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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)
