Adaptive agent-based manufacturing control and its application to flow shop routing control

The manufacturing industry is currently facing unprecedented challenges from changes and disturbances. The sources of these changes and disturbances are of different scope and magnitude. They can be of a commercial nature, or linked to fast product development and design, or purely operational (e.g. rush order, machine breakdown, material shortage etc.). In order to meet these requirements it is increasingly important that a production operation be flexible and is able to adapt to new and more suitable ways of operating. This paper focuses on a new strategy for enabling manufacturing control systems to adapt to changing conditions both in terms of product variation and production system upgrades. The approach proposed is based on two key concepts: (1) An autonomous and distributed approach to manufacturing control based on multi-agent methods in which so called operational agents represent the key physical and logical elements in the production environment to be controlled - for example, products and machines and the control strategies that drive them and (2) An adaptation mechanism based around the evolutionary concept of replicator dynamics which updates the behaviour of newly formed operational agents based on historical performance records in order to be better suited to the production environment. An application of this approach for route selection of similar products in manufacturing flow shops is developed and is illustrated in this paper using an example based on the control of an automobile paint shop.

Assessing the responsiveness of existing production operations

Production responsiveness refers to the ability of a production system to achieve its operational goals in the presence of supplier, internal and customer disturbances, where disturbances are those sources of change which occur independently of the system's intentions. A set of audit tools for assessing the responsiveness of production operations is being prepared as part of an EPSRC funded investigation. These tools are based on the idea that the ability to respond is linked to: the nature of the disturbances or changes requiring a response; their impact on production goals; and the inherent response capabilities of the operation. These response capabilities include information gathering and processing (to detect disturbances and production conditions), decision processes (which initiate system responses to disturbances) and various types of process flexibilities and buffers (which provide the physical means of dealing with disturbances). The paper discusses concepts and issues associated with production responsiveness, describes the audit tools that have been developed and illustrates their use in the context of a steel manufacturing plant.

Stall inception in axial compressors

Detailed measurements have been made of the transient stalling process in an axial compressor stage. The stage is of high hub-casing ratio and stall is initiated in the rotor. If the rotor tip clearance is small stall inception occurs at the hub, but at clearances typical for a multistage compressor the inception is at the tip. The crucial quantity in both cases is the blockage caused by the endwall boundary layer. Prior to stall disturbances rotate around the inlet flow in sympathy with rotating variations in the endwall blockage; these can persist for some time prior to stall, rising and falling in amplitude before the final increase which occurs as the compressor stalls.

Stall inception in axial compressors

Detailed measurements have been made of the transient stalling process in an axial compressor stage. The stage is of high hub-casing ratio and stall is initiated in the rotor. If the rotor tip clearance is small stall inception occurs at the hub, but at clearances typical for a multistage compressor the inception is at the tip. The crucial quantity in both cases is the blockage caused by the endwall boundary layer. Prior to stall, disturbances rotate around the inlet flow in sympathy with rotating variations in the endwall blockage.

Compressor wake/leading-edge interactions at off design incidences

In this paper, the effects of wake/leading-edge interactions were studied at off-design conditions. Measurements were performed on the stator-blade suction surface at midspan. The leading-edge flow-field was investigated using hotwire micro-traverses, hotfilm surface shear-stress sensors and pressure micro-tappings. The trailing-edge flow-field was investigated using hotwire boundary-layer traverses. Unsteady CFD calculations were also performed to aid the interpretation of the results. At low flow coefficients, the time-averaged momentum thickness of the leading-edge boundary layer was found to rise as the flow coefficient was reduced. The time-resolved momentum-thickness rose due to the interaction of the incoming rotor wake. As the flow coefficient was reduced, the incoming wakes increased in pitch-wise extent, velocity deficit and turbulence intensity. This increased both the time-resolved rise in the momentum thickness and the turbulent spot production within the wake affected boundary-layer. Close to stall, a drop in the leading-edge momentum thickness was observed in-between wake events. This was associated with the formation of a leading-edge separation bubble in-between wake events. The wake interaction with the bubble gave rise to a shedding phenomenon, which produced large length scale disturbances in the surface shear stress. Copyright © 2008 by ASME.

Detached-eddy simulation of transonic flow past a fan-blade section

Detached-eddy simulation of transonic flow past a thin section of a fan blade has been carried out. The inflow Mach number is 1.03, and a bow shock forms upstream of the blade. The shock (corresponding to an adjacent blade) impinges on the suction-side boundary layer which causes separation and rapid transition to turbulence. The boundary layer later re-attaches near the trailing edge. The pressure-side boundary layer transitions near the leading edge and remains attached. Mean surface pressure shows basic agreement with a steady RANS calculation; strong shock motion in the DES is the major cause of discrepancy. Surface pressure spectra are investigated, and low-frequency two-dimensional disturbances associated with the shock motion are dominant. Removing the two-dimensional component from the spectra, the pressure-side three-dimensional spectra reproduce the spectral shape given by a correlation for flat-plate boundary layer wall-pressure spectra developed by Goody. 1 The suction-side disturbances produce similar high- and intermediate-frequency scalings despite substantially different boundary layer development. Near-wake results show that disturbance kinetic energy peaks at the suction-side inflection point of the mean profile, and that the energy is concentrated at low frequencies relative to the near-trailing edge surface pressure. Copyright © 2009 by the authors.

Stabilizing effect of surrounding gas flow on a plane liquid sheet

The stability of a plane liquid sheet is studied experimentally and theoretically, with an emphasis on the effect of the surrounding gas. Co-blowing with a gas velocity of the same order of magnitude as the liquid velocity is studied, in order to quantify its effect on the stability of the sheet. Experimental results are obtained for a water sheet in air at Reynolds number Rel = 3000 and Weber number W e = 300, based on the half-thickness of the sheet at the inlet, water mean velocity at the inlet, the surface tension between water and air and water density and viscosity. The sheet is excited with different frequencies at the inlet and the growth of the waves in the streamwise direction is measured. The growth rate curves of the disturbances for all air flow velocities under study are found to be within 20 % of the values obtained from a local spatial stability analysis, where water and air viscosities are taken into account, while previous results from literature assuming inviscid air overpredict the most unstable wavelength with a factor 3 and the growth rate with a factor 2. The effect of the air flow on the stability of the sheet is scrutinized numerically and it is concluded that the predicted disturbance growth scales with (i) the absolute velocity difference between water and air (inviscid effect) and (ii) the square root of the shear from air on the water surface (viscous effect).

Stabilizing effect of surrounding gas flow on a plane liquid sheet

The stability of a plane liquid sheet is studied experimentally and theoretically, with an emphasis on the effect of the surrounding gas. Co-blowing with a gas velocity of the same order of magnitude as the liquid velocity is studied, in order to quantify its effect on the stability of the sheet. Experimental results are obtained for a water sheet in air at Reynolds number Rel = 3000 and Weber number We = 300, based on the half-thickness of the sheet at the inlet, water mean velocity at the inlet, the surface tension between water and air and water density and viscosity. The sheet is excited with different frequencies at the inlet and the growth of the waves in the streamwise direction is measured. The growth rate curves of the disturbances for all air flow velocities under study are found to be within 20% of the values obtained from a local spatial stability analysis, where water and air viscosities are taken into account, while previous results from literature assuming inviscid air overpredict the most unstable wavelength with a factor 3 and the growth rate with a factor 2. The effect of the air flow on the stability of the sheet is scrutinized numerically and it is concluded that the predicted disturbance growth scales with (i) the absolute velocity difference between water and air (inviscid effect) and (ii) the square root of the shear from air on the water surface (viscous effect).

Impedance control and internal model use during the initial stage of adaptation to novel dynamics in humans.

This study investigated the neuromuscular mechanisms underlying the initial stage of adaptation to novel dynamics. A destabilizing velocity-dependent force field (VF) was introduced for sets of three consecutive trials. Between sets a random number of 4-8 null field trials were interposed, where the VF was inactivated. This prevented subjects from learning the novel dynamics, making it possible to repeatedly recreate the initial adaptive response. We were able to investigate detailed changes in neural control between the first, second and third VF trials. We identified two feedforward control mechanisms, which were initiated on the second VF trial and resulted in a 50% reduction in the hand path error. Responses to disturbances encountered on the first VF trial were feedback in nature, i.e. reflexes and voluntary correction of errors. However, on the second VF trial, muscle activation patterns were modified in anticipation of the effects of the force field. Feedforward cocontraction of all muscles was used to increase the viscoelastic impedance of the arm. While stiffening the arm, subjects also exerted a lateral force to counteract the perturbing effect of the force field. These anticipatory actions indicate that the central nervous system responds rapidly to counteract hitherto unfamiliar disturbances by a combination of increased viscoelastic impedance and formation of a crude internal dynamics model.

Feedback modulation: a window into cortical function.

A recent study demonstrates involvement of primary motor cortex in task-dependent modulation of rapid feedback responses; cortical neurons resolve locally ambiguous sensory information, producing sophisticated responses to disturbances.

The nonlinear heat release response of stratified lean-premixed flames to acoustic velocity oscillations

This paper analyzes the forced response of swirl-stabilized lean-premixed flames to high-amplitude acoustic forcing in a laboratory-scale stratified burner operated with CH4 and air at atmospheric pressure. The double-swirler, double-channel annular burner was specially designed to generate high-amplitude acoustic velocity oscillations and a radial equivalence ratio gradient at the inlet of the combustion chamber. Temporal oscillations of equivalence ratio along the axial direction are dissipated over a long distance, and therefore the effects of time-varying fuel/air ratio on the response are not considered in the present investigation. Simultaneous measurements of inlet velocity and heat release rate oscillations were made using a constant temperature anemometer and photomultiplier tubes with narrow-band OH*/CH* interference filters. Time-averaged and phase-synchronized CH* chemiluminescence intensities were measured using an intensified CCD camera. The measurements show that flame stabilization mechanisms vary depending on equivalence ratio gradients for a constant global equivalence ratio (φg=0.60). Under uniformly premixed conditions, an enveloped M-shaped flame is observed. In contrast, under stratified conditions, a dihedral V-flame and a toroidal detached flame develop in the outer stream and inner stream fuel enrichment cases, respectively. The modification of the stabilization mechanism has a significant impact on the nonlinear response of stratified flames to high-amplitude acoustic forcing (u'/U∼0.45 and f=60, 160Hz). Outer stream enrichment tends to improve the flame's stiffness with respect to incident acoustic/vortical disturbances, whereas inner stream stratification tends to enhance the nonlinear flame dynamics, as manifested by the complex interaction between the swirl flame and large-scale coherent vortices with different length scales and shedding points. It was found that the behavior of the measured flame describing functions (FDF), which depend on radial fuel stratification, are well correlated with previous measurements of the intensity of self-excited combustion instabilities in the stratified swirl burner. The results presented in this paper provide insight into the impact of nonuniform reactant stoichiometry on combustion instabilities, its effect on flame location and the interaction with unsteady flow structures. © 2011 The Combustion Institute.

Multiplexed model predictive control

Most academic control schemes for MIMO systems assume all the control variables are updated simultaneously. MPC outperforms other control strategies through its ability to deal with constraints. This requires on-line optimization, hence computational complexity can become an issue when applying MPC to complex systems with fast response times. The multiplexed MPC scheme described in this paper solves the MPC problem for each subsystem sequentially, and updates subsystem controls as soon as the solution is available, thus distributing the control moves over a complete update cycle. The resulting computational speed-up allows faster response to disturbances, and hence improved performance, despite finding sub-optimal solutions to the original problem. The multiplexed MPC scheme is also closer to industrial practice in many cases. This paper presents initial stability results for two variants of multiplexed MPC, and illustrates the performance benefit by an example. Copyright copy; 2005 IFAC. Copyright © 2005 IFAC.

Study of spike and modal stall phenomena in a low-speed axial compressor

This paper presents a study of stall inception mechanisms a in low-speed axial compressor. Previous work has identified two common flow breakdown sequences, the first associated with a short lengthscale disturbance known as a `spike', and the second with a longer lengthscale disturbance known as a `modal oscillation'. In this paper the physical differences between these two mechanisms are illustrated with detailed measurements. Experimental results are also presented which relate the occurrence of the two stalling mechanisms to the operating conditions of the compressor. It is shown that the stability criteria for the two disturbances are different: long lengthscale disturbances are related to a two-dimensional instability of the whole compression system, while short lengthscale disturbances indicate a three-dimensional breakdown of the flow-field associated with high rotor incidence angles. Based on the experimental measurements, a simple model is proposed which explains the type of stall inception pattern observed in a particular compressor. Measurements from a single stage low-speed compressor and from a multistage high-speed compressor are presented in support of the model.

Tools for Assessing the Responsiveness of Existing Production Operations

A set of audit tools is being prepared for assessing the response capability of a production operation, as part of an EPSRC1 funded investigation into improving the responsiveness of manufacturing production systems. These tools are based on the idea that the ability to respond is linked to i) the nature of the disturbances or changes requiring a response, ii) their impact on production goals and iii) the decision processes which initiate system responses to disturbances.

Initial modelling and controller design for active control of spacecraft microvibrations

Microvibrations, at frequencies between 1 and 1000 Hz, generated by on board equipment, propagate throughout a spacecraft structure affecting the performance of sensitive payloads. The purpose of this work is to investigate strategies to model and reduce these dynamic disturbances by active control. Initial studies were performed by considering a mass loaded panel where the disturbance excitation source consisted of point forces, the objective being to minimise the displacement at an arbitrary output location. Piezoelectric patches acting as sensors and actuators were used. The equations of motion are derived by using Lagrange's equation with modal shapes as Ritz functions. The number of sensors/actuators and their location is variable. The set of equations obtained is then transformed into state variables and some initial controller design studies have been undertaken. These are based on feedback control implemented using a full state feedback and an observer which reconstructs the state vector from the available sensor signal. Here, the basics behind the structural modelling and controller design will be described. This preliminary analysis will also be used to identify short to medium term further work.