Simulation of a flexible manufacturing system for machining some
industrial parts
PAUL CIPRIAN PATIC
Valahia University of Targoviste, ROMANIA
Keywords: Graphic Programming, Flexible manufacturing system Industrial Robot, Simulation, 3D Objects.
Received: April 25, 2022. Revised: August 23, 2023. Accepted: September 24, 2023. Published: October 6, 2023.
1. Introduction
HE chronology of flexible manufacturing systems begins
in 1968, when Cincinnati Milling Machine implemented
the first SFF, officially registered as a manufacturing and
commercial trademark, under the name "Variable Mission
Manufacturing System".
The new system implements revolutionary notions at that
time, widely used even today in the profile industry, such as:
modular equipment with automated tools, automated
replacement of the working head and pallets; the machines, the
conveyor for transporting the tools, connected to a central
computer, various indications grouped around the machines
and controlled automatically in a waiting line, in random
order; flexibility, to make a family of benchmarks in small
batches [1].
The short duration of time, to respond to the constructive
changes of the benchmarks and the change of models.
The first SFFs performed mechanical machining operations
by chipping, symbolizing a replacement of the traditional
structure, on groups of machines, in the manufacture of
landmarks.
From the above, it shows that an authentic SFF is necessary
to involve several processing centers and material handling
systems embedded in the computer control hierarchy.
Moreover, even an SFF is advised by the constraint of a
random trajectory of landmarks, instead of the recent situation,
in which landmarks are modified and moved in a straight
direction, between stations, work points, as is done in
specialized automated systems, of transfer line category.
Sometime the terms "Computer Manufacturing System -
CMS" and "Variable Mission Manufacturing - VMM" were
used synonymously with the concept of SFF. In a flexible
manufacturing system, the numerically controlled (NC)
devices are coordinated by the computer, the landmarks are
handled by robots and the finished products, transported to
their characteristic destinations, by means of automatically
controlled vehicles (AGV). Both tool sheds and automatic tool
change systems are a structural part of the manufacturing
system [3].
As changes occur in the constructive design or product
technology, they are incorporated into computer programs or
databases. In 1980, Cincinnati Milacron was the first company
to describe and present a "genuine SFF" at the Chicago
Machine Tool Fair, USA.
In the 90s, Cincinnati Milacron initiated a revolutionary new
concept in flexible manufacturing, called the module family
typed "Flexible Manufacturing Cells - CFF", later named
"Chronos".
Regarding the Flexible Manufacturing System, there is a
diversity of notions, which express the points of view of
different producing companies, consumers, of national and
international organizations.
The need for this diversity allows the analysis of a special
range of opinions regarding what the manufacturing
technology of the 21st century means [7].
A flexible manufacturing system is characterized as "an
autonomous production facility, which can be used in an active
and heterogeneous market, with a minimum reaction period
from the moment the manufacturing order enters the system
until the realization of a salable product, using a minimum
amount of capital".
A limited definition in the field of processing
technologies is the following: "An SFF is an integrated
complex, controlled by a computer, made of numerically
controlled machine tools, automatic material and tool handling
equipment and automatic control and testing equipment ,
which, with a minimum of interference and change time, can
adapt any product belonging to a specific family that is
included within the limits of its forced competence and in
accordance with a predetermined manufacturing program [10].
T
Abstract: One thought about this work because we consider that the operating procedure of flexible systems could be introduced in most
factories that propose and have as a priority large-scale production. The mode of operation and planning of each robot is very close to reality
thanks to the 3D simulation, made in the Alice three-dimensional graphic environment. With this procedure, one can highlight the main
characteristic of a flexible manufacturing system, that is, the flexibility obtained through automation and at the same time the saving of working
time. Thanks to the fact that a computerized machine system is used, any piece can be executed, at any time and in any quantity, representing
an advantage for any factory that uses this system. Another major advantage is the development of new programs that allow the solution of
numerous problems related to the coordination of the various components of the system and the optimal operation of the machine.
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A broader, descriptive definition is the one belonging to the
"US Office" for "Technology Assessment", according to which
an SFF is a manufacturing unit capable of making a class of
discontinuous products, under the conditions of minimal
human intervention [9].
It is made up of workstations equipped with production
equipment (machines, tools or other equipment for
manufacturing, assembly, or thermal transformations),
connected by a material handling system, which moves the
landmarks from one workstation to another and which
functions as an integrated system, under full programmable
control.
SFFs can also be studied from the point of view of
robotics.
Robots are characterized as "equipment capable of
performing a variety of execution, manipulation and/or
movement functions, in relation to programmed instructions
and/or impulses from various sensors".
A robot can be successfully used in a multi-product
assembly line, to perform execution and/or movement tasks.
Robots can be associated in three large categories:
accessible robots;
various robots;
various robotic cells.
At the same time, the use of diverse robots, with different
levels of industrial incorporation, appeared recently, being
able to rank the "multirobot" systems in two broad directions:
autonomous multirobot assemblies;
cooperative multirobot assemblies.
Robots constitute a class of technical systems that imitate or
substitute human or intellectual human functions [12].
This is done by associating different types of manipulation
or locomotor systems, determining the anthropomorphic
character of the robot, with different types of computing or
logic equipment that determine its intellectual functions.
Robots perform their activity in a concrete environment,
whose characteristics may remain constant or variable over
time.
Robotics is an interdisciplinary branch of engineering and
science that includes mechanical engineering, electronic
engineering, computer science, and others.
Robotics deals with the design, construction, operation and
use of robots, as well as computer systems for their control,
sensory feedback and information processing [5].
Robotics is a branch of engineering that involves the
conception, design, manufacture and operation of robots.
This field overlaps with electronics, informatics, artificial
intelligence, mechatronics, nanotechnology and
bioengineering.
Robots are made to manipulate by lifting, modifying or
destroying a certain object.
They are used most of the time for the purpose of replacing
the human, allowing them to perform some tasks in place of
the human.
So, the hands of a robot are also called "effectors end", and
the arm is represented as a manipulator.[4]
Typically, robots are used to perform difficult, dangerous or
monotonous work for humans. Lifts heavy objects, paints,
welds, handles chemicals and performs assembly work for
several days without suffering from fatigue.
Finally, as one knows, the robot's governing structure is a
hierarchical structure. This driving principle is due to the
special complexity of the systems that are part of the robot and
the difficulties created by the imposed operating tasks.
The hierarchical organization of the robot control systems is
vertical, each level hierarchically covering the inferior level in
relation to the driving problems addressed. A level of control
communicates with the immediate inferior level through
control instructions and receives from it characteristic
information which, together with the decisions provided by the
immediate next level, allows it to determine the future strategy
of action [8].
Robot systems generally include a variable number of
hierarchical levels depending on the complexity and degree of
intelligence of the driving system used.
2. Simulation with Alice 3D Graphic
Environment
To carry out the simulation in Alice we need acquired
knowledge, such as: java programming language, 3d rendering
using 3DMax.
Alice is software that can be very useful to a large category
of specialists, with its help we can put into practice a
simulation of real life, using object-oriented programming.
Being very intuitive, the 3D Alice graphic environment can be
downloaded for free, it has evolved a lot in recent years [13].
Alice 3D is a program that helps us create 3D applications
(creating a game or a video).
With the 3D objects in Alice, we can create an animation as
close as possible to reality, programming each object, such as:
robots, vehicles, different objects.
Alice proposes an interface in which commands are
presented that help us move objects and allow us to run the
application to see what the connection between the
programming of objects and their behavior in the graphical
simulation is. Alice was thought and developed later to solve
three problems on that we meet in educational programs:
almost all programming languages that we know are created to
have additional complexity, that is why Alice is thought in
such a way that we can use object-oriented programming as
easily as possible [11].
Those who use the program can imagine a virtual world and
can place objects from the program's gallery by the "drag and
drop" method of objects.
The Alice software is united with the IDE, that is, the menu
and the development environment help us to program with as
little difficulty as possible, the programming structure is based
entirely on object-oriented programming [2].
To create an animation or a game we need certain steps:
Defining the scenario - we think about something
from real life and want to simulate it in the 3D
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application. One must choose the objects we need and
the programming of the chosen objects.
Animation projection for the script: visual, textual or
both.
Realization of the application.
Running the application.
3. Presentation of the Graphic Interface
of the Project
When we open the program, a dialogue box appears on the
screen, "Select project", it has 6 tabs: « tutorial, recent worlds,
templates, examples, Textbook and open a world [14].
Preparing the graphic environment for work and calling the
own libraries/libraries to extract the industrial robots used in
the application.
4. Simulation of a Flexible
Manufacturing System for Machining
Industrial Parts
The application is called "Simulation of a flexible
manufacturing system for machining industrial parts". Once
the animation starts, you can see how each industrial and
mechanical robot was programmed. To create the animation,
one used object from the Alice gallery, but we imported some
objects that we converted with the help of 3Ds Max 2010. In
making the graphic simulation one used 3D objects, all
programmed to execute a command [6].
Running the application
To begin with one used an automatic camera positioning
command and one set the camera so that wherever we are in
the virtual world when we give it "run" the camera is
positioned in the place set by me. After positioning the camera
this is followed by another command, for moving forward
"camera move forward 180 meters".
Once we entered the factory, we met the robots and the
presses used to make the parts.
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For the piece to be able to move on the tape, one used the
following command:
Once it reaches the end of the strip, the drilling robot will
start, using the command:
Immediately after the robot finishes drilling, a red or green
LED lights up. Green shows that the part is ready for transport
and red it must go through quality control.
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The robot for quality control.
If the part does not pass the quality test, it will be added to
the scrap box, handled by a robotic arm.
The robot for cutting the piece.
If the LED lights up green, then the piece will be picked up
by a mobile robot operated by a robotic arm and will be
transported to boarding.
Outside the factory, there is a car for transporting
manufactured parts. Thus, the parts can end up in a warehouse
or go directly to customers.
Factory overview
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5. Conclusions
Making this graphic simulation, one had to use the different
knowledge such as: interactive java language, object modeling
in 3DMax, object-oriented programming, flexible
manufacturing system, industrial robots. Flexible
Manufacturing System illustrates an automated assembly that
unites several machines through a handling system, and the
actions that take place inside the system are carefully
monitored and checked by means of a computer. The
advantage that a flexible manufacturing line has over an
automatic production line is to be able to produce several
types of products simultaneously. This particularity is decisive
in a production line because it allows various modules to be
able to modify a part of the part. When transformations of
products or production programs occur, the system is
technically competent to adjust for new configurations of the
required example. Flexible manufacturing systems work and
have group technology implemented, so no system can work
completely flexibly and manufacture an infinite number of
parts. Such a system is subject to the production of parts and
these are included in a class of processes, sizes and types. As a
conclusion, a flexible manufacturing line is planned in such a
way that it can create a limited number of products. Another
well-conceived notion in Alice is the development
environment because it presents the concept of object-oriented
programming. When we use object classes, methods,
parameters, the program allows us to view and control objects
in the interface. Programming using software that offers 3D
simulation is considered a successful job, bringing a major
contribution to the development of technology, thus canceling
the degree of difficulty encountered in using some devices.
The idea of implementing flexible manufacturing systems is a
necessity for all large manufacturers to be able to guarantee
the quality of the manufactured product. This acquisition is
obtained using automated machine tools, which require a high
investment cost, calculating the profit capacity with the
manufacturing expenses.
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Contribution of Individual Authors to the
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The author contributed in the present research, at all
stages from the formulation of the problem to the
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Conflict of Interest
The author has no conflict of interest to declare that
is relevant to the content of this article.
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DESIGN, CONSTRUCTION, MAINTENANCE
DOI: 10.37394/232022.2023.3.14
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