the manufacturing system features, static/dynamic considerations, continual/discrete representation, problem formulation, and resolution approach. Several research directions are pointed out and discussed in our conclusion.     

A process knowledge representation approach for decision support in design of complex engineered systems

Process knowledge is of considerable significance to the digitalization and intelligentization of the manufacturing industry. Current research on the process knowledge representation of decision-making in engineering design has predominantly focused on either mathematical models of individual decisions at the micro-level or organizational models of group decision consensus at the macro-level. However, the management of complexity and uncertainty in the model-based realization of engineered systems is critical to achieving rational, comprehensive, and robust decisions, especially in terms of knowledge-intensive design. The efficiency and effectiveness of decisions in system design are intrinsically linked to the process, knowledge, and system concepts involved, necessitating a more flexible and systematic decision process representation scheme that supports both the management of complexity and uncertainty. Hence, in this paper, we propose a decision-centric design process representation scheme named the Phase-Event-Information X (PEI-X) diagram and its corresponding systematic design guidance method for designing decision workflows. Using the proposed method, designers have the ability to (1) model hierarchical decision processes that cover vertical and horizontal interaction patterns, and (2) exploit the synthesis of the “Formulating-Identifying-Reusing-Exploring” iterative process to extend the understanding and prediction of decision process behaviors in design. We achieve the aforesaid abilities through the implementation of a knowledge-based design guidance system for collaborative decision support and we demonstrate the efficacy by adopting a specific multi-stage manufacturing process design problem, hot rod rolling system design, and carry out an integrated design of materials, products, and related manufacturing processes.     

Dynamic neural network method-based improved PSO and BR algorithms for transient probabilistic analysis of flexible mechanism

To improve the computing efficiency and precision of transient probabilistic analysis of flexible mechanism, dynamic neural network method (DNNM)-based improved particle swarm optimization (PSO)/Bayesian regularization (BR) (called as PSO/BR-DNNM) is proposed based on the developed DNNM with the integration of extremum response surface method (ERSM) and artificial neural network (ANN). The mathematical model of DNNM is established based on ANN on the foundation of investigating ERSM. Aiming at the high nonlinearity and strong coupling characteristics of limit state function of flexible mechanism, accurate weights and thresholds of PSO/BR-DNNM function are discussed by searching initial weights and thresholds based on the improved PSO and training final weights and thresholds by the BR-based training performance function. The probabilistic analysis of two-link flexible robot manipulator (TFRM) was investigated with the proposed method. Reliability degree, distribution characteristics and major factors (section sizes of link-2) of TFRM are obtained, which provides a useful reference for a more effective TFRM design. Through the comparison of three methods (Monte Carlo method, DNNM, PSO/BR-DNNM), it is demonstrated that PSO/BR-DNNM reshapes the probability of flexible mechanism probabilistic analysis and improves the computing efficiency while keeping acceptable computational precision. Moreover, the proposed method offers a useful insight for reliability-based design optimization of flexible mechanism and thereby also enriches the theory and method of mechanical reliability design.     

制造系统中的单向环型设备布局设计

提出一种优化建模与虚拟现实技术相结合的求解策略，较好地解决了制造系统中的单向环型设备布局问题．研究该问题的固有特性，提出三条定理，构建了一个启发式算法，并实现了一个沉浸式虚拟布局设计的例子．