Intelligent Machines and Smart Productsulsoy/pdf/Ubiquiti_IMSP.pdf · Issues warning to driver,...
13
Intelligent Machines and Smart Products A. Galip Ulsoy C.D. Mote, Jr. Distinguished University Professor of Mechanical Engineering and the William Clay Ford Professor of Manufacturing Ubiquiti Meeting, May 4, 2010 A. Galip Ulsoy, C.D. Mote, Jr. Distinguished University Professor and the William Clay Ford Professor of Manufacturing Mechanical Engineering, University of Michigan, Ann Arbor, MI 48109-2125 USA 03/29/2010 2 Engineering “Scientists discover the world that exists; engineers create the world that never was.” - Theodore Von Karman • Engineering is the discipline focused on creating physical artifacts! • Engineering design is often based on trial and error (e.g., continuous improvement), and “failure” is the key to good design. • Engineering research provides principles, methods and tools (i.e., knowledge) for engineered systems, and mechatronics provides the opportunity to embed such knowledge in the system itself! [Tryggvason & Apelian, 2010]
Transcript of Intelligent Machines and Smart Productsulsoy/pdf/Ubiquiti_IMSP.pdf · Issues warning to driver,...
A. Galip Ulsoy, C.D. Mote, Jr. Distinguished University Professor!and the William Clay Ford Professor of Manufacturing!Mechanical Engineering, University of Michigan, Ann Arbor, MI 48109-2125 USA!
03/29/2010!1!
!
!Intelligent Machines and Smart
Products!!!!
A. Galip Ulsoy!!
C.D. Mote, Jr. Distinguished University Professor of Mechanical Engineering !and the William Clay Ford Professor of Manufacturing!
!Ubiquiti Meeting, May 4, 2010!
A. Galip Ulsoy, C.D. Mote, Jr. Distinguished University Professor!and the William Clay Ford Professor of Manufacturing!Mechanical Engineering, University of Michigan, Ann Arbor, MI 48109-2125 USA!
03/29/2010!2!
Engineering!"“Scientists discover the world that exists; !
engineers create the world that never was.”! - Theodore Von Karman!
!!!!!!!!!"!
•# Engineering is the discipline focused on creating physical artifacts!!•# Engineering design is often based on trial and error (e.g., continuous improvement), and “failure” is the key to good design.!•# Engineering research provides principles, methods and tools (i.e., knowledge) for engineered systems, and mechatronics provides the opportunity to embed such knowledge in the system itself!!
# "!
[Tryggvason & Apelian, 2010]!
A. Galip Ulsoy, C.D. Mote, Jr. Distinguished University Professor!and the William Clay Ford Professor of Manufacturing!Mechanical Engineering, University of Michigan, Ann Arbor, MI 48109-2125 USA!
03/29/2010!3!
Mechatronics!!Mechatronics is the synergistic integration of mechanical engineering ("mecha" for mechanisms), electronic engineering ("tronics" for electronics), and software engineering [Wikipedia].!
•# Identified as one of “Ten emerging technologies that will change the world.” [MIT Technology Review, Feb. 2003], e.g. fuel injection, hybrids, autonomous robots, ...!
•# Enables knowledge about a system to be embedded in the system itself, and knowledge about system failures to be discovered and used in design!!
A. Galip Ulsoy, C.D. Mote, Jr. Distinguished University Professor!and the William Clay Ford Professor of Manufacturing!Mechanical Engineering, University of Michigan, Ann Arbor, MI 48109-2125 USA!
03/29/2010!4!
Outline!•# Introduction •#Active Safety Systems •# Intelligent Stamping •#Co-Design of Smart Products •#Reliable Operation of UGVs •#Safe Operation of Autonomous Vehicles •#Concluding Remarks •#Acknowledgements
A. Galip Ulsoy, C.D. Mote, Jr. Distinguished University Professor!and the William Clay Ford Professor of Manufacturing!Mechanical Engineering, University of Michigan, Ann Arbor, MI 48109-2125 USA!
03/29/2010!5!
Preventing SVRD Accidents!
Prototype Vehicle
1994 Ford Taurus SHO
Single-Vehicle-Road-Departure (SVRD) events cause about 1/4 of all accidents and 1/3 of all fatalities on US highways. !A system was developed to prevent SVRD accidents by predicting vehicle path, estimating lane geometry using computer vision, and assessing driver state. Issues warning to driver, provides driving steering assist and/or intervention via differential braking.!
A. Galip Ulsoy, C.D. Mote, Jr. Distinguished University Professor!and the William Clay Ford Professor of Manufacturing!Mechanical Engineering, University of Michigan, Ann Arbor, MI 48109-2125 USA!
03/29/2010!6!
Preventing SVRD Accidents!
Evaluated on test track and on I-696!
A. Galip Ulsoy, C.D. Mote, Jr. Distinguished University Professor!and the William Clay Ford Professor of Manufacturing!Mechanical Engineering, University of Michigan, Ann Arbor, MI 48109-2125 USA!
03/29/2010!7!
Outline!•# Introduction •#Active Safety Systems •# Intelligent Stamping •#Co-Design of Smart Products •#Reliable Operation of UGVs •#Safe Operation of Autonomous Vehicles •#Concluding Remarks •#Acknowledgements
A. Galip Ulsoy, C.D. Mote, Jr. Distinguished University Professor!and the William Clay Ford Professor of Manufacturing!Mechanical Engineering, University of Michigan, Ann Arbor, MI 48109-2125 USA!
03/29/2010!8!
Intelligent Stamping:"Process Control!
•# Stamping: highly reconfigurable process for low-cost, high-volume production of complex parts.!
•# Main quality considerations are formability (i.e., wrinkling and tearing) and dimensional accuracy (i.e.,springback).!
A. Galip Ulsoy, C.D. Mote, Jr. Distinguished University Professor!and the William Clay Ford Professor of Manufacturing!Mechanical Engineering, University of Michigan, Ann Arbor, MI 48109-2125 USA!
03/29/2010!9!
Intelligent Stamping:"Experimental System!•# Experimental setup!-# Inputs: 12 hydraulic actuators at the bottom of the die.!-# Outputs: 4 punch force sensors at each corner of press.!-# Based on the experimentally verified assumption: each punch force output is
affected only by three nearest BHF as inputs.!# The press is a 1000-ton mechanical press operating at 12 strokes/minute.!
Punch speed 215 mm/sec
Punch stroke 150 mm (Max.)
Sampling rate 500 Hz
Lubrication Dry
Material CR EDD steel
Blank size 1640x1600x0.8
Top view
A. Galip Ulsoy, C.D. Mote, Jr. Distinguished University Professor!and the William Clay Ford Professor of Manufacturing!Mechanical Engineering, University of Michigan, Ann Arbor, MI 48109-2125 USA!
03/29/2010!10!
Intelligent Stamping:"Experiments!
•# Various experiments were performed, and the results shown are typical.!
•# These results show how the system performs when there is unexpected lubrication change.!
•# The process controller eliminates part quality problems, such as wrinkling and tearing.!
•# The fixed-gain process controller does not perform as well as the adaptive version.!
•# Auto-tuning is useful for initializing the adaptive controller.!
A. Galip Ulsoy, C.D. Mote, Jr. Distinguished University Professor!and the William Clay Ford Professor of Manufacturing!Mechanical Engineering, University of Michigan, Ann Arbor, MI 48109-2125 USA!
03/29/2010!11!
Outline!•# Introduction •#Active Safety Systems •# Intelligent Stamping •#Co-Design of Smart Products •#Reliable Operation of UGVs •#Safe Operation of Autonomous Vehicles •#Concluding Remarks •#Acknowledgements
A. Galip Ulsoy, C.D. Mote, Jr. Distinguished University Professor!and the William Clay Ford Professor of Manufacturing!Mechanical Engineering, University of Michigan, Ann Arbor, MI 48109-2125 USA!
03/29/2010!12!
Co-Design of Smart Artifacts!•# Smart products require the design of an artifact (e.g., engine) and the design
of a controller for that artifact (e.g., ECU).!•# Traditionally accomplished sequentially, i.e., design the artifact first, then
given the artifact, design its controller.!•# Can do better by a simultaneous, or combined, or co-design.!•# However, co-design is complex and costly, both organizationally and
computationally.!•# Desirable to know when two design problems are coupled, and co-design is
needed, and when they are uncoupled and a sequential approach yields satisfactory performance.!
•# Also of interest to modify traditional sequential design approach such that it efficiently yields a design with performance similar to the more complex simultaneous approach.!
•# These can be accomplished using the Controllability Gramian, Wc, which is a property of the artifact only and not the design of the controller, as a Control Proxy Function (CPF) in the artifact design stage.!
A. Galip Ulsoy, C.D. Mote, Jr. Distinguished University Professor!and the William Clay Ford Professor of Manufacturing!Mechanical Engineering, University of Michigan, Ann Arbor, MI 48109-2125 USA!
03/29/2010!13!
Co-Design:"Optimal “Passive/Active” Car Suspension!
•# Active-only system : high quality, but requires more control effort.!•# Combined passive-active: high quality with much less control effort compared to active-only.!
•# Co-designed system (B): better performance at same control compared to sequentially designed (A).!
Con
trol E
ffort!
Suspension Cost!
A. Galip Ulsoy, C.D. Mote, Jr. Distinguished University Professor!and the William Clay Ford Professor of Manufacturing!Mechanical Engineering, University of Michigan, Ann Arbor, MI 48109-2125 USA!
03/29/2010!14!
Co-Design: "MEMS Co-Design Example!
•# MEMS Actuator!-# Four electrostatic comb drives produce
in-plane motion (DX)!-# Micro-hinge flexes to produce out-of-
plane motion (DZ)!-# Displacement (DZ) depends on applied
voltage, physical dimensions of device.!•# Co-Design Problem!
-# Maximize displacement Z, and minimize settling time, ts, subject to constraints.!
Ki/s 1/s 1/s
K/M
C/M
K1
K2
+-
+ +--
- -A(!"!/M
u(t)=V2 x2=!" x1=!" !"
!"r(t)
.
!"..
A. Galip Ulsoy, C.D. Mote, Jr. Distinguished University Professor!and the William Clay Ford Professor of Manufacturing!Mechanical Engineering, University of Michigan, Ann Arbor, MI 48109-2125 USA!
03/29/2010!15!
Co-Design: "CPF Results for MEMS Actuator!
A. Galip Ulsoy, C.D. Mote, Jr. Distinguished University Professor!and the William Clay Ford Professor of Manufacturing!Mechanical Engineering, University of Michigan, Ann Arbor, MI 48109-2125 USA!
03/29/2010!16!
Outline!•# Introduction •#Active Safety Systems •# Intelligent Stamping •#Co-Design of Smart Products •#Reliable Operation of UGVs •#Safe Operation of Autonomous Vehicles •#Concluding Remarks •#Acknowledgements
A. Galip Ulsoy, C.D. Mote, Jr. Distinguished University Professor!and the William Clay Ford Professor of Manufacturing!Mechanical Engineering, University of Michigan, Ann Arbor, MI 48109-2125 USA!
03/29/2010!17!
Robotics and Autonomous Systems!
Autonomous Operations
Collaborative Unmanned
Systems
User Interfaces
Advanced Platform Design
Making the robots work well with others!
!Today: Robots used
individually and independently!
Vision: Robots that are fully networked and collaborative!
Making the robots smarter!!Today: Human input required to control
every aspect of robot!Vision: Robots that are able to think
and act intelligently and independently!
Making the robots easier to use!!Today: Robot control requires
specialized equipment and training!Vision: Robots that are intuitively easy
to command and control!
Making the … robots!!Today: Robot operations not reliable
and confined to limited environments!Vision: Robots that are able to operate
reliably in any environment at any time!
A. Galip Ulsoy, C.D. Mote, Jr. Distinguished University Professor!and the William Clay Ford Professor of Manufacturing!Mechanical Engineering, University of Michigan, Ann Arbor, MI 48109-2125 USA!
03/29/2010!18!
Challenge:"Reliable Operation of UGVs!
•# Robotics has grown out of a hobbyist mindset (i.e., prototypes, demos)!
•# Serious reliability problems!-# mean-time-between-failures of 6-20
hours!-# Availability of 30-60%!
•# Reliability issues due to:!-# emerging industry!-# unstructured environment!-# operator misuse!-# new technologies (e.g.,
sensors, software)!!
“The robotics industry faces many of the same challenges that the personal computer business faced 30 years ago”
A. Galip Ulsoy, C.D. Mote, Jr. Distinguished University Professor!and the William Clay Ford Professor of Manufacturing!Mechanical Engineering, University of Michigan, Ann Arbor, MI 48109-2125 USA!
03/29/2010!19!
Reliable UGV Operations!New types of sensors not proven for usage in the field
Manufacturing defects cause component failures (pinched wires in assembly)
Obstacles Slopes, ditches Dust, mud, rocks Temperature
Drive up steep slope Turn left instead of right Exceed motor limits
Manufacturing Design
User Environment
Reliable UGV
Operations
Specification
Technology
Standards Procedures
Human
Interference
Hazard
Impact
Mistakes
Slips
Machines
Interface
A. Galip Ulsoy, C.D. Mote, Jr. Distinguished University Professor!and the William Clay Ford Professor of Manufacturing!Mechanical Engineering, University of Michigan, Ann Arbor, MI 48109-2125 USA!
03/29/2010!20!
•# Understand and model failure modes and dependencies:!
•# analyze available field failure data (COLTS database)!•# unpredictable random failures and uncertain usage of robots, !•# small sample size under each failure mechanism. !•# use simulation models to assess and predict robotic system reliability. !
•# Improve design and manufacturing, e.g.!•# improve capabilities of robotic arm by addition of torsional springs mounted in parallel to the worm gear at the joint of a robot arm. !•# reliability based design optimization (RBDO)!
Reliability Analysis and Reliable Design!
Simulation and development models
of field robots
2 Improving
Design and Manufacturing
Identify and improve critical components’
reliability via current design
1Understanding &
Modeling ofFailure Modes
and Dependency
Field failure data
Analyzing and predicting system
reliability
Improved Robot Reliability
A. Galip Ulsoy, C.D. Mote, Jr. Distinguished University Professor!and the William Clay Ford Professor of Manufacturing!Mechanical Engineering, University of Michigan, Ann Arbor, MI 48109-2125 USA!
03/29/2010!21!
Outline!•# Introduction •#Active Safety Systems •# Intelligent Stamping •#Co-Design of Smart Products •#Reliable Operation of UGVs •#Safe Operation of Autonomous Vehicles •#Concluding Remarks •#Acknowledgements
A. Galip Ulsoy, C.D. Mote, Jr. Distinguished University Professor!and the William Clay Ford Professor of Manufacturing!Mechanical Engineering, University of Michigan, Ann Arbor, MI 48109-2125 USA!
03/29/2010!22!
Purpose: Development of a Moving Obstacle Avoidance and Navigation Algorithm!
www.theodoresworld.net
The purpose is to develop a system that can avoid moving obstacles using limited, uncertain sensor data!The system should operate in an unknown environment, and allow a robot to safely and autonomously navigate to a goal!
nxtbot.com
Current Systems:!•# Stationary obstacle avoidance with uncertain sensor data!•#Moving obstacle avoidance with complete obstacle knowledge!
A. Galip Ulsoy, C.D. Mote, Jr. Distinguished University Professor!and the William Clay Ford Professor of Manufacturing!Mechanical Engineering, University of Michigan, Ann Arbor, MI 48109-2125 USA!
03/29/2010!23!
Velocity Occupancy Space: "Calculating VOS!
Approximate location and velocity of obstacle, in configuration space, while considering sensor error!
The velocity obstacle in velocity space!
The location of the goal !and the velocity goal in !velocity space!
Velocity occupancy space grid, where desired robot velocity is determined!
A. Galip Ulsoy, C.D. Mote, Jr. Distinguished University Professor!and the William Clay Ford Professor of Manufacturing!Mechanical Engineering, University of Michigan, Ann Arbor, MI 48109-2125 USA!
03/29/2010!24!
Velocity Occupancy Space: "Example Simulation!
A. Galip Ulsoy, C.D. Mote, Jr. Distinguished University Professor!and the William Clay Ford Professor of Manufacturing!Mechanical Engineering, University of Michigan, Ann Arbor, MI 48109-2125 USA!
03/29/2010!25!
Concluding Remarks!•# Intelligent machines and smart products are systems where
knowledge is embedded directly in the system itself. !•# Mechatronics is a major enabler, which is now making such
intelligent systems ubiquitous, as engineering research provides the required knowledge.!
•# I discussed several examples: !-# Road departure prevention!-# Intelligent system for stamping!-# Methodology for co-design of smart products!-# Reliable operation of UGVs!-# Safe operation of autonomous vehicles!
•# Intelligent machines and smart products are in their infancy; the future will undoubtedly bring many dramatic advances (e.g., fully autonomous and “self-x” systems).!
A. Galip Ulsoy, C.D. Mote, Jr. Distinguished University Professor!and the William Clay Ford Professor of Manufacturing!Mechanical Engineering, University of Michigan, Ann Arbor, MI 48109-2125 USA!
03/29/2010!26!
Acknowledgements!
US Army TARDEC!
