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Sensors, Data and HPC, the Untapped and Rapidly Approaching Opportunities

for Manufacturing

Thomas R. Kurfess, Ph.D., P.E. HUSCO/Ramirez Distinguished Chair in Fluid Power and Motion Control

Woodruff School of Mechanical Engineering Georgia Institute of Technology

Atlanta, Georgia USA

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Why Manufacturing Matters

! Conducts 70% of US R&D, 90% of patents issued ! Close connection between R&D, design, and manufacturing ! Health of industrial commons (know how, process engineering

capability, workforce skills, suppliers) ! Manufacturing multiplier ($1.40 for $1 of manufacturing output) ! Critical for national security

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Some Key Terminology

! Internet of things (IoT) –  Linking everything together

! Industrial Internet –  Linking everything in industry together

! Big Data –  Lots of data and they are free (sort of)…

! Industry 4.0 –  4th Industrial Revolution

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Common Connections via Standards Enable…

Information: verifying simulation with REAL data Utilization, OEE, consumable needs, maintenance, quality/inspection results…

Improved Management: Scheduling, process sequencing (macro planning), process variables (microplanning), CAM programs, facilities, tooling, quality metrics, rates, cost, plant wide integration, asset management…

Data: Sensor-based status, failures/faults, process/tooling/machine, energy, quality data/inspection output…

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Connectivity / Big Data – Overview

! Machine monitoring ! Operational visualization ! Data utilization ! Ease of implementation ! Leveraging open options

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Simple Cloud Architecture for Manufacturing

6

WebServer

BusinessLogic Database

Web Page

Machine Data

Cloud Services

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Separate Data Capture – Fog Computing

! High frequency data acquisition –  Analog, digital, serial

! Embedded computing platforms –  Arduino –  Beaglebone –  Raspberry Pi

! Computation performed on embedded device –  Transmit data in MTConnect format to agent –  Interface directly with database

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Data Storage: Enterprise Cloud Solutions ! Amazon Web Services (AWS)

–  Send data to the cloud database using HTTP post –  Easy management of the database –  Webpage hosting –  Real time data

! Database Server Storage Costs –  10 GB can store ~200 million records –  $0.10 per GB-month storage costs –  10 GB storage is $1/month (+ server)

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Data Storage and Analysis: Google Sheets

! Google Apps Scripts –  Allows publishing data to Google Sheets –  Capable of getting data from online machines –  Cloud based analysis –  Internet accessible –  No cost (2 million cells) –  1 Machine = 1000 cells

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Mobile Device Integration – Smartphones / Tablets ! Local and Online Machines

–  Direct access to machine data –  Display the current status

! Cloud for local machines –  Data transmits to a cloud database

(AWS, Google Sheets) –  Display current and historical data

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Going Probabalistic

! 

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Statistical Data Fusion

StateofHealth

Accelerometer

Dynamometer

MTConnect

PowerMeter

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Beyond Machining

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HPC Applications in Subtractive and Additive

! Allows for easy creation of organic or non-traditional geometry –  Parts that would normally be candidates for additive manufacturing

! Virtual platform implementation (Desktop as a Service, DaaS)

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Scaled Trial in ME UG Course

! The virtualized implementation 2nd year design/build course

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Where are We Going? ! Distributed manufacturing ! Tools will morph to leverage new workforce ! Security / Safety / Privacy ! Embedded low cost systems (processing, memory, connectivity) ! Web and Desktop as a Service will be commonplace ! Flexibility / customization will grow ! Not just OEMs, but suppliers as well ! Open source / repurposed hardware will rule

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Analog Digital Compressed Distributed

1D:Sound

2D:Image

TIME

3D:Volume

1991 201x

1987 1992

BREP, CSG, Triangular

mesh

Voxel model

201x

201x

New volume representation

and compression technology

Cloud computing, Parallel

processing, GPGPU

1982

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Back to the Big Picture ! Wealth creation ! Enabling SME’s ! A new workforce foundation ! New technical leadership for policy ! The United States of America

–  Enabling innovation –  Ensuring the talent pipeline

! The World – Making a difference “In times of change, learners inherit the earth; while the learned find themselves beautifully equipped to deal with a world that no longer exists.” (Eric Hoffer 1902-1983)