Operations Research, Systems Engineering and Industrial Engineering Commons^™

Adaptive Critic-Based Neural Network Controller For Uncertain Nonlinear Systems With Unknown Deadzones, Pingan He, Jagannathan Sarangapani, S. N. Balakrishnan

Electrical and Computer Engineering Faculty Research & Creative Works

A multilayer neural network (NN) controller in discrete-time is designed to deliver a desired tracking performance for a class of nonlinear systems with input deadzones. This multilayer NN controller has an adaptive critic NN architecture with two NNs for compensating the deadzone nonlinearity and a third NN for approximating the dynamics of the nonlinear system. A reinforcement learning scheme in discrete-time is proposed for the adaptive critic NN deadzone compensator, where the learning is performed based on a certain performance measure, which is supplied from a critic. The adaptive generating NN rejects the errors induced by the deadzone whereas a …

Simulation Of Engineering Systems Described By High-Index Dae And Discontinuous Ode Using Single Step Methods, Marc Compere

Publications

This dissertation presents numerical methods for solving two classes of or-dinary diferential equations (ODE) based on single-step integration meth-ods. The first class of equations addressed describes the mechanical dynamics of constrained multibody systems. These equations are ordinary differential equations (ODE) subject to algebraic constraints. Accordinly they are called differential-algebraic equations (DAE).

Specific contributions made in this area include an explicit transforma-tion between the Hessenberg index-3 form for constrained mechanical systems to a canonical state-space form used in the nonlinear control communities. A hybrid solution method was developed that incorporates both sliding-mode control (SMC) from the controls literature and post-stabilization from …

Computer-Aided Engineering For Tool Design In Manufacturing Engineering Curriculum, Daniel J. Waldorf

Industrial and Manufacturing Engineering

At Cal Poly – San Luis Obispo, a variety of tool design issues are covered in a junior-level manufacturing engineering course called Tool Engineering. In the course, designing fixtures – for any process – is a major component of the content. The process of designing a fixture is similar to the method a mechanical engineer would use to design a new product. The course is therefore an excellent opportunity to teach design principles to manufacturing engineers. This project involves an attempt to introduce computer-aided methods, including the finite element method (FEM), for analysis of tool design into the Tool Engineering …

Teaching Factory, Sema E. Alptekin, Reza Pouraghabagher, Patricia Mcquaid, Daniel Waldorf

Industrial and Manufacturing Engineering

Academia must develop a new approach to teaching in order to better prepare engineering students to function efficiently and adjust readily within the framework of the factories in the real world. Some engineering programs emphasize theory, while others emphasize application as isolated blocks. The "Teaching Factory" being developed at Cal Poly combines both theory and applications. It makes use of state-of-the-art industrial grade production equipment, computer hardware and software in the form of the following two systems: 1) a functioning "real" factory hardware environment, and 2) a Production Planning and Control Center.

Plastic Solder Paste Stencil For Surface Mount Technology, Christopher K. Wong, Daniel Waldorf

Industrial and Manufacturing Engineering

Solder paste masks or stencils are an integral part of the manufacturing process for surface mount PCBs. This study examines the feasibility of a process for rapid creation of a solder paste stencil using thermoplastic material. CNC laser cutting of the stencil geometry is replacing traditional use of chemical etching on metal sheets to produce stencils. Laser cutting has been used to improve process speed, accuracy, and cost. This research attempts to continue to simplify and reduce costs in the stencil making process by proposing as the stencil material a common thermoplastic that can be cut easily and quickly using …

Product Flexibility In Selecting Manufacturing Planning And Control Strategy, Emine Persentili, Sema E. Alptekin

Industrial and Manufacturing Engineering

The manufacturing systems capable of producing several products simultaneously are frequently subject to changes in product types due to demand fluctuations. In such systems a product flexible manufacturing planning and control (MPC) strategy is needed to change from one product type to another with minimum deterioration to system performance levels. The objective of this research is to develop a systematic analysis and evaluation approach in order to compare the MRP-push and JIT-pull strategies quantitatively based on a product flexibility measure. A new product flexibility measure is developed based on the sensitivity to change concept and presented together with the implementation …

Application Of Wavelets And Principal Component Analysis In Image Query And Mammography, Sol Neeman Ph.D.

Engineering Studies Faculty Publications and Creative Works

Breast cancer is currently one of the major causes of death for women in the U.S. Mammography is currently the most effective method for detection of breast cancer and early detection has proven to be an efficient tool to reduce the number of deaths. Mammography is the most demanding of all clinical imaging applications as it requires high contrast, high signal to noise ratio and resolution with minimal x-radiation. According to studies [36], 10% to 30% of women having breast cancer and undergoing mammography, have negative mammograms, i.e. are misdiagnosed. Furthermore, only 20%-40% of the women who undergo biopsy, have …

Simtrainer: A Management Training Tool, Wade Stark, Sema E. Alptekin

Industrial and Manufacturing Engineering

Abstract published of poster paper presented at conference.

An Evaluation Of Ploughing Models For Orthogonal Machining, Daniel J. Waldorf, Richard E. Devor, Shiv G. Kapoor

Industrial and Manufacturing Engineering

An analytical comparison is made between two basic models of the flow of workpiece material around the edge of an orthogonal cutting tool during steady-state metal removal. Each has been the basis for assumptions in previous studies which attempt to model the machining process, but no direct comparison had been made to determine which, if either, is an appropriate model. One model assumes that a separation point exists on the rounded cutting edge while the other includes a stable build-up adhered to the edge and assumes a separation point at the outer extreme of the build-up. Theories of elastic-plastic deformation …

Scheduling Semiconductor Device Test Operations On Multihead Testers, Tali Freed, Robert C. Leachman

Industrial and Manufacturing Engineering

Past attempts to devise scheduling methods for the device test operations of semiconductor manufacturing firms fail to address a significant characteristic of multiple-head test systems—the dependency of processing rates on the lots processed simultaneously on the testers. Since the problem has never been modeled accurately in the scheduling literature, feasibility and performance of previously proposed scheduling methodologies for multihead testers may not be accurately assessed. In this paper, we describe the multihead tester scheduling problem, present an enumeration solution procedure, and illustrate the problems of previously suggested tester scheduling algorithms.

Gauge Repeatability & Reproducibility Study For A 3-D Solder Paste Inspection System, Jianbiao Pan, Gregory L. Tonkay, Robert H. Storer, Ronald M. Sallade, David J. Leandri

Industrial and Manufacturing Engineering

Due to the increased use of Ball Grid Arrays (BGAs) and fine pitch and ultra fine pitch Quad Flat Packages (QFPs), there is a dramatic increase in demand for solder paste inspection after the stencil printing process. The important response variables of the printing process are deposited solder paste volume, area, height and position. To identify and remove defects at the earliest possible process step, a 3-D solder paste inspection system should be used to monitor solder paste deposited on all pads on every board before component placement. An example is a fully automatic laser-based 3-D triangulation solder paste inspection …

Critical Variables Of Solder Paste Stencil Printing For Micro-Bga And Fine Pitch Qfp, Jianbiao Pan, Gregory L. Tonkay, Robert H. Storer, Ronald M. Sallade, David J. Leandri

Industrial and Manufacturing Engineering

Stencil printing continues to be the dominant method of solder deposition in high volume surface mount assembly. Control of the amount of solder paste deposited is critical for fine pitch and ultra-fine pitch SMT assembly. The process is still not well understood as indicated by the fact that industry reports 52-71% of SMT defects are related to the solder paste stencil printing process. The purpose of this paper is to identify the critical variables that influence the deposited solder paste volume, area, and height. An experiment was conducted to investigate the effects of relevant process parameters on the amount of …

Screen Printing Process Design Of Experiments For Fine Line Printing Of Thick Film Ceramic Substrates, Jianbiao Pan, Gregory L. Tonkay, Alejandro Quintero

Industrial and Manufacturing Engineering

Screen printing has been the dominant method of thick film deposition because of its low cost. Many experiments in industry have been done and many models of the printing process have been developed since the 1960's. With a growing need for denser packaging and a drive for higher pin count, screen printing has been refined to yield high resolution prints. However, fine line printing is still considered by industry to be difficult. In order to yield high resolution prints with high first pass yields and manufacturing throughput, the printing process must be controlled stringently.

This paper focuses on investigating the …

Industrial Engineering Made Simple, Deena Daggett, Sema E. Alptekin

Industrial and Manufacturing Engineering

Many high school students these days do not quickly recognize or identify Industrial Engineering (IE) procedures, practices, and products. Recruitment of qualified students into IE programs requires continuous planning, publicizing, and networking. Traditional recruitment efforts have included high school visits, brochures & flyers, and university-sponsored workshops. However, these techniques have only achieved mediocre success. Currently, a need exists for new promotional materials that utilize visual tools and provide a “hands-on” approach. We have developed several exercises that successfully introduce IE. Two such exercises are explained in this paper. The first exercise demonstrates the differences between Assembly line and Cellular Manufacturing …

Worn Tool Forces Based On Ploughing Stresses, Daniel Waldorf, Shiv G. Kapoor, Richard E. Devor

Industrial and Manufacturing Engineering

Recent work in modeling of the ploughing mechanism in basic metal machining may provide a means of estimating the additional forces to be expected when cutting with a worn tool. The results predict the rubbing stresses due to the finite radius of an unworn tool edge. Since an unworn tool can be thought of as a worn tool with a wear land width VB = 0, these stresses can make up part of a strategy for predicting the additional forces incurred by a worn tool. This paper develops a wear model by proposing a technique for utilizing the stresses predicted …

Combining Wavelets And Hotelling Transforms In Image Query, Sol Neeman Ph.D.

Engineering Studies Faculty Publications and Creative Works

In the "content based" image query, also referred to as "query by example," "similarity retrieval" or "sketch retrieval," the query image is provided by the user either as a sketch of the object, as the output of a scanner or a video camera. Some of the difficulties associated with content based image query are described in [1], e.g. significant difference between the "query image" and the "target image," artifacts and poor resolution of the query image make a straightforward comparison of images using L1 and l2 metrics not effective.

In [2] a new strategy is suggested based on wavelet decomposition …

Screen Printing Process Design Of Experiments For Fine Line Printing Of Thick Film Ceramic Substrates, Jianbiao Pan, Gregory L. Tonkay, Alejandro Quintero

Industrial and Manufacturing Engineering

Screen printing has been the dominant method of thick film deposition because of its low cost. Many experiments in industry have been done and many models of the printing process have been developed since the 1960’s. With a growing need for denser packaging and a drive for higher pin count, screen printing has been refined to yield high resolution prints. However, fine line printing is still considered by industry to be difficult. In order to yield high resolution prints with high first pass yields and manufacturing throughput, the printing process must be controlled stringently.

This paper focuses on investigating the …

A Slip-Line Field For Ploughing During Orthogonal Cutting, Daniel J. Waldorf, Richard E. Devor, Shiv. G. Kapoor

Industrial and Manufacturing Engineering

Under normal machining conditions, the cutting forces are primarily due to the bulk shearing of the workpiece material in a narrow zone called the shear zone. However, under finishing conditions, when the uncut chip thickness is of the order of the cutting edge radius, a ploughing component of the forces becomes significant as compared to the shear forces. Predicting forces under these conditions requires an estimate of ploughing. A slip-line field is developed to model the ploughing components of the cutting force. The field is based on other slip-line fields developed for a rigid wedge sliding on a half-space and …

Fuzzy Logic Control Of A Model Airplane, Jon C. Ervin, Sema E. Alptekin

Industrial and Manufacturing Engineering

Common uses of fuzzy logic control today are found in relatively simple applications in products. These applications only scratch the surface of the potential of fuzzy logic control in complex mechatronic systems. In order to demonstrate the utility of fuzzy logic in complex device control, a fuzzy logic fly-by-wire system has been developed for a model airplane. The model airplane is a complex system of several critical inputs that require rapid processing and action in order to maintain flight stability. In addition, payload and power constraints severely limit the size, weight and processing power of the hardware to be carried …

Development Of A Mechatronics Design Studio, Sema E. Alptekin

Industrial and Manufacturing Engineering

Mechatronics is a combination of mechanics, electronics and information technology intended to raise the intelligence level and flexibility of products and devices. There is a need to develop programs and laboratories in Mechatronics to create an understanding of how new technologies influence the traditional methods of designing products and manufacturing systems. A model "Mechatronics Design Studio" has recently been developed to support the Mechatronics and Manufacturing Automation courses offered at Cal Poly's Industrial and Manufacturing Engineering Department. Laboratory experiments have been developed and several student projects have been completed. In this paper, an overview of the design studio and select …

An Integrated Approach To Simulation And Activity-Based Costing For Evaluating Alternative Manufacturing Cell Designs, Robert Williams, Paul Savory, Rodney Rasmussen

Department of Industrial and Management Systems Engineering: Faculty Publications

One effective technique for improving manufacturing efficiency involves the application of group technology part families and manufacturing cells. Selection of the best or optimum configuration of the manufacturing cell relies on the experience and judgment of the cell designer. This paper describes how activity-based costing (ABC) concepts can be integrated into a discrete-event simulation model and be used to evaluate manufacturing cell configurations. The output of the combined ABC simulation model provides a detailed “Bill of Activity” which allows the cell designer to consider costs as a critical factor in the cell design problem. Alternative cell configurations studied in this …

Arts, Computers And Artificial Intelligence, Sol Neeman Ph.D.

Engineering Studies Faculty Publications and Creative Works

Science and art seem to belong to different cultures. Science and technology, mainly the products of the intellect, use terminology and vocabulary that are concise and well defined. In contrast, in artistic expression, ambiguity is a powerful component. Still the relationship between these two different categories of human activity is interesting and fascinating. In this paper, a general comparison of these two disciplines will be introduced. Then the possibility of mechanical creation of art using computers and artificial intelligence will be discussed. This will be followed by two techniques which are used to create poetry and music. First, a statistical …

Preparing The Leaders For Mechatronics Education, Sema E. Alptekin

Industrial and Manufacturing Engineering

Mechatronics is the synergetic combination of precision mechanical engineering, electronic control and systems thinking in the design of products and processes. There is a need to develop interdisciplinary programs in Mechatronics that better prepare our graduates to design, build, and operate the products and systems of today and tomorrow. To address this need, National Science Foundation funded a project entitled "Preparing the Leaders for Mechatronics Education" undertaken by Cal Poly in 1995 - 1996. In this paper, the activities that took place during this two-year program is outlined. Several courses and course modules have already been developed and implemented by …

Incorporating Matlab's Signal Processing Toolbox Into A Dsp Course At An Undergraduate E.E. Program, Sol Neeman Ph.D.

Engineering Studies Faculty Publications and Creative Works

This paper provides some suggestions for incorporating MATLAB's Signal Processing Toolbox into a DSP course. Often, in a DSP course, students have difficulties understanding abstract and non-intuitive concepts and seeing their relevance to the practical part of their curriculum. The tools offered by MATLAB's Signal Processing Toolbox, can help to make these concepts more tangible and provide a perspective for students. Some basic tools relevant to an undergraduate DSP course will be introduced, including examples of tool use and graphic results. The tools presented will be applied in the areas of synthesis and analysis of signals, FFT computation, impulse response …

A Psychological Perspective On Service Segmentation Models: The Significance Of Accounting For Consumers' Perceptions Of Waiting And Service, Ziv Carmon, J. George Shanthikumar, Tali F. Carmon

Industrial and Manufacturing Engineering

We examine how service should be divided and scheduled when it can be provided in multiple separate segments. We analyze variants of this problem using a model with a conventional function describing the waiting cost, that is modified to account for some aspects of the psychological cost of waiting in line. We show that consideration of the psychological cost can result in prescriptions that are inconsistent with the common wisdom of queuing theorists derived according to the conventional approach (e.g., equal load assignments). More generally, our intention in this paper is to illustrate that aspects of the psychological cost of …

Using Matlab To Illustrate The 'Phenomenon Of Aliasing', Sol Neeman, Ph.D.

Engineering Studies Faculty Publications and Creative Works

The phenomenon of aliasing is important when sampling analog signals. In cases where the signal is bandlimited, one can avoid aliasing by ensuring that the sampling rate is higher than the Nyquist rate . But in cases where the signal is not bandlimited , aliasing is unavoidable if the signal is not filtered before it is sampled. It is then crucial to understand the phenomenon in order to estimate the distortion generated when the signal is reconstructed from its samples. Using the software package MATLAB by MathWorks, Inc ., two examples are presented. The first is a pure sinusoid which …

A Preliminary Model For Lot Sizing In Semiconductor Manufacturing, Tali F. Carmon, Steven Nahmias

Industrial and Manufacturing Engineering

No abstract provided.

Error Recovery In Intelligent Robotic Workcells, R. D. Borchelt, Sema E. Alptekin

Industrial and Manufacturing Engineering

This paper focuses on the requirements for achieving automated diagnosis and error recovery in a robotic assembly cell. Untended robust operation is the goal which is discussed, and the use of a knowledge-base oriented diagnostic/control system to support on-line error recovery is advocated. It is proposed that error recovery attempts should be made, not only based on information gathered by system sensors, but also by using additional cell-specific knowledge pertaining to recovery strategies. Recovery attempts are to be made even in the absence of complete diagnosis, in order to gather additional information. A control structure developed to implement this approach …

The Importance Of Considering Size Effect Along The Cutting Edge In Predicting The Effective Lead Angle For Turning, William J. Endres, Daniel Waldorf

Industrial and Manufacturing Engineering

The concept of an effective orthogonal cutting edge in turning is considered. The orientation of this edge in the radial-longitudinal plane, as commonly modeled through an effective lead angle, is studied. The methods of effective lead angle prediction used in numerous previously developed force models are plagued with large errors over ranges of process inputs, in particular feed rate and depth of cut. Four previously developed methods of effective lead angle prediction are reviewed and compared to a new method presented here. This new method accounts for the size effect as introduced through the variation in chip thickness along the …

Set-Up Saving Schemes For Printed Circuit Boards Assembly, Oded Z. Maimon, Ezey M. Dar-El, Tali F. Carmon

Industrial and Manufacturing Engineering

Focusing on a basic printed circuit board (PCB) assembly line configuration characterized by very long set-up times, we examine two scheduling methods that can significantly reduce the set-up. Both methods -the Grouped Set-Up (GSU) method that has been recently introduced in the literature and the Sequence Dependent Scheduling (SDS) method, which has not been studied in this context -are based on component commonality among PCB types. Using the typical traditional scheduling method as a benchmark, the GSU and the SDS methods are compared in terms of three performance measures: line throughput, average work-in-process (WIP) inventory level, and implementation complexity. Guidelines …