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Driving
Change in the Automobile Industry: Technology Trends and Challenges in
the 21st Century
Alan Taub
Executive Director, Research & Development, General Motors
Corporation
Abstract
The DNA of the automobile
has not changed for over 100 years. Vehicles continue to be largely
energized by petroleum, powered by internal combustion engines, and
operated via mechanical linkages. However, given today challenges
related to energy, environment, safety, and congestion, one must
question whether the continued evolution of this DNA will enable
sustainable industry growth. Fortunately, a new and revolutionary
automotive DNA is at hand, made possible by the convergence of advanced
propulsion, electrical and electronic controls and systems, telematics,
and advanced and smart materials. The convergence of these technologies
will enable the industry to reinvent the automobile and address the
externalities currently associated with our vehicles. The major issues
will be discussed in each technology arena, which in many cases
includes infrastructure and standards development. The presentation
will highlight how solutions to these issues will help the industry
reinvent the automobile and continue to grow the business sustainably.
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Surface Metrology for Control of Manufacture
David Whitehouse
Warwick
University
Abstract
The paper will show how the
surface finish has been used in production from the earliest time to
the latest developments. Surfaces have been used to control manufacture
for many years. It started in the late 1930s and has been developing
ever since. The reason for its usefulness is that the surface roughness
is very sensitive to change of any sort in the manufacturing process.
At first very simple parameters were used for example AA (CLA), Ra all
words for the average value of the roughness or sometimes Rt the peak
to valley. These were easy to measure from a chart. With the advent of
digital methods other aspects of the surface geometry could be used
such as waviness and form as well as signals from instruments measuring
roundness which enabled the machine tool to be monitored. Soon with the
use of random process analysis it became possible to measure tool wear
as well as factors such as grinding efficiency. In particular
correlation methods were used in abrasive processes such as polishing
and power spectral methods were used for single point cutting such as
turning. More recently multidimensional functions have been introduced.
One of these called the Wigner Distribution Function measures in time
as well space at the same time and can differentiate between different
forms of machine tool vibration including axial and radial modes. Chirp
signals indicating changing damping conditions in cutting can also be monitored.
The paper also shows how fractal analysis can be of use in assessing
some aspects of surface integrity especially of fine processes. Some
recent developments are introduced. These include three generations of
wavelet analysis which are now being used to characterize surface
defects on silicon wafers and free-form techniques for controlling
complicated geometries now being designed for optical applications in
scanners and similar devices.
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Nano-manufacturing£Vision and Missions
Bingheng Lu
Fellow of
Chinese
Academy
of Enginnering
Professor,
Institute Of Advanced Manufacturing Technology,
Xian Jiaotong University
,
China
Abstract
The conceptions based on
discoveries made by scientists in nanoscience over the past decades
promise various encouraging products or systems which can change our
world in this century. But How long will it be before all of these
becomes true and what should be done from the perspective of
manufacturing engineering to turn the scientists' conceptions to real
life products in mass scale to serve human welfares. It is widely
believed that the timing has come for turning from nanoscience to
nanomanufacturing. This talk is based on the proposal of a grand
research program "Basic Research of Nanomanufacturing" to
China National Natural Science Foundation. The proposal is the result
of the efforts by dozens of cross-disciplinary exports in
China
over the past two years. This talk is a brief introduction of the
proposal, in an attempt to provide a vision into nanomanufacturing
concepts and define focus studies for researchers working in the
related fields. The talk has come to mainly the following conclusions
(1) It is the critical mission for manufacturing engineers to develop
tools and consistent processes which enable a cost-effective and
mass-scale building of nanometer-scale structures, features, devices,
and systems suitable for integration across higher dimensional scales
(micro-, meso- and macroscale) to provide functional products and
useful services. The development of both these functional products and
their building processes may be inspired by the conceptions or
discoveries made in the nanoscience fields.
(2) Nanomanufacturing may be subdivided into three inter-related
research fields, i.e., (a)manufacturing of macro-scale objects or
structures in a nanometer or sub-nanometer level precision;
(b)Manufacturing of nanometer-scale objects or structures in large
mass; (c)assembly or integration of cross-scale or cross-dimensional
objects or structures into functional systems.
(3) The enabling technologies for nanomanufacturing which have to be
explored by manufacturing experts may include processes and tools for
creating nano-textured or sub-nano precision surfaces, generating
nano-scale patterns and multi-dimensions structures, connecting or
bonding cross-scale objects, and mass-manipulating cross-scale objects
in a nanometer precision.
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Dominant Design
for Product and Service Innovation: Strategies, Tools, and Case studies
Jay Lee
Ohio
Eminent Scholar
and
L.W. Scott Alter
Chair Professor in Advanced Manufacturing,
Univ.
of
Cincinnati
Abstract
Innovation is not an option
for today's industry. For the past decade, globalization and
transformation of the flat-world economy has produced vast new
challenges for industry. Innovation is not just about new product
development; it also refers to the creation of new value-added services
to transform better productivity and business performance. As the
practice of product design have expanded both in economic and social
impact and in technological complexity, so the demands upon innovative
service systems. For example, GE Medical changed its name to GE
Healthcare Technologies to expand its business opportunities. Companies
such as IBM and Xerox are also transforming to be smart service
business leaders. The key innovation of these successes is based on a
dominant design thinking and strategy on combined business model and
technology breakthroughs.
This presentation introduces the strategies for product and service
innovation based on a Dominant Design approach. Innovation matrix and
application space mapping tools will be used to illustrate how to
formulate "gaps" between product and customer needs. In
addition, examples will be used to illustrate how world-class companies
and small to media size companies can transform to innovative service
business.
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US National
Science Foundation Program in Nanomanufacturing
Shaochen Chen
Program Director
for Nanomanufacturing, Division of Civil,Mechanical and Manufacturing
Innovation,National Science Foundation, Room 545,
Wilson
Blvd.,
Arlington
,
VA
22230
,
USA
Abstract
The National Science
Foundation provided approximately $26.58 million in Fiscal Year 2007
for fundamental research and education in nanomanufacturing in the
United States
,
mostly to colleges and universities, with some support provided to
small businesses. The core Nanomanufacturing Program emphasizes
scale-up of nanotechnology to increase the production rate,
reliability, robustness, yield, and efficiency of manufacturing
processes and reduce the cost of nanotechnology products and services.
Nanomanufacturing capitalizes on the special material properties and
processing capabilities at the nanoscale, promotes integration of
nanostructures to functional micro devices and meso/macroscale
architectures and systems, and addresses interfacing issues across
dimensional scales. The program promotes multi-functionality across all
energetic domains, including mechanical, thermal, fluidic, chemical,
biochemical, electromagnetic, optical etc. The focus incorporates a
systems approach, encompassing nanoscale materials and structures,
fabrication and integration processes, production equipment and
characterization instrumentation, theory/modeling/simulation and
control tools, biomimetic design and integration of multiscale
functional systems, and industrial application. In this talk, I will
overview research projects recently funded in the Nanomanufacturing
Program at NSF.
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¡øTitle:
Challenges and Innovations in Electronics Manufacturing
Ji Oh Song
Executive Vice
President
Mechatronics &
Manufacturing Technology Center, Samsung Electronics Co., Ltd.
Abstract
The global electronics manufacturing
industries continue to expand as more electronic devices are becoming essential
commodities. The evolution of digital and information technology is
expanding the consumer electronics market in an unprecedented speed while
steep price drops are common for most products. The industry needs to
be more responsive to such market situations by adopting various innovations
in product design and manufacturing.
Many electronics companies are
trying to focus on their core competencies such as R&D and design
while manufacturing off-shore or through
EMS
companies to reduce cost and capital investment. However, competency in
manufacturing is equally important as it differentiates products by
quality, uniqueness, and cost.
Samsung Electronics, the
largest consumer electronics company in the world, is driving intensifying
manufacturing initiatives by ¡®Re-discovering of manufacturing¡¯. The
speech will deliver some cases of flexible and leaner manufacturing practiced
in Samsung Electronics. Products are designed for manufacturability,
maintenance, and environment. In-house developed equipment and
automation system enable better productivity and quality. Customized
manufacturing software systems form the fundamentals of lean manufacturing
system in Samsung. Discovering of invisible factory involves finding various
loss factors in manufacturing processes. Modifying de facto standard equipment
and optimizing by IE (Industrial Engineering) provide extra
productivity without investment. Traditional conveyor belt production lines
are replaced with cell manufacturing systems while low cost intelligent
automation and information technology support human workers. Finally,
our initiatives in developing young human resources for skilled works
by cooperating with the World Skills International will be presented.
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From Flexible to Adaptive
Manufacturing: an Approach for Laser MaterialsProcessing
Stefan Kaierle
Head of Department System Technology, Fraunhofer Institute for
Laser Technology
Abstract
The trend towards flexible
manufacturing has been an important driver for the development of
modern manufacturing technologies during the last decade. Approaches
such as flexible manufacturing systems have been investigated and
partly been realized. Such methods have mostly been resource-based
whereas it has become aware in recent time that a change towards
knowledge-based manufacturing appears to be expedient. This is clearly
underlined in the Strategic Research Agenda of the Manufuture European
Technology Platform. Manufuture had been founded - similar to the
Photonics21 platform - in order to develop and elaborate a research
agenda for the domain of manufacturing.
The presentation will give an overview on the demands and drivers for
new manufacturing approaches, broken down for laser technology. This
will be illustrated by the advancements of the recent years that have
been achieved in autonomous laser processing. A view into adaptive
manufacturing technology for laser materials processing will top off
this presentation.
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Theory and
Application of Railway Vehicle-Track Coupling Dynamics
Wanming Zhai
Southwest Jiaotong University
,
China
Abstract
Chinese Railways are in the
high transportation capacity condition for a long time, which results
in intense dynamic interaction between train and track. The safety
problem becomes severer than ordinary railways. The author and his
research team have done in-depth investigation on this area and got
systematical research achievements as follows:
(1) A new theory system has been built on vehicle-track coupling
dynamics, including the academic idea, theoretical model, numerical
method, simulation method and experimental method, which provide the
key theoretical base for the safety design of the vehicle and track
dynamic systems on Chinese railways with very high transportation
capacity and very high dynamic loads.
(2) The detailed vehicle-track coupling models were established for
typical locomotives, passenger cars, freight cars and various tracks.
Three research advances were made. Firstly, the models completely
describe the dynamic properties and the interactive characteristic of
the vehicle and track system. Secondly, a new wheel/rail dynamically
coupled model has been established, which abandons three unreasonable
hypotheses, i.e., the rail is without movement, the wheel and the rail
are rigid, and the wheel always keep contact with the rail. The third,
a model was built for the analysis of railway ballast vibrations.
(3) A simulation platform has been developed for optimal design of the
overall vehicle-track dynamic systems of high-speed railways,
heavy-hual railways as well as the speed-up railways in
China
,
which include two simulation systems, VICT for vertical system and
TTISIM for lateral system.
(4) A field measurement system was developed to assess the safety of
dynamic interactions between railway vehicles and tracks. Several
full-scale field measurements have been carried out for the safety
assessments of high-speed and heavy-hual wheel/rail dynamic systems.
(5) A series of key dynamic problems have been investigated and solved
in Chinese railway engineering, e.g., the nonlinear lateral vibration
of SS7E type locomotive, the wheel/rail dynamic safety on very small
radius curves in mountain areas, and the optimal design of high-speed
slab track structures.
Above research achievement was selected to the top ten advances on
science and technology in Chinese university in the year of 2005, which
was also assigned as the first-class prize of National Award for
Science and Technology Progress by State Department in 2005. |
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