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The purpose of this paper is to describe the development, testing and scientific evaluation of a novel, load‐cell‐controlled reactive reconfigurable tooling (RRT) solution. This RRT not only addresses the underlying inherent problems with traditional reconfigurable tools but also potentially expands their use into the area of condition monitoring.

The paper covers the design intent and methodology. The construction and evaluation of both a simple prototype and a fully functional tool are described.

The tool was successfully demonstrated using friction stir welding (FSW) of fuselage panels as a demanding application and the full functionality of the tool was demonstrated. The condition and process monitoring system was also demonstrated and shown to be able to distinguish both between different types of weld and tool failure conditions.

Having successfully designed and tested the novel RRT system under the extreme conditions of FSW, it is apparent that there are many more applications and developments that this system could be used for. The same requirements for accurate control of geometry exist in processes such as water jet cutting, trimming and machining. However, there was not sufficient resource or time within the research programme to verify this. One disadvantage of the tool is the cost of the individual load cells and the associated charge amplifiers; however, this cost is offset by the opportunity to use them in a tool condition monitoring function as well.

The tool developed not only has the potential to provide cost benefits but also time reductions due to the elimination of the need to move large and heavy tools in and out of the FSW machine when part production runs are changed.

The originality of work described is the tool's ability to both adapt and monitor the component being held. This places it considerably beyond the state of the art in large‐scale industrial reconfigurable tooling. The research's value lies in applicability and demonstration for real production parts and processes.

Robot tools, or in more general terms, end‐of‐arm tools, or robot end‐effectors are general purpose, programmable or task‐oriented devices connected between the robot wrist and the object or load to be manipulated and/or processed by the robot. They can offer and/or limit the versatility of grasping and/or processing of different components, sensing their characteristics and working together with the robot control system to provide a reliable “service” throughout the component manipulation cycle. Reconfigurable robot tooling enables the robot to rapidly change its end‐effectors or fingers of its end‐effectors, typically under programmable software control. The importance of providing lean‐flexibility by means of reconfigurable, automated robot hand changers (ARHC), particularly in small‐batch robotic welding, assembly, machine loading and in other flexible robot cells, is discussed with examples. Some known systems are demonstrated and the “Ranky‐type” ARHC design is illustrated in more detail.

In manufacturing, dedicated machine tools and flexible machine tools are failing to satisfy the ever-changing manufacturing demands of short life cycles and dynamic nature of products. These machines are limited when new product designs are introduced. The solution lies in developing responsive machines that can be adjusted or be changed functionally when these change requirements arise. These machines are reconfigurable machines which are becoming the new focus, as they rapidly respond to product variety and volume changes. A sheet metal working machine known as a reconfigurable guillotine shear and bending press machine (RGS&BPM) has been developed. The purpose of this paper is to present a methodology, function-oriented design approach (FODA), which was developed for the design of the RGS&BPM.

The design of the machine is based on the six principles of reconfigurable manufacturing systems (RMSs), namely, modularity, scalability integrability, convertibility, diagnosability and customisability. The methodology seeks to optimise the design process of the RGS&BPM through a design of modules that make up the machine, enable its conversion and reconfiguration. The FODA is focussed on function identification to select the operational function required. Two main functions are recognised for the machine, these being cutting and bending; hence, the design revolves around these two and reconfigurability.

The developed design methodology was tested in the design of a prototype for the reconfigurable guillotine shear and bending press machine. The prototype is currently being manufactured and will be subjected to functional tests once completed. This paper is being presented not only to present the methodology by to show and highlight its practical applicability, as the prototype manufacturers have been enthusiastic about this new approach.

The research was limited to the design methodology for the RGS&BPM, the machine which has been designed to completion using this methodology, with prototype being manufactured.

This study presents critical steps and considerations in the development of reconfigurable machines. The main thrust being to explore the best possibility of developing the machines with dual functionality that will assist in availing the technology to manufacturer. As the machine has been development, the success of the design can be directly attributed to the FODA methodology, among other contributing factors. It also highlights the significance of the principles of RMS in reconfigurable machine design.

The RGS&BM machine is an answer for the small-to-medium enterprises (SMEs), as the machine replaces two machines with one, and the methodology ensures its affordable design. It contributes immensely to the machine availability by eliminating trial and error approaches.

This study presents a new approach to the design of reconfigurable dual machines using principles of RMS. As the targeted market is the SME, it is not limited to that as any entrepreneur may use the machine to their advantage. The design methodology presented contributes to the body of knowledge in dual reconfigurable machine tool design.

Reconfigurable machines tools (RMTs) are gaining momentum as the new solutions to customised products in the manufacturing world. The driving force, among others, behind these machines is the part envelope and the part family of products that they can produce. The purpose of this paper is to propose a new class of RMT known as a reconfigurable guillotine shear and bending press machine (RGS&BPM). A part family of products that this machine can produce is developed using hierarchical clustering methodologies. The development of these part families is guided by the relationship of the parts in the family in terms of complexity and geometry.

Part families cannot be developed in isolation, but that process has to incorporate the machine modules used in the reconfiguration process for producing the parts. Literature was reviewed, and group technology principles explored, to develop a concept that can be used to develop the part families. Matrices were manipulated to generate part families, and this resulted in the development of a dendrogram of six possible part families. A software with a graphic user interface for manipulation was also developed to help generate part families and machine modules. The developed concept will assist in the development of a machine by first developing the part family of products and machine modules required in the variable production process.

The developed concepts assist in the development of a machine by first developing the part family of products and machine modules required in the variable production process. The development of part families for the RGS&BPM is key to developing the machine work envelope and modules to carry out the work. This work has been presented to demonstrate the importance of machine development in conjunction with a part family of products that the machine will produce. The paper develops an approach to manufacturing where part families of products are developed prior to developing the machine. The families of products are then used to develop modules that enable the manufacture of the parts and subsequently the size of the machine.

The research was limited to the development of part families for a new RGS&BPM, which is still under development.

The study reflects the development of reconfigurable machines as a solution to manufacturing challenges in terms of group technology approaches adopted in the design phase. It also highlights the significance of the concepts in the reconfigurable machine tool design. The part families define the machine work envelop and its reconfiguration capability.

The success of the research will usher an alternative to smaller players in sheet metal work. It will contribute to the easy development of the machine that will bridge the high cost of machine tools.

The study contributes to the new approach in sheet metal manufacturing where dedicated machines may be substituted by a highly flexible reconfigurable machine that has a dual operation, making the investment for small to medium enterprises affordable. It also contributes to the body of knowledge in reconfigurable machine development and the framework for such activities, especially in developing countries.

The purpose of this paper is to discuss an example of modelling with experiments of robot prototype with dependent joint concept, including a full description of related functionalities. Reduction in active degrees of freedom in a machine can lead to improved accuracy, improved reliability and lower cost. The reconfiguration of machines and systems is a key technology for future responsive manufacturing systems. The concept of dependent joints helps to implement much specified sub-workspaces depending on functional needs in the machine.

This is inherently made possible using smart mechanical concepts having embedded sensors and reconfigurable control systems. This paper introduces structural reconfiguration systems and discusses a sample approach to functional reconfiguration.

A successful manipulator design with extended features when considering reduction in active degrees of freedom in a machine would lead to specific sub-workspace with improved accuracy, improved reliability and lower cost.

Reduction in active degrees of freedom in a machine can lead not only towards a dedicated functional workspace but also towards improved accuracy, improved reliability and lower cost.

This paper is of value to engineers and researchers developing robotic manipulators for use in various aspects of industry.

A reconfigurable manufacturing system (RMS) can provide manufacturing flexibility, meet changing market demands and deliver high performance, among other benefits. However, adoption and performance improvement are critical activities in it. The current study aims to identify the important factors influencing RMS adoption and validate a conceptual model as well as develop a structural model for the identified factors.

An extensive review of RMS articles was conducted to identify the eight factors and 47 sub-factors that are relevant to RMS adoption and performance improvement. For these factors, a conceptual framework was developed as well as research hypotheses were framed. A questionnaire was developed, and 117 responses from national and international domain experts were collected. To validate the developed framework and test the research hypothesis, structural equation modeling was used, with software tools SPSS and AMOS.

The findings support six hypotheses: “advanced technologies,” “quality and safety practice,” “strategy and policy practice,” “organizational practices,” “process management practices,” and “soft computing practices.” All of the supported hypotheses have a positive impact on RMS adoption. However, the two more positive hypotheses, namely, “sustainability practices” and “human resource policies,” were not supported in the analysis, highlighting the need for greater awareness of them in the manufacturing community.

The current study is limited to the 47 identified factors; however, these factors can be further explored and more sub-factors identified, which are not taken into account in this study.

Managers and practitioners can use the current work’s findings to develop effective RMS implementation strategies. The results can also be used to improve the manufacturing system’s performance and identify the source of poor performance.

This paper identifies critical RMS adoption factors and demonstrates an effective structural-based modeling method. This can be used in a variety of fields to assist policymakers and practitioners in selecting and implementing the best manufacturing system.

The purpose of this paper is to present an organized review of existing research on reconfigurable manufacturing system (RMS). The paper considers majority of the prominent research articles in the domain of RMS published ever since RMS was envisaged in 1997.

The paper systematically reviews, classifies and analyses the published literature on postulations and design of RMSs. The general observations from the literature and research gaps recognized thereon are highlighted at the end of each section/sub-section.

The paper reveals important aspects related to RMS research since its inception. It also recognizes the areas of RMS research requiring more focus. The study also highlights open issues and future directions for further research.

The literature in the domain of RMS has so far been narrow. This paper reviews the prominent research in this field and presents an overview of its conceptual developments and various mathematical models for the RMS design and its optimization so far developed by the researchers. Further, manufacturing advancements and future directions have also been proposed for the efficient execution of RMS paradigm in manufacturing industries.

The paper provides an organized listing of published research work in the field of RMS. This work will provide an insight to the researchers, practitioners and others related directly or indirectly to this field to develop and understand better strategies for supervising and controlling the smooth implementation of RMS.

The purpose of this paper is to research the impact of hybrid series‐parallel and parallel‐series system configurations on system performances based on system reliability and to develop a configuration model to meet the requirement of reconfigurable manufacturing system (RMS).

Based on the criterion of system reliability, a RMS configuration model is presented – the hybrid parallel‐series model with waiting system characteristics. The configuration model is evaluated from reliability, productivity, and cost by combining system engineering theory, Boolean algebra methodology with statistical analysis theory. The model reliability has been used to ameliorate by adopting the integrated algorithm based on Shrama and Misra optimization algorithm.

The need for application of this method and model – some constraints must be limited, the hybrid parallel‐series configuration is superior and the integrated algorithm is effective to RMS system configuration.

Cost constraints, equipment weight constraints, and function independency of equipment are main limitations.

The model and method have been used to ameliorate the reconfigurable automobile parts product line in SH automobile motor company of Shanghai. The operation result illustrates the validity of this configuration model and algorithm.

The new RMSs configuration model has been proposed. The new algorithm is proposed to ameliorate and optimize a reconfigurable product line with the integrated algorithm based on Shrama and Misra algorithm. The actual running effect is significant.

The objective of this paper is to develop geometric algorithms and planning strategies to enable the development of a novel hybrid manufacturing process, which combines rapidly re‐configurable mold tooling and multi‐axis machining.

The presented hybrid process combines advantages of both reconfigurable molding and machining processes. The mold's re‐configurability is based on the concept of using an array of discrete pins. By positioning the pins, the reconfigurable molding process allows forming the mold cavity directly from the object's 3D design model, without any human intervention. After a segment of the part is molded using the reconfigurable molding process, a multi‐axis machining operation is used to create accurate parts with better surface finish. Geometric algorithms are developed to decompose the design model into segments based on the part's moldability and machinability. The decomposed features are used for planning the reconfigurable molding and the multi‐axis machining operations.

Computer implementation and illustrative examples are also presented in this paper. The results showed that the developed algorithms enable the proposed hybrid re‐configurable molding and multi‐axis machining process. The developed decomposition and planning algorithms are used for planning the reconfigurable molding and the multi‐axis machining operations. Owing to the decomposition strategy, more geometrically complex parts can be fabricated using the developed hybrid process.

This paper presents geometric analysis and planning to enable the development of a novel hybrid manufacturing process, which combines rapidly re‐configurable mold tooling and multi‐axis machining. It is expected that the proposed hybrid manufacturing process can produce highly customized parts with better surface finish, and part accuracy, with shorter build times, and reduced setup and tooling costs.