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.

Experimental study into the flow physics of three-dimensional shock control bumps

This paper describes a fundamental experimental study of the flow structure around a single three-dimensional (3D) transonic shock control bump (SCB) mounted on a flat surface in a wind tunnel. Tests have been carried out with a Mach 1.3 normal shock wave located at a number of streamwise positions relative to the SCB. Details of the flow have been studied using the experimental techniques of schlieren photography, surface oil flow visualization, pressure sensitive paint, and laser Doppler anemometry. The results of the work build on the findings of previous researchers and shed new light on the flow physics of 3D SCBs. It is found that spanwise pressure gradients across the SCB ramp and the shape of the SCB sides affect the magnitude and uniformity of flow turning generated by the bump, which can impact on the spanwise propagation of the quasi-two-dimensional (2D) shock structure produced by a 3DSCB. At the bump crest, vortices can form if the pressure on the crest is significantly lower than at either side of the bump. The trajectories of these vortices, which are relatively weak, are strongly influenced by any spanwise pressure gradients across the bump tail. Asignificant difference between 2D and 3D SCBs highlighted by the study is the impact of spanwise pressure gradients on 3D SCB performance. The magnitude of these spanwise pressure gradients is determined largely by SCB geometry and shock position. Copyright © 2011 by the American Institute of Aeronautics and Astronautics, Inc.

Normal shock boundary layer control with various vortex generator geometries

Various vortex generators which include ramp, split-ramp and a new hybrid concept "ramped-vane" are investigated under normal shock conditions with a diffuser at Mach number of 1.3. The dimensions of the computational domain were designed using Reynolds Average Navier-Stokes studies to be representative of the flow in an external-compression supersonic inlet. Using this flow geometry, various vortex generator concepts were studied with Implicit Large Eddy Simulation. In general, the ramped-vane provided increased vorticity compared to the other devices and reduced the separation length downstream of the device centerline. In addition, the size, edge gap and streamwise position respect to the shock were studied for the ramped-vane and it was found that a height of about half the boundary thickness and a large trailing edge gap yielded a fully attached flow downstream of the device. This ramped-vane also provided the largest reduction in the turbulent kinetic energy and pressure fluctuations. Additional benefits include negligible drag while the reductions in boundary layer displacement thickness and shape factor were seen compared to other devices. © 2010 by Sang Lee.

Normal shock boundary layer control with various vortex generator geometries

Various vortex generators which include ramp, split-ramp and a new hybrid concept "ramped-vane" are investigated under normal shock conditions with a diffuser at Mach number of 1.3. The dimensions of the computational domain were designed using Reynolds Average Navier-Stokes studies to be representative of the flow in an external-compression supersonic inlet. Using this flow geometry, various vortex generator concepts were studied with Implicit Large Eddy Simulation. In general, the ramped-vane provided increased vorticity compared to the other devices and reduced the separation length downstream of the device centerline. In addition, the size, edge gap and streamwise position respect to the shock were studied for the ramped-vane and it was found that a height of about half the boundary thickness and a large trailing edge gap yielded a fully attached flow downstream of the device. This ramped-vane also provided the largest reduction in the turbulent kinetic energy and pressure fluctuations. Additional benefits include negligible drag while the reductions in boundary layer displacement thickness and shape factor were seen compared to other devices. © 2011 Elsevier Ltd.

Shock / boundary-layer interaction control using three-dimensional bumps for transonic wings

Three-dimensional bumps have been developed and investigated, aiming at the two major objectives of shock-wave / boundary-layer interaction control, i.e. drag reduction and suppression of separation, simultaneously. An experimental investigation has been conducted for a default rounded bump in channel now at University of Cambridge and a computational study has been performed for a spanwise series of rounded bumps mounted on a transonic aerofoil at University of Stuttgart. Observed in both cases are wave drag reduction owing to A-shock structures produced by three-dimensional surface bumps and mild control effects on the boundary layer. The effects of rough surface and tall extension have been investigated as well as several geometric variations and multiple bump configurations. A double configuration of narrow rounded bumps has been found to best perform amongst the tested, considerably reducing wave drag through a well-established A-shock structure with little viscous penalty and thus achieving substantial overall drag reduction. Counter-rotating streamwise vortex pairs have been produced by some configurations as a result of local flow separation, but they have been observed to be confined in relatively narrow wake regions, expected to be beneficial in suppressing large-scale separation under off-design condition despite increase of viscous drag. On the whole a large potential of three-dimensional control with discrete rounded bumps has been demonstrated both experimentally and numerically, and experimental investigation of bumps fitted on a transonic aerofoil or wing is suggested toward practical application.

Experimental investigation of 3D shock / boundary layer interaction control in transonic flows

A novel supersonic wind tunnel setup is proposed to enable the investigation of control on a normal shock wave. Previous experimental arrangements were found to suffer from shock instability. Wind tunnel tests with and without control have confirmed the capability of the new setup to stabilise a shock structure at a target position without changing the nature of the shock wave / boundary layer interaction flow at M∞ = 1.3 and M ∞ = 1.5. Flow visualisation and pressure measurements with the new setup have revealed detailed characteristics of shock wave / boundary layer interactions and a λ-shock structure as well as benefits of control in total drag reduction in the presence of 3D bump control.

The time-resolved flow within an unsteady ejector

The flow field within an unsteady ejector has been investigated using experimental and computational techniques. The experimental results show a peak thrust augmentation of 1.4; numerical simulation gives a value of 1.37. It is shown that the vortex ring dominates the flow field. At optimal thrust augmentation the vortex ring acts like a fluid piston accelerating the fluid inside the ejector. A model is proposed for the operation of unsteady ejectors, based on the vortex ring acting like a fluid piston. Control volume analysis is presented showing that mass entrainment is responsible for thrust augmentation. It is proposed that the spacing of successive vortex rings determines the mass entrainment and therefore thrust augmentation. The efficiency of unsteady ejectors was found to vary between 28% and 32% depending on the L/D ratio of the unsteady jet source. Copyright © 2008 by J H Heffer.

Flow of wet powder in a conical centrifugal filter-an analytical model

A one-dimensional analytical model is developed for the steady state, axisymmetric, slender flow of saturated powder in a rotating perforated cone. Both the powder and the fluid spin with the cone with negligible slip in the hoop direction. They migrate up the wall of the cone along a generator under centrifugal force, which also forces the fluid out of the cone through the powder layer and the porous wall. The flow thus evolves from an over-saturated paste at inlet into a nearly dry powder at outlet. The powder is treated as a Mohr-Coulomb granular solid of constant void fraction and permeability. The shear traction at the wall is assumed to be velocity and pressure dependent. The fluid is treated as Newtonian viscous. The model provides the position of the colour line (the transition from over- to under-saturation) and the flow velocity and thickness profiles over the cone. Surface tension effects are assumed negligible compared to the centrifugal acceleration. Two alternative conditions are considered for the flow structure at inlet: fully settled powder at inlet, and progressive settling of an initially homogeneous slurry. The position of the colour line is found to be similar for these two cases over a wide range of operating conditions. Dominant dimensionless groups are identified which control the position of the colour line in a continuous conical centrifuge. Experimental observations of centrifuges used in the sugar industry provide preliminary validation of the model. © 2011 Elsevier Ltd.

A theoretical approach to the passive control of spiral vortex breakdown

Previous numerical simulations have shown that vortex breakdown starts with the formation of a steady axisymmetric bubble and that an unsteady spiralling mode then develops on top of this.We study how this spiral mode of vortex breakdown might be suppressed or promoted. We use a Lagrangian approach to identify regions of the flow which are sensitive to small open-loop steady and unsteady (harmonic) forces. We find these regions to be upstream of the vortex breakdown bubble. We investigate passive control using a small axisymmetric control ring. In this case, the steady and unsteady control forces are caused by the drag force on the control ring. We find a narrow region upstream of the bubble where the control ring will stabilise the flow and we verify this using numerical simulations. © 2012 IEEE.