An optimal design process for an adequate product?

The 'optimal' or 'best' design process may be the shortest or cheapest process, or the one that leads to a particularly desirable product, or to a reliable and maintainable product, or to a manufacturable product, or some combination of all of these. It is likely to satisfy the aspirations of the organisation to invest an appropriate amount of resource in the development of a specific new market opportunity, set in the context of longer-term business goals. This paper describes the progress made in over ten years of research on process modelling undertaken at the Cambridge Engineering Design Centre to identify an 'optimal' design process with which to develop an 'adequate' product.

Validation of a lattice Boltzmann model for gas-solid reactions with experiments

A lattice Boltzmann method is used to model gas-solid reactions where the composition of both the gas and solid phase changes with time, while the boundary between phases remains fixed. The flow of the bulk gas phase is treated using a multiple relaxation time MRT D3Q19 model; the dilute reactant is treated as a passive scalar using a single relaxation time BGK D3Q7 model with distinct inter- and intraparticle diffusivities. A first-order reaction is incorporated by modifying the method of Sullivan et al. [13] to include the conversion of a solid reactant. The detailed computational model is able to capture the multiscale physics encountered in reactor systems. Specifically, the model reproduced steady state analytical solutions for the reaction of a porous catalyst sphere (pore scale) and empirical solutions for mass transfer to the surface of a sphere at Re=10 (particle scale). Excellent quantitative agreement between the model and experiments for the transient reduction of a single, porous sphere of Fe 2O 3 to Fe 3O 4 in CO at 1023K and 10 5Pa is demonstrated. Model solutions for the reduction of a packed bed of Fe 2O 3 (reactor scale) at identical conditions approached those of experiments after 25 s, but required prohibitively long processor times. The presented lattice Boltzmann model resolved successfully mass transport at the pore, particle and reactor scales and highlights the relevance of LB methods for modelling convection, diffusion and reaction physics. © 2012 Elsevier Inc.

Validation of Vision Tracking at Egnatia Odos Motorway

Tracking applications provide real time on-site information that can be used to detect travel path conflicts, calculate crew productivity and eliminate unnecessary processes at the site. This paper presents the validation of a novel vision based tracking methodology at the Egnatia Odos Motorway in Thessaloniki, Greece. Egnatia Odos is a motorway that connects Turkey with Italy through Greece. Its multiple open construction sites serves as an ideal multi-site test bed for validating construction site tracking methods. The vision based tracking methodology uses video cameras and computer algorithms to calculate the 3D position of project related entities (e.g. personnel, materials and equipment) in construction sites. The approach provides an unobtrusive, inexpensive way of effectively identifying and tracking the 3D location of entities. The process followed in this study starts by acquiring video data from multiple synchronous cameras at several large scale project sites of Egnatia Odos, such as tunnels, interchanges and bridges under construction. Subsequent steps include the evaluation of the collected data and finally, performing the 3D tracking operations on selected entities (heavy equipment and personnel). The accuracy and precision of the method's results is evaluated by comparing it with the actual 3D position of the object, thus assessing the 3D tracking method's effectiveness.

Reusing steel and aluminum components at end of product life.

Reusing steel and aluminum components would reduce the need for new production, possibly creating significant savings in carbon emissions. Currently, there is no clearly defined set of strategies or barriers to enable assessment of appropriate component reuse; neither is it possible to predict future levels of reuse. This work presents a global assessment of the potential for reusing steel and aluminum components. A combination of top-down and bottom-up analyses is used to allocate the final destinations of current global steel and aluminum production to product types. A substantial catalogue has been compiled for these products characterizing key features of steel and aluminum components including design specifications, requirements in use, and current reuse patterns. To estimate the fraction of end-of-life metal components that could be reused for each product, the catalogue formed the basis of a set of semistructured interviews with industrial experts. The results suggest that approximately 30% of steel and aluminum used in current products could be reused. Barriers against reuse are examined, prompting recommendations for redesign that would facilitate future reuse.

A validation of commercial flow solver performance on hybridised octree meshes

In recent years we have been developing a meshing system which is aimed at eliminating the bottleneck represented by building meshes for real-world, complex turbomachinery configurations. This system is based on a rapid octree meshing technology which is then made conformal to the bodies present. The objective of this paper is to demonstrate that this class of mesh is not only very fast to produce but also fit-for-purpose in the sense that simulations generated with third-party commercial flow solvers like Fluent have the same accuracy as those performed on more conventional meshes. A range of standard examples and test cases will be presented. Copyright © 2011 by ASME.

Change impact on a product and its redesign process: A tool for knowledge capture and reuse

Change propagates, potentially affecting many aspects of a design and requiring much rework to implement. This article introduces a cross-domain approach to decompose a design and identify possible change propagation linkages, complemented by an interactive tool that generates dynamic checklists to assess change impact. The approach considers the information domains of requirements, functions, components, and the detail design process. Laboratory experiments using a vacuum cleaner suggest that cross-domain modelling helps analyse a design to create and capture the information required for change prediction. Further experiments using an electronic product show that this information, coupled with the interactive tool, helps to quickly and consistently assess the impact of a proposed change. © 2012 Springer-Verlag London Limited.

Product intelligence: Theory and practice

Are there any benefits in allowing orders and products to be able to manage their own progress through a supply chain? The notion of associating (and even embedding) information management and reasoning capabilities with a physical product has been discussed for over ten years now. This talk will review the notions of product intelligence and examine the rationales for these models and the practicality of their implementation. Both theoretical and practical issues associated with product intelligence will be examined referencing a number of trial deployments in manufacturing, logistics and aerospace equipment servicing. © 2012 IFAC.

Product scheduling for thermal energy reduction in papermaking industries

Papermaking is considered as an energy-intensive industry partly due to the fact that the machinery and procedures have been designed at the time when energy was both cheap and plentiful. A typical paper machine manufactures a variety of different products (grades) which impose variable per-unit raw material and energy costs to the mill. It is known that during a grade change operation the products are not market-worthy. Therefore, two different production regimes, i.e. steady state and grade transition can be recognised in papermaking practice. Among the costs associated with paper manufacture, the energy cost is 'more variable' due to (usually) day-to-day variations of the energy prices. Moreover, the production of a grade is often constrained by customer delivery time requirements. Given the above constraints and production modes, the product scheduling technique proposed in this paper aims at optimising the sequence of orders in a single machine so that the cost of production (mainly determined by the energy) is minimised. Simulation results obtained from a commercial board machine in the UK confirm the effectiveness of the proposed method. © 2011 IFAC.

Achieving Csiszár's source-channel coding exponent with product distributions

We derive a random-coding upper bound on the average probability of error of joint source-channel coding that recovers Csiszár's error exponent when used with product distributions over the channel inputs. Our proof technique for the error probability analysis employs a code construction for which source messages are assigned to subsets and codewords are generated with a distribution that depends on the subset. © 2012 IEEE.