Reconfigurable test execution systems machine and process development

Abstract

Reconfigurable manufacturing systems (RMS) are a key enabling technology to meet new challenges in a global market. These emerging products and markets are defined as having short development cycles, being highly customisable and manufactured in sufficient quantity to meet the demands of a diversified consumer base[1]. RMS?s are designed for rapid adjustment of functionality and production capacity in response to new process technology, customer requirements and market conditions. The RMS has several characteristics which are distinct from other forms of manufacturing execution systems. These include; modularity, integrability, customization, convertibility and diagnosability. Such requirements are achieved through leveraging recent technological advances in cloud computing and Internet of Things (IoT) and the concepts of cyber-physical systems and Industry 4.0. To achieve a holistic RMS, these design principles must be applied to each phase in the manufacturing process, from initial materials processing to end-of-line testing. The objective of the work presented in this thesis was to design an end-of-line test execution system (TES) based on modular, reconfigurable and plug and produce concepts. The TES is designed for utilisation in an Irish SME for the automated test of infrared ceramic heating elements. The TES was constructed with a view for integration and expansion and comprised an asynchronous conveyor system with a number of modular test stations. Several process measurement systems were integrated into each test station. These systems were characterised and specific process parameters were identified for successful product testing as part of the commissioning of the TES. This investigation provided critical insight into the material properties and functional performance of the product. The TES developed within this research and the product database created as a result of its operation will provide a platform for future research in reconfigurable manufacturing and test systems.