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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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