knowledge based approach to fuel cell assembly equipment selection
TRANSCRIPT
Shaping the Future
Knowledge-based approach to assembly equipment selection – A
fuel cell case study
IECON Japan – 12th November 2015
Mussawar [email protected]
Co-AuthorsBorja Ramis Ferrer, Prof. Robert Harrison, Dr Bilal Ahmad, Prof. José L. Martinez Lastra, Dr.
James Meredith, Dr. Axel Bindel
Outline
Background The big picture and the this work The fuel cell problem What is manufacturing know-how? Storing knowledge Model description Test and results Conclusion Proposed further work
Background Automation Systems Group – WMG– Industrial automation systems– Process control– Virtual engineering – Tools developed for virtual commissioning
Partnered with Arcola Energy on Innovate UK – Fuel Cell Manufacturing Project
Collaboration with Tampere University of Technology (TUT) regarding domain mapping
PhD sponsored by EPSRC and High Speed Sustainable Manufacturing Institute (HSSMI)
The big picture To be competitive, manufacturers must be able to quickly meet
many demands of many customers and maintain affordability This means MASS CUSTOMISATION CUSTOMISATION = PRODUCT VARIETY + HEADACHE Requires flexibility and reconfigurability in the manufacturing
system This research focuses on assembly system, using a PPR model
Product
Process
Resource
Time
Maturity of product
realisation
Concurrency is supposed to reduced lead times, but without effective communication between domains, time and cost can increase i.e. pure series approach could be better!
characteristics
components
performance
The big picture
Product
Process
requirements sequence
bill of process
tasks Resource
equipment
safety
Build & Commission factory – make mistakes layout
.
.
....
.
.
Product realisation process
• Different organisations• Different “language”• Cultural differences• Loss of critical information• Lack of effective communication
up and downstream
This work
characteristics
components
performance
Product
Process
requirements sequence
bill of process
tasks Resource
equipment
safetylayout
.
.
.
More detailed mapping, with more considerations about the PRODUCT. Thus, if product characteristics are changed, the assessment of impact on the assembly system is more accurate
PEM Applications and Types
Horizon H-series
10 100 500 1000 2000 5000 10000 50000 100000
Horizon XP-series
Horizon AEROSTACKS
Horizon MFCs
Air c
oole
d
Nuvera Orion
Liqu
id c
oole
d
Ballard FCgen 1020ACS
Ballard FCgen 1300
Ballard FCvelocity 9SSL
Horizon Educational
The H-Series stacks are not designed with a specific application in mind
Power (W)
PEM Assembly
Diffusion layers
Membrane “Sub”-cell
Also referred to as an MEA (membrane electrode assembly)
Gaskets
PEM AssemblyOpen cathode Stack Closed cathode stack Liquid cooled stack
More power
More complexity
But…there is an underlying commonality!
If you can make one, can you make them all?
Know-how
The ProblemFuel cells are great, but…
Lack of hydrogen infrastructure
Costly compared to incumbent technologies
Material costs Manufacturing costs
Assembly Component manufactureAssembly costs:• 10-30% [1] of labour• Up to 50% of total
manufacturing [2, 3]
[1] J. L. Nevins and D. E. Whitney, “Concurrent design of product and processes,” McGraw-Hill, New York, 1989 [2] U. Rembold, C. Blume, and R. Dillmann, “Computer- integrated manufacturing technology and systems,” Mar-cel Dekker, New York, 1985 [3] S. S. F. Smith, “Using multiple genetic operators to re-duce premature convergence in genetic assembly plan-ning,” Computers in Industry, Vol. 54, Iss. 1, pp. 35–49, May 2004.
Equipment
Processes
Methods
Control
Criticality
Tolerances
Sequence
The Proposed Solution
Know-howKnowledge
Capture Store Reuse
Knowledge-baseOntology
“an explicit specification of a conceptualization” [4]
[4] T. R. Gruber, A translation approach to portable ontology specifications. Knowledge Acquisition, 5(2): 199-200, 1993[5] Jose L. Martinez Lastra, Ivan M. Delamer, Fernando Ubis; Domain Ontologies for Reasoning Machines in Factory Automation; ISBN: 978-1-936007-01-1, 2010; 138 pages
Formally describe a ‘domain’ [5]
ExtensibleScalableFlexible
Ontological model - PPR
What is needed?
How to put it together?What is being
made?
Resource Domain
VolumesRequirements
Cost
Process Domain
Product Domain
Enterprise Domain
Customer/Competition
Ontology
Semantic rules
Mapping
Axioms
Prod
uct
Char
acte
rist
ics
Fact
ory
com
mis
sio
ning
Virtual engineering and commissioning tool
Use parametric product CAD to quickly assess what changes may be required on the manufacturing system.
Ontological Model Used Protégé - an ontology editor Uses a semantic language – Web Ontology Language (OWL) Extension of Resource Description Framework (RDF) Queried using SPARQL Protocol and RDF Query Language (SPARQL) Rules can be written in Semantic Web Rule Language (SWRL) RDF-based models are RDF triples which semantically describe concepts Mimics and formalises natural language Model has classes, hierarchies and relationships These are used to describe real world concepts
Subject Predicate Object
FuelCell hasType PEMFuelCell
PEMFuelCell hasVariant OpenCathodeCathodeStack
OpenCathodeStack hasComponent AnodeFlowFieldPlate
AnodeFlowFieldPlate hasLiaisonWith AnodeGDL
The even bigger picture
What is needed?
How to put it together?What is being
made?
Resource Domain
VolumesRequirements
Cost
Process Domain
Product Domain
Enterprise Domain
Customer/Competition
Ontology
Semantic rules
Mapping
Axioms
Prod
uct
Char
acte
rist
ics
Fact
ory
com
mis
sio
ning
Virtual engineering and commissioning tool
Liaisons and Precedence
This method allows the modelling of the PROCESS SEQUENCE and thus the ASSEMBLY EQUIPMENT CONFIGURATION
Testing and Results
Queries are written using SPARQL to test the model Two tests were carried out
Resource
DomainProcess Domain
Product Domai
n
1. Check that the mappings results in the selection of appropriate equipment
2. Check the model technique for precedence works
Conclusion The concept has been proved– Equipment can be generated– Sequence model works
Designed to allow the addition of more information in the future
Some progress on building a fuel cell assembly KB BUT– It’s a time consuming process– Concepts being modelled are simple - unforeseen
complexity may need a model redesign– Standards not used! ISA-95 is being used by TUT
Further Work
XML File Ontology
Resource Domain
Process Domain
Product Domain
What is being made?
How to put it together?
What is needed?
VolumesRequirements
Cost
Enterprise Domain
Customer/Competition
XML File
Virtual engineering and commissioning tool
Use parametric product CAD to quickly assess what changes may be required on the manufacturing system.
0. At component level (this work)1. At station level2. At line level3. At factory level