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West, A. A.
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Distributed Engineering of Automotive Manufacturing Machines under the Foresight Vehicle Programme

Loughborough University, UK-A. A. West, R. Harrison, R. H. Weston, R. P. Monfared, D. A. Vera, D. W. Thomas, C. S. McLeod, M. Wilkinson, S. M. Lee, S. F. Qin, M. H. Ong
Published 2002-03-04 by SAE International in United States
A method to enable the impact of a novel component based approach to the implementation of production machinery design and build processes from the perspectives of the manufacturing engineering partners within the automotive industry is reported in this paper. The assessment method is based upon the representation (using CIMOSA based constructs) and simulation (using the ithinktm software package) of the activity, actor and event relationships between distributed partners when involved in a global engine manufacture programme. Assessment is vital to ensure that the impact of any novel approach is appreciated in terms and metrics that are consistent with the current operational and interaction paradigms. Without this information is it extremely difficult for the engineering partners to appreciate the impact of changes on their roles, responsibilities and profits and hence determine a roadmap and timescale for the adoption of the changes associated with the novel technology.
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A Process Definition Environment for Component Based Manufacturing Machine Control Systems Developed Under the Foresight Vehicle Programme

Loughborough University-D. W. Thomas, A. A. West, R. Harrison, C. S. McLeod
Published 2002-03-04 by SAE International in United States
The COMponent Based Paradigm for AGile Automation (COMPAG) provides a component-based solution to engine production-line machine control systems. The traditional PLC system is replaced with a distributed control network containing intelligent nodes comprising locally controlled actuators and sensors.The Process Definition Environment provides support for the specification, configuration, and maintenance of the machine control application and facilitates both the initial design and maintenance stages of the lifecycle by describing the control logic as a set of consistent timing and state transition diagrams commonly used in the initial design stages.
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Foresight Vehicle: Physical Media for Automotive Multiplex Networks Implemented on Large Area Flexible Printed Circuit Boards

Wolfson School of Mechanical and Manufacturing Engineering, Loughborough Univ.-D. P. Webb, M. C. W. Cottrill, W. A. Jaggernauth, A. A. West, P. J. Palmer, P. P. Conway
Published 2002-03-04 by SAE International in United States
Large area flexible printed circuits (FPCs) are attracting attention as a replacement for automotive wire harness. Reasons include weight and space saving, increased automation of production, improved consistency of performance, and added value through mounting of components on the harness. Automotive multiplexed networks are increasingly important for the functioning of automobiles. The ISO11898 Controller Area Network standard places requirements on the electrical parameters of the physical transmission medium. In this paper fabrication of FPC transmission lines, and subsequent testing for compliance with ISO11898, are described. It is demonstrated that the ISO11898 requirements can be met using a high volume, low cost print-and-etch process.
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Foresight Vehicle: Large Area Flexible Circuits for Automotive Applications Manufacturing Technology - A Review of Process Options

Wolfson School of Mechanical and Manufacturing Engineering, Loughborough Univ.-M. C. W. Cottrill, W. A. Jaggernauth, D. P. Webb, P. J. Palmer, P. P. Conway, A. A. West
Published 2002-03-04 by SAE International in United States
It is the intention of motor vehicle manufacturers to achieve weight and cost savings by replacing wiring harnesses with flexible printed circuits in doors, roof liners, boots and cockpits.These circuits will be required in high volume and must meet the requirements of the vehicle and equipment suppliers with respect to cost effectiveness and reliability while presenting an achievable, economically sound manufacturing technology to the circuit suppliers.Design issues include requirements for CAN-bus1, EMC/RFI protection, 42 volt systems and the integration of functional modules 2,3,4.Alternative construction options and criteria for their assessment are proposed.The range of processes from which a manufacturing technology can be established are identified and discussed.The challenges presented to available processes and equipment by the potentially very large circuits are examined.
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Human Factors Issues in the Application of a Novel Process Description Environment for Machine Design and Control Developed under the Foresight Vehicle Programme

Loughborough University-M. H. Ong, D. Vera, A. A. West, R. Harrison
Published 2002-03-04 by SAE International in United States
In the globalization of the automotive businesses, manufacturing companies and their suppliers are forced to distribute the various lifecycle phases in different geographical locations. Misunderstandings arising from the variety of personnel involved, each with different requirements, backgrounds, roles, cultures and skills for example can result in increased cost and development time.To enable collaborating companies to have a common platform for interaction, the COMPANION project at Loughborough University has been undertaken to develop a common model-based environment for manufacturing automotive engines. Through the use of this environment, the stakeholders will be able to “visualize” consistently the evolution of automated systems at every lifecycle stage i.e. requirements definition, specification, design, analysis, build, evaluation, maintenance, diagnostics and recycle. It is important that the new approach is evaluated with respect to the requirements of the stakeholders since cost and technical issues are unlikely be the only factors that could enable / inhibit the uptake of this new approach. Research has been carried out to study the implications of human factors issues on the application of the COMPANION toolset by…
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Component Based Distributed Control Systems for Automotive Manufacturing Machinery Developed under the Foresight Vehicle Programme

Loughborough University, UK-R. Harrison, S. M. Lee, A. A. West
Published 2002-03-04 by SAE International in United States
A component based approach to the design and implementation of distributed control systems for automotive engine manufacturing machines is described in this paper. The research is being undertaken in collaboration with the In-Line and Diesel Engine (IL&DE) division of the Ford Motor Company and several of its leading machine builders. The approach offers significant advantages over traditional methods. The external drivers of change affecting the automotive manufacturing sector are reviewed and the need for a better solution to the design and implementation of control systems is explained within this context. Existing best practise for the implementation of control systems for automotive engine manufacturing machinery is described.The new approach supports the implementation fully distributed control systems where a centralised PLC or PC based controller is not required and the control logic is embedded into the components of the machine. Adoption of this component based approach makes it possible for accurate visualisations of machine behaviour to be more easily made available to interested parties throughout the machine lifecycle (e.g. during simultaneous engineering, runtime monitoring and diagnostics). The…
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Foresight Vehicle: Specification and Acceptability Criteria for Copper-Clad Dielectric Materials Used in Large Automotive Flexible Printed Circuits

Loughborough Univ.-W. A. Jaggernauth, D. P. Webb, M. C. W. Cottrill, P. J. Palmer, P. P. Conway, A. A. West
Published 2002-03-04 by SAE International in United States
Flexible Printed Circuits (FPCs) have been used extensively in instrument clusters and more recently in headliners of some vehicles. Interest in large area FPCs as a replacement for traditional wiring harnesses has been propelled by the potential benefits, which include weight and space savings, ease of assembly into the vehicle, intelligence through direct mounting of electronic components, and creative design opportunities. This paper describes the development of a specification for flexible copper-clad dielectric materials to be used in the construction of a large FPC intended to replace an instrument panel wiring harness.
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A User-Oriented Interface Methodology for Automotive Manufacturing Machines Developed under the Foresight Vehicle Programme

Loughborough University, UK-R. P. Monfared, A. A. West, R. Harrison, M. Wilkinson
Published 2002-03-04 by SAE International in United States
This paper reports on the development and implementation of a user-oriented interface methodology for Human Machine Interfaces (HMIs) on transfer lines and engine assembly machines. This approach to HMI implementation has been developed in conjunction with a Fully Distributed machine Control System (FDCS) that its potential to replace conventional centralised PLC/PC based machine control methods is being investigated by researchers at Loughborough University. The paper also provides a brief description on user and task stereotype models defined for a domain of automotive industry and explains the use of software components to develop a prototype HMI for a machine test rig.
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