Ansätze zum Management der Additive Manufacturing Supply Chain

Da sich Additive Manufacturing (AM) von traditionellen Produktionsverfahren unterscheidet, entstehen neue Möglichkeiten im Produktdesign und im Supply Chain Setup. Die Auswirkungen der Aufhebung traditionellen Restriktionen im Produktdesign werden unter dem Begriff „Design for Additive Manufacturing“ intensiv diskutiert. In gleicher Weise werden durch AM Restriktionen im traditionellen Supply Chain Setup aufgehoben. Insbesondere sind die folgenden Verbesserungen möglich: Reduktion von Losgrössen und Lieferzeiten, bedarfsgerechte Produktion auf Abruf, dezentrale Produktion, Customization auf Ebene Bauteil und kontinuierliche Weiterentwicklung von Bauteilen. Viele Firmen investieren nicht selbst in die AM Technologien, sondern kaufen Bauteile bei Lieferanten. Um das Potential der AM Supply Chain mit Lieferanten umzusetzen, entstehen die folgenden Anforderungen an AM Einkaufsprozesse. Erstens muss der Aufwand pro Bestellung reduziert werden. Zweitens brauchen AM Nutzer einen direkten Zugang zu den Lieferanten ohne Umweg über die Einkaufsabteilung. Drittens müssen geeignete AM Lieferanten einfach identifiziert werden können. Viertens muss der Wechsel von Lieferanten mit möglichst geringem Aufwand möglich sein. Ein mögliche Lösung sind AM spezifische E-Procurement System um diese Anforderungen zu erfüllen

Establishing occupational and environmental health design requirements for Lunar and Mars settlements

In a study of Lunar and Mars settlement concepts, an analysis was made of fundamental design assumptions in five technical areas against a model list of occupational and environmental health concerns. The technical areas included the proposed science projects to be supported, habitat and construction issues, closed ecosystem issues, the "MMM" issues--mining, material-processing, and manufacturing, and the human elements of physiology, behavior and mission approach. Four major lessons were learned. First it is possible to relate public health concerns to complex technological development in a proactive design mode, which has the potential for long-term cost savings. Second, it became very apparent that prior to committing any nation or international group to spending the billions to start and complete a lunar settlement, over the next century, that a significantly different approach must be taken from those previously proposed, to solve the closed ecosystem and "MMM" problems. Third, it also appears that the health concerns and technology issues to be addressed for human exploration into space are fundamentally those to be solved for human habitation of the earth (as a closed ecosystem) in the 21st century. Finally, it is proposed that ecosystem design modeling must develop new tools, based on probabilistic models as a step up from closed circuit models. ^

Influence of Abutment Design on Stiffness, Strength, and Failure of Implant-Supported Monolithic Resin Nano Ceramic (RNC) Crowns

BACKGROUND Recent technical development allows the digital manufacturing of monolithic reconstructions with high-performance materials. For implant-supported crowns, the fixation requires an abutment design onto which the reconstruction can be bonded. PURPOSE The aim of this laboratory investigation was to analyze stiffness, strength, and failure modes of implant-supported, computer-assisted design and computer-aided manufacturing (CAD/CAM)-generated resin nano ceramic (RNC) crowns bonded to three different titanium abutments. MATERIALS AND METHODS Eighteen monolithic RNC crowns were produced and loaded in a universal testing machine under quasi-static condition according to DIN ISO 14801. With regard to the type of titanium abutment, three groups were defined: (1) prefabricated cementable standard; (2) CAD/CAM-constructed individualized; and (3) novel prefabricated bonding base. Stiffness and strength were measured and analyzed statistically with Wilcoxon rank sum test. Sections of the specimens were examined microscopically. RESULTS Stiffness demonstrated high stability for all specimens loaded in the physiological loading range with means and standard deviations of 1,579 ± 120 N/mm (group A), 1,733 ± 89 N/mm (group B), and 1,704 ± 162 N/mm (group C). Mean strength of the novel prefabricated bonding base (group C) was 17% lower than of the two other groups. Plastic deformations were detectable for all implant-abutment crown connections. CONCLUSIONS Monolithic implant crowns made of RNC seem to represent a feasible and stable prosthetic construction under laboratory testing conditions with strength higher than the average occlusal force, independent of the different abutment designs used in this investigation.

Assessment of occupational exposures to organic chemicals in a plastics manufacturing facility

The objective of this dissertation was to design and implement strategies for assessment of exposures to organic chemicals used in the production of a styrene-butadiene polymer at the Texas Plastics Company (TPC). Linear statistical retrospective exposure models, univariate and multivariate, were developed based on the validation of historical industrial hygiene monitoring data collected by industrial hygienists at TPC, and additional current industrial hygiene monitoring data collected for the purposes of this study. The current monitoring data served several purposes. First, it provided information on current exposure data, in the form of unbiased estimates of mean exposure to organic chemicals for each job title included. Second, it provided information on homogeneity of exposure within each job title, through the use of a carefully designed sampling scheme which addressed variability of exposure both between and within job titles. Third, it permitted the investigation of how well current exposure data can serve as an evaluation tool for retrospective exposure estimation. Finally, this dissertation investigated the simultaneous evaluation of exposure to several chemicals, as well as the use of values below detection limits in a multivariate linear statistical model of exposures. ^

Development of Efficient Techniques for the Analysis and Design of Antennas in Dual-Reflectarray Configuration

This thesis contributes to the analysis and design of printed reflectarray antennas. The main part of the work is focused on the analysis of dual offset antennas comprising two reflectarray surfaces, one of them acts as sub-reflector and the second one acts as mainreflector. These configurations introduce additional complexity in several aspects respect to conventional dual offset reflectors, however they present a lot of degrees of freedom that can be used to improve the electrical performance of the antenna. The thesis is organized in four parts: the development of an analysis technique for dualreflectarray antennas, a preliminary validation of such methodology using equivalent reflector systems as reference antennas, a more rigorous validation of the software tool by manufacturing and testing a dual-reflectarray antenna demonstrator and the practical design of dual-reflectarray systems for some applications that show the potential of these kind of configurations to scan the beam and to generate contoured beams. In the first part, a general tool has been implemented to analyze high gain antennas which are constructed of two flat reflectarray structures. The classic reflectarray analysis based on MoM under local periodicity assumption is used for both sub and main reflectarrays, taking into account the incident angle on each reflectarray element. The incident field on the main reflectarray is computed taking into account the field radiated by all the elements on the sub-reflectarray.. Two approaches have been developed, one which employs a simple approximation to reduce the computer run time, and the other which does not, but offers in many cases, improved accuracy. The approximation is based on computing the reflected field on each element on the main reflectarray only once for all the fields radiated by the sub-reflectarray elements, assuming that the response will be the same because the only difference is a small variation on the angle of incidence. This approximation is very accurate when the reflectarray elements on the main reflectarray show a relatively small sensitivity to the angle of incidence. An extension of the analysis technique has been implemented to study dual-reflectarray antennas comprising a main reflectarray printed on a parabolic surface, or in general in a curved surface. In many applications of dual-reflectarray configurations, the reflectarray elements are in the near field of the feed-horn. To consider the near field radiated by the horn, the incident field on each reflectarray element is computed using a spherical mode expansion. In this region, the angles of incidence are moderately wide, and they are considered in the analysis of the reflectarray to better calculate the actual incident field on the sub-reflectarray elements. This technique increases the accuracy for the prediction of co- and cross-polar patterns and antenna gain respect to the case of using ideal feed models. In the second part, as a preliminary validation, the proposed analysis method has been used to design a dual-reflectarray antenna that emulates previous dual-reflector antennas in Ku and W-bands including a reflectarray as subreflector. The results for the dualreflectarray antenna compare very well with those of the parabolic reflector and reflectarray subreflector; radiation patterns, antenna gain and efficiency are practically the same when the main parabolic reflector is substituted by a flat reflectarray. The results show that the gain is only reduced by a few tenths of a dB as a result of the ohmic losses in the reflectarray. The phase adjustment on two surfaces provided by the dual-reflectarray configuration can be used to improve the antenna performance in some applications requiring multiple beams, beam scanning or shaped beams. Third, a very challenging dual-reflectarray antenna demonstrator has been designed, manufactured and tested for a more rigorous validation of the analysis technique presented. The proposed antenna configuration has the feed, the sub-reflectarray and the main-reflectarray in the near field one to each other, so that the conventional far field approximations are not suitable for the analysis of such antenna. This geometry is used as benchmarking for the proposed analysis tool in very stringent conditions. Some aspects of the proposed analysis technique that allow improving the accuracy of the analysis are also discussed. These improvements include a novel method to reduce the inherent cross polarization which is introduced mainly from grounded patch arrays. It has been checked that cross polarization in offset reflectarrays can be significantly reduced by properly adjusting the patch dimensions in the reflectarray in order to produce an overall cancellation of the cross-polarization. The dimensions of the patches are adjusted in order not only to provide the required phase-distribution to shape the beam, but also to exploit the crosses by zero of the cross-polarization components. The last part of the thesis deals with direct applications of the technique described. The technique presented is directly applicable to the design of contoured beam antennas for DBS applications, where the requirements of cross-polarisation are very stringent. The beam shaping is achieved by synthesithing the phase distribution on the main reflectarray while the sub-reflectarray emulates an equivalent hyperbolic subreflector. Dual-reflectarray antennas present also the ability to scan the beam over small angles about boresight. Two possible architectures for a Ku-band antenna are also described based on a dual planar reflectarray configuration that provides electronic beam scanning in a limited angular range. In the first architecture, the beam scanning is achieved by introducing a phase-control in the elements of the sub-reflectarray and the mainreflectarray is passive. A second alternative is also studied, in which the beam scanning is produced using 1-bit control on the main reflectarray, while a passive subreflectarray is designed to provide a large focal distance within a compact configuration. The system aims to develop a solution for bi-directional satellite links for emergency communications. In both proposed architectures, the objective is to provide a compact optics and simplicity to be folded and deployed.

Design and Optimization of Power Delivery and Distribution Systems Using Evolutionary Computation Techniques

Nowadays computing platforms consist of a very large number of components that require to be supplied with diferent voltage levels and power requirements. Even a very small platform, like a handheld computer, may contain more than twenty diferent loads and voltage regulators. The power delivery designers of these systems are required to provide, in a very short time, the right power architecture that optimizes the performance, meets electrical specifications plus cost and size targets. The appropriate selection of the architecture and converters directly defines the performance of a given solution. Therefore, the designer needs to be able to evaluate a significant number of options in order to know with good certainty whether the selected solutions meet the size, energy eficiency and cost targets. The design dificulties of selecting the right solution arise due to the wide range of power conversion products provided by diferent manufacturers. These products range from discrete components (to build converters) to complete power conversion modules that employ diferent manufacturing technologies. Consequently, in most cases it is not possible to analyze all the alternatives (combinations of power architectures and converters) that can be built. The designer has to select a limited number of converters in order to simplify the analysis. In this thesis, in order to overcome the mentioned dificulties, a new design methodology for power supply systems is proposed. This methodology integrates evolutionary computation techniques in order to make possible analyzing a large number of possibilities. This exhaustive analysis helps the designer to quickly define a set of feasible solutions and select the best trade-off in performance according to each application. The proposed approach consists of two key steps, one for the automatic generation of architectures and other for the optimized selection of components. In this thesis are detailed the implementation of these two steps. The usefulness of the methodology is corroborated by contrasting the results using real problems and experiments designed to test the limits of the algorithms.

Novel free-form optical surface design with spiral symmetry

Manufacturing technologies as injection molding or embossing specify their production limits for minimum radii of the vertices or draft angle for demolding, for instance. These restrictions may limit the system optical efficiency or affect the generation of undesired artifacts on the illumination pattern when dealing with optical design. A novel manufacturing concept is presented here, in which the optical surfaces are not obtained from the usual revolution symmetry with respect to a central axis (z axis), but they are calculated as free-form surfaces describing a spiral trajectory around z axis. The main advantage of this new concept lies in the manufacturing process: a molded piece can be easily separated from its mold just by applying a combination of rotational movement around axis z and linear movement along axis z, even for negative draft angles. The general designing procedure will be described in detail

Analysis of noise temperature sensitivity for the design of a broadband thermal noise primary standard

A broadband primary standard for thermal noise measurements is presented and its thermal and electromagnetic behaviour is analysed by means of a novel hybrid analytical?numerical simulation methodology. The standard consists of a broadband termination connected to a 3.5mm coaxial airline partially immersed in liquid nitrogen and is designed in order to obtain a low reflectivity and a low uncertainty in the noise temperature. A detailed sensitivity analysis is made in order to highlight the critical characteristics that mostly affect the uncertainty in the noise temperature, and also to determine the manufacturing and operation tolerances for a proper performance in the range 10MHz to 26.5 GHz. Aspects such as the thermal bead design, the level of liquid nitrogen or the uncertainties associated with the temperatures, the physical properties of the materials in the standard and the simulation techniques are discussed.

COMSOL Multyphisics Super Resolution Analysis of a Spherical Geodesic Waveguide Suitable for Manufacturing

Recently it has been proved theoretically (Miñano et al, 2011) that the super-resolution up to ?/500 can be achieved using an ideal metallic Spherical Geodesic Waveguide (SGW). This SGW is a theoretical design, in which the conductive walls are considered to be lossless conductors with zero thickness. In this paper, we study some key parameters that might influence the super resolution properties reported in (Miñano et al, 2011), such as losses, metal type, the thickness of conductive walls and the deformation from perfect sphere. We implement a realistic SGW in COMSOL multiphysics and analyze its super-resolution properties. The realistic model is designed in accordance with the manufacturing requirements and technological limitations.

Super resolution using a modified Spherical Geodesic Waveguide suitable for manufacturing

The previous publications (Miñano et al, 2011) have shown that using a Spherical Geodesic Waveguide (SGW), it can be achieved the super-resolution up to ? /500 close to a set of discrete frequencies. These frequencies are directly connected with the well-known Schumann resonance frequencies of spherical symmetric systems. However, the Spherical Geodesic Waveguide (SGW) has been presented as an ideal system, in which the technological obstacles or manufacturing feasibility and their influence on final results were not taken into account. In order to prove the concept of superresolution experimentally, the Spherical Geodesic Waveguide is modified according to the manufacturing requirements and technological limitations. Each manufacturing process imposes some imperfections which can affect the experimental results. Here, we analyze the influence of the manufacturing limitations on the super-resolution properties of the SGW. Beside the theoretical work, herein, there has been presented the experimental results, as well.

Facing the climate change challenges in the mining and mineral industry as providers of a sustainable manufacturing process

A sustainable manufacturing process must rely on an also sustainable raw materials and energy supply. This paper is intended to show the results of the studies developed on sustainable business models for the minerals industry as a fundamental previous part of a sustainable manufacturing process. As it has happened in other economic activities, the mining and minerals industry has come under tremendous pressure to improve its social, developmental, and environmental performance. Mining, refining, and the use and disposal of minerals have in some instances led to significant local environmental and social damage. Nowadays, like in other parts of the corporate world, companies are more routinely expected to perform to ever higher standards of behavior, going well beyond achieving the best rate of return for shareholders. They are also increasingly being asked to be more transparent and subject to third-party audit or review, especially in environmental aspects. In terms of environment, there are three inter-related areas where innovation and new business models can make the biggest difference: carbon, water and biodiversity. The focus in these three areas is for two reasons. First, the industrial and energetic minerals industry has significant footprints in each of these areas. Second, these three areas are where the potential environmental impacts go beyond local stakeholders and communities, and can even have global impacts, like in the case of carbon. So prioritizing efforts in these areas will ultimately be a strategic differentiator as the industry businesses continues to grow. Over the next forty years, world?s population is predicted to rise from 6.300 million to 9.500 million people. This will mean a huge demand of natural resources. Indeed, consumption rates are such that current demand for raw materials will probably soon exceed the planet?s capacity. As awareness of the actual situation grows, the public is demanding goods and services that are even more environmentally sustainable. This means that massive efforts are required to reduce the amount of materials we use, including freshwater, minerals and oil, biodiversity, and marine resources. It?s clear that business as usual is no longer possible. Today, companies face not only the economic fallout of the financial crisis; they face the substantial challenge of transitioning to a low-carbon economy that is constrained by dwindling natural resources easily accessible. Innovative business models offer pioneering companies an early start toward the future. They can signal to consumers how to make sustainable choices and provide reward for both the consumer and the shareholder. Climate change and carbon remain major risk discontinuities that we need to better understand and deal with. In the absence of a global carbon solution, the principal objective of any individual country should be to reduce its global carbon emissions by encouraging conservation. The mineral industry internal response is to continue to focus on reducing the energy intensity of our existing operations through energy efficiency and the progressive introduction of new technology. Planning of the new projects must ensure that their energy footprint is minimal from the start. These actions will increase the long term resilience of the business to uncertain energy and carbon markets. This focus, combined with a strong demand for skills in this strategic area for the future requires an appropriate change in initial and continuing training of engineers and technicians and their awareness of the issue of eco-design. It will also need the development of measurement tools for consistent comparisons between companies and the assessments integration of the carbon footprint of mining equipments and services in a comprehensive impact study on the sustainable development of the Economy.

Optical systems design using the SMS method and optimizations

Resumen El diseño de sistemas ópticos, entendido como un arte por algunos, como una ciencia por otros, se ha realizado durante siglos. Desde los egipcios hasta nuestros días los sistemas de formación de imagen han ido evolucionando así como las técnicas de diseño asociadas. Sin embargo ha sido en los últimos 50 años cuando las técnicas de diseño han experimentado su mayor desarrollo y evolución, debido, en parte, a la aparición de nuevas técnicas de fabricación y al desarrollo de ordenadores cada vez más potentes que han permitido el cálculo y análisis del trazado de rayos a través de los sistemas ópticos de forma rápida y eficiente. Esto ha propiciado que el diseño de sistemas ópticos evolucione desde los diseños desarrollados únicamente a partir de la óptica paraxial hasta lo modernos diseños realizados mediante la utilización de diferentes técnicas de optimización multiparamétrica. El principal problema con el que se encuentra el diseñador es que las diferentes técnicas de optimización necesitan partir de un diseño inicial el cual puede fijar las posibles soluciones. Dicho de otra forma, si el punto de inicio está lejos del mínimo global, o diseño óptimo para las condiciones establecidas, el diseño final puede ser un mínimo local cerca del punto de inicio y lejos del mínimo global. Este tipo de problemática ha llevado al desarrollo de sistemas globales de optimización que cada vez sean menos sensibles al punto de inicio de la optimización. Aunque si bien es cierto que es posible obtener buenos diseños a partir de este tipo de técnicas, se requiere de muchos intentos hasta llegar a la solución deseada, habiendo un entorno de incertidumbre durante todo el proceso, puesto que no está asegurado el que se llegue a la solución óptima. El método de las Superficies Múltiples Simultaneas (SMS), que nació como una herramienta de cálculo de concentradores anidólicos, se ha demostrado como una herramienta también capaz utilizarse para el diseño de sistemas ópticos formadores de imagen, aunque hasta la fecha se ha utilizado para el diseño puntual de sistemas de formación de imagen. Esta tesis tiene por objeto presentar el SMS como un método que puede ser utilizado de forma general para el diseño de cualquier sistema óptico de focal fija o v afocal con un aumento definido así como una herramienta que puede industrializarse para ayudar al diseñador a afrontar de forma sencilla el diseño de sistemas ópticos complejos. Esta tesis está estructurada en cinco capítulos: El capítulo 1, es un capítulo de fundamentos donde se presentan los conceptos fundamentales necesarios para que el lector, aunque no posea una gran base en óptica formadora de imagen, pueda entender los planteamientos y resultados que se presentan en el resto de capítulos El capitulo 2 aborda el problema de la optimización de sistemas ópticos, donde se presenta el método SMS como una herramienta idónea para obtener un punto de partida para el proceso de optimización. Mediante un ejemplo aplicado se demuestra la importancia del punto de partida utilizado en la solución final encontrada. Además en este capítulo se presentan diferentes técnicas que permiten la interpolación y optimización de las superficies obtenidas a partir de la aplicación del SMS. Aunque en esta tesis se trabajará únicamente utilizando el SMS2D, se presenta además un método para la interpolación y optimización de las nubes de puntos obtenidas a partir del SMS3D basado en funciones de base radial (RBF). En el capítulo 3 se presenta el diseño, fabricación y medidas de un objetivo catadióptrico panorámico diseñado para trabajar en la banda del infrarrojo lejano (8-12 μm) para aplicaciones de vigilancia perimetral. El objetivo presentado se diseña utilizando el método SMS para tres frentes de onda de entrada utilizando cuatro superficies. La potencia del método de diseño utilizado se hace evidente en la sencillez con la que este complejo sistema se diseña. Las imágenes presentadas demuestran cómo el prototipo desarrollado cumple a la perfección su propósito. El capítulo 4 aborda el problema del diseño de sistemas ópticos ultra compactos, se introduce el concepto de sistemas multicanal, como aquellos sistemas ópticos compuestos por una serie de canales que trabajan en paralelo. Este tipo de sistemas resultan particularmente idóneos para él diseño de sistemas afocales. Se presentan estrategias de diseño para sistemas multicanal tanto monocromáticos como policromáticos. Utilizando la novedosa técnica de diseño que en este capítulo se presenta el diseño de un telescopio de seis aumentos y medio. En el capítulo 5 se presenta una generalización del método SMS para rayos meridianos. En este capítulo se presenta el algoritmo que debe utilizarse para el diseño de cualquier sistema óptico de focal fija. La denominada optimización fase 1 se vi introduce en el algoritmo presentado de forma que mediante el cambio de las condiciones iníciales del diseño SMS que, aunque el diseño se realice para rayos meridianos, los rayos skew tengan un comportamiento similar. Para probar la potencia del algoritmo desarrollado se presenta un conjunto de diseños con diferente número de superficies. La estabilidad y potencia del algoritmo se hace evidente al conseguirse por primera vez el diseño de un sistema de seis superficies diseñado por SMS. vii Abstract The design of optical systems, considered an art by some and a science by others, has been developed for centuries. Imaging optical systems have been evolving since Ancient Egyptian times, as have design techniques. Nevertheless, the most important developments in design techniques have taken place over the past 50 years, in part due to the advances in manufacturing techniques and the development of increasingly powerful computers, which have enabled the fast and efficient calculation and analysis of ray tracing through optical systems. This has led to the design of optical systems evolving from designs developed solely from paraxial optics to modern designs created by using different multiparametric optimization techniques. The main problem the designer faces is that the different optimization techniques require an initial design which can set possible solutions as a starting point. In other words, if the starting point is far from the global minimum or optimal design for the set conditions, the final design may be a local minimum close to the starting point and far from the global minimum. This type of problem has led to the development of global optimization systems which are increasingly less sensitive to the starting point of the optimization process. Even though it is possible to obtain good designs from these types of techniques, many attempts are necessary to reach the desired solution. This is because of the uncertain environment due to the fact that there is no guarantee that the optimal solution will be obtained. The Simultaneous Multiple Surfaces (SMS) method, designed as a tool to calculate anidolic concentrators, has also proved useful for the design of image-forming optical systems, although until now it has occasionally been used for the design of imaging systems. This thesis aims to present the SMS method as a technique that can be used in general for the design of any optical system, whether with a fixed focal or an afocal with a defined magnification, and also as a tool that can be commercialized to help designers in the design of complex optical systems. The thesis is divided into five chapters. Chapter 1 establishes the basics by presenting the fundamental concepts which the reader needs to acquire, even if he/she doesn‟t have extensive knowledge in the field viii of image-forming optics, in order to understand the steps taken and the results obtained in the following chapters. Chapter 2 addresses the problem of optimizing optical systems. Here the SMS method is presented as an ideal tool to obtain a starting point for the optimization process. The importance of the starting point for the final solution is demonstrated through an example. Additionally, this chapter introduces various techniques for the interpolation and optimization of the surfaces obtained through the application of the SMS method. Even though in this thesis only the SMS2D method is used, we present a method for the interpolation and optimization of clouds of points obtained though the SMS3D method, based on radial basis functions (RBF). Chapter 3 presents the design, manufacturing and measurement processes of a catadioptric panoramic lens designed to work in the Long Wavelength Infrared (LWIR) (8-12 microns) for perimeter surveillance applications. The lens presented is designed by using the SMS method for three input wavefronts using four surfaces. The powerfulness of the design method used is revealed through the ease with which this complex system is designed. The images presented show how the prototype perfectly fulfills its purpose. Chapter 4 addresses the problem of designing ultra-compact optical systems. The concept of multi-channel systems, such as optical systems composed of a series of channels that work in parallel, is introduced. Such systems are especially suitable for the design of afocal systems. We present design strategies for multichannel systems, both monochromatic and polychromatic. A telescope designed with a magnification of six-and-a-half through the innovative technique exposed in this chapter is presented. Chapter 5 presents a generalization of the SMS method for meridian rays. The algorithm to be used for the design of any fixed focal optics is revealed. The optimization known as phase 1 optimization is inserted into the algorithm so that, by changing the initial conditions of the SMS design, the skew rays have a similar behavior, despite the design being carried out for meridian rays. To test the power of the developed algorithm, a set of designs with a different number of surfaces is presented. The stability and strength of the algorithm become apparent when the first design of a system with six surfaces if obtained through the SMS method.

Design and control of multi-finger haptic devices for dexterous manipulation

En la interacción con el entorno que nos rodea durante nuestra vida diaria (utilizar un cepillo de dientes, abrir puertas, utilizar el teléfono móvil, etc.) y en situaciones profesionales (intervenciones médicas, procesos de producción, etc.), típicamente realizamos manipulaciones avanzadas que incluyen la utilización de los dedos de ambas manos. De esta forma el desarrollo de métodos de interacción háptica multi-dedo dan lugar a interfaces hombre-máquina más naturales y realistas. No obstante, la mayoría de interfaces hápticas disponibles en el mercado están basadas en interacciones con un solo punto de contacto; esto puede ser suficiente para la exploración o palpación del entorno pero no permite la realización de tareas más avanzadas como agarres. En esta tesis, se investiga el diseño mecánico, control y aplicaciones de dispositivos hápticos modulares con capacidad de reflexión de fuerzas en los dedos índice, corazón y pulgar del usuario. El diseño mecánico de la interfaz diseñada, ha sido optimizado con funciones multi-objetivo para conseguir una baja inercia, un amplio espacio de trabajo, alta manipulabilidad y reflexión de fuerzas superiores a 3 N en el espacio de trabajo. El ancho de banda y la rigidez del dispositivo se han evaluado mediante simulación y experimentación real. Una de las áreas más importantes en el diseño de estos dispositivos es el efector final, ya que es la parte que está en contacto con el usuario. Durante este trabajo se ha diseñado un dedal de bajo peso, adaptable a diferentes usuarios que, mediante la incorporación de sensores de contacto, permite estimar fuerzas normales y tangenciales durante la interacción con entornos reales y virtuales. Para el diseño de la arquitectura de control, se estudiaron los principales requisitos para estos dispositivos. Entre estos, cabe destacar la adquisición, procesado e intercambio a través de internet de numerosas señales de control e instrumentación; la computación de equaciones matemáticas incluyendo la cinemática directa e inversa, jacobiana, algoritmos de detección de agarres, etc. Todos estos componentes deben calcularse en tiempo real garantizando una frecuencia mínima de 1 KHz. Además, se describen sistemas para manipulación de precisión virtual y remota; así como el diseño de un método denominado "desacoplo cinemático iterativo" para computar la cinemática inversa de robots y la comparación con otros métodos actuales. Para entender la importancia de la interacción multimodal, se ha llevado a cabo un estudio para comprobar qué estímulos sensoriales se correlacionan con tiempos de respuesta más rápidos y de mayor precisión. Estos experimentos se desarrollaron en colaboración con neurocientíficos del instituto Technion Israel Institute of Technology. Comparando los tiempos de respuesta en la interacción unimodal (auditiva, visual y háptica) con combinaciones bimodales y trimodales de los mismos, se demuestra que el movimiento sincronizado de los dedos para generar respuestas de agarre se basa principalmente en la percepción háptica. La ventaja en el tiempo de procesamiento de los estímulos hápticos, sugiere que los entornos virtuales que incluyen esta componente sensorial generan mejores contingencias motoras y mejoran la credibilidad de los eventos. Se concluye que, los sistemas que incluyen percepción háptica dotan a los usuarios de más tiempo en las etapas cognitivas para rellenar información de forma creativa y formar una experiencia más rica. Una aplicación interesante de los dispositivos hápticos es el diseño de nuevos simuladores que permitan entrenar habilidades manuales en el sector médico. En colaboración con fisioterapeutas de Griffith University en Australia, se desarrolló un simulador que permite realizar ejercicios de rehabilitación de la mano. Las propiedades de rigidez no lineales de la articulación metacarpofalange del dedo índice se estimaron mediante la utilización del efector final diseñado. Estos parámetros, se han implementado en un escenario que simula el comportamiento de la mano humana y que permite la interacción háptica a través de esta interfaz. Las aplicaciones potenciales de este simulador están relacionadas con entrenamiento y educación de estudiantes de fisioterapia. En esta tesis, se han desarrollado nuevos métodos que permiten el control simultáneo de robots y manos robóticas en la interacción con entornos reales. El espacio de trabajo alcanzable por el dispositivo háptico, se extiende mediante el cambio de modo de control automático entre posición y velocidad. Además, estos métodos permiten reconocer el gesto del usuario durante las primeras etapas de aproximación al objeto para su agarre. Mediante experimentos de manipulación avanzada de objetos con un manipulador y diferentes manos robóticas, se muestra que el tiempo en realizar una tarea se reduce y que el sistema permite la realización de la tarea con precisión. Este trabajo, es el resultado de una colaboración con investigadores de Harvard BioRobotics Laboratory. ABSTRACT When we interact with the environment in our daily life (using a toothbrush, opening doors, using cell-phones, etc.), or in professional situations (medical interventions, manufacturing processes, etc.) we typically perform dexterous manipulations that involve multiple fingers and palm for both hands. Therefore, multi-Finger haptic methods can provide a realistic and natural human-machine interface to enhance immersion when interacting with simulated or remote environments. Most commercial devices allow haptic interaction with only one contact point, which may be sufficient for some exploration or palpation tasks but are not enough to perform advanced object manipulations such as grasping. In this thesis, I investigate the mechanical design, control and applications of a modular haptic device that can provide force feedback to the index, thumb and middle fingers of the user. The designed mechanical device is optimized with a multi-objective design function to achieve a low inertia, a large workspace, manipulability, and force-feedback of up to 3 N within the workspace; the bandwidth and rigidity for the device is assessed through simulation and real experimentation. One of the most important areas when designing haptic devices is the end-effector, since it is in contact with the user. In this thesis the design and evaluation of a thimble-like, lightweight, user-adaptable, and cost-effective device that incorporates four contact force sensors is described. This design allows estimation of the forces applied by a user during manipulation of virtual and real objects. The design of a real-time, modular control architecture for multi-finger haptic interaction is described. Requirements for control of multi-finger haptic devices are explored. Moreover, a large number of signals have to be acquired, processed, sent over the network and mathematical computations such as device direct and inverse kinematics, jacobian, grasp detection algorithms, etc. have to be calculated in Real Time to assure the required high fidelity for the haptic interaction. The Hardware control architecture has different modules and consists of an FPGA for the low-level controller and a RT controller for managing all the complex calculations (jacobian, kinematics, etc.); this provides a compact and scalable solution for the required high computation capabilities assuring a correct frequency rate for the control loop of 1 kHz. A set-up for dexterous virtual and real manipulation is described. Moreover, a new algorithm named the iterative kinematic decoupling method was implemented to solve the inverse kinematics of a robotic manipulator. In order to understand the importance of multi-modal interaction including haptics, a subject study was carried out to look for sensory stimuli that correlate with fast response time and enhanced accuracy. This experiment was carried out in collaboration with neuro-scientists from Technion Israel Institute of Technology. By comparing the grasping response times in unimodal (auditory, visual, and haptic) events with the response times in events with bimodal and trimodal combinations. It is concluded that in grasping tasks the synchronized motion of the fingers to generate the grasping response relies on haptic cues. This processing-speed advantage of haptic cues suggests that multimodalhaptic virtual environments are superior in generating motor contingencies, enhancing the plausibility of events. Applications that include haptics provide users with more time at the cognitive stages to fill in missing information creatively and form a richer experience. A major application of haptic devices is the design of new simulators to train manual skills for the medical sector. In collaboration with physical therapists from Griffith University in Australia, we developed a simulator to allow hand rehabilitation manipulations. First, the non-linear stiffness properties of the metacarpophalangeal joint of the index finger were estimated by using the designed end-effector; these parameters are implemented in a scenario that simulates the behavior of the human hand and that allows haptic interaction through the designed haptic device. The potential application of this work is related to educational and medical training purposes. In this thesis, new methods to simultaneously control the position and orientation of a robotic manipulator and the grasp of a robotic hand when interacting with large real environments are studied. The reachable workspace is extended by automatically switching between rate and position control modes. Moreover, the human hand gesture is recognized by reading the relative movements of the index, thumb and middle fingers of the user during the early stages of the approximation-to-the-object phase and then mapped to the robotic hand actuators. These methods are validated to perform dexterous manipulation of objects with a robotic manipulator, and different robotic hands. This work is the result of a research collaboration with researchers from the Harvard BioRobotics Laboratory. The developed experiments show that the overall task time is reduced and that the developed methods allow for full dexterity and correct completion of dexterous manipulations.

A knowledge based application for industrialization design

After being designed, a product has to be manufactured, which means converting concepts and information into a real, physical object. This requires a big amount of resources and a careful planning. The product manufacturing must be designed too, and that is called Industrialization Design. An accepted methodology for this activity is starting defining simple structures and then progressively increasing the detail degree of the manufacturing solution. The impact of decisions taken at first stages of Industrialization Design is remarkable, and software tools to assist designers are required. In this paper a Knowledge Based Application prototype for the Industrialization Design is presented. The application is implemented within the environment CATIA V5/DELMIA. A case study with a simple Product from aerospace sector illustrates the prototype development.

A knowledge based application for industrialization design

After being designed, a product has to be manufactured, which means converting concepts and information into a real, physical object. This requires a big amount of resources and a careful planning. The product manufacturing must be designed too, and that is called Industrialization Design. An accepted methodology for this activity is starting defining simple structures and then progressively increasing the detail degree of the manufacturing solution. The impact of decisions taken at first stages of Industrialization Design is remarkable, and software tools to assist designers are required. In this paper a Knowledge Based Application prototype for the Industrialization Design is presented. The application is implemented within the environment CATIA V5/DELMIA. A case study with a simple Product from aerospace sector illustrates the prototype development.